1996 Evinrude 9.9 Flywheel Question - ANSWERED!

[bankerjohn]

Quick question ... what size are the 3 holes in the flywheel for attaching a puller?

I want to be sure the puller set I purchase comes with the correct grade 8 bolts!

Edit: I think they are 1/4"-20 ... or 5/16"-18 ...

 

[JB]

Re: 1996 Evinrude 9.9 Flywheel Question

Re: 1996 Evinrude 9.9 Flywheel Question

I would guess the same, John, but I don't know.

Let's go back to the top and see who does know.

 

[Rick.]

Re: 1996 Evinrude 9.9 Flywheel Question

Re: 1996 Evinrude 9.9 Flywheel Question

7o's and 80's years are 1/4 so I would guess 96 would be the same. Rick.

 

[bankerjohn]

Re: 1996 Evinrude 9.9 Flywheel Question

Re: 1996 Evinrude 9.9 Flywheel Question

Tried some 1/4"-20 bolts in the flywheel, and they are too small ... must be 5/16"-18 bolts are the correct ones. Back to the hardware store!

 

[bankerjohn]

Re: 1996 Evinrude 9.9 Flywheel Question

Re: 1996 Evinrude 9.9 Flywheel Question

OK ... so now I've got both 5/16"-18 and 5/16"-24 bolts ... but I can't tell which one to use because I can't screw either size in with my hand (presumably because the flywheel has never been off, and the threads still have paint in them, making even the correct size a tight fit!).

I don't want to risk messing up the threads in the flywheel by trying to screw in the wrong size ... HELP!!!

 

[mnmx3]

Re: 1996 Evinrude 9.9 Flywheel Question

Re: 1996 Evinrude 9.9 Flywheel Question

Well, I read on this forum somewhere that someone couldn't get his flywheel off with the factory size bolt so he ended up drilling the holes larger and tapping them and he was able to use a larger bolt to pop that thing off. If it was me, I would slowly work the 5/16 - 18 with a wrench, going back and forth a little at a time and see what happens. If the threads get torn up you can do the drill/tap thing.

 

[Tim Frank]

Re: 1996 Evinrude 9.9 Flywheel Question

Re: 1996 Evinrude 9.9 Flywheel Question

Before you try threading in a bolt, try a 17/64 drill.
It is in between the tap drill size for a NC and NF thread (5/16")
If it doesn't go into the hole, use the NC tap, if it does, use the NF.

 

[steelespike]

Re: 1996 Evinrude 9.9 Flywheel Question

Re: 1996 Evinrude 9.9 Flywheel Question

Is It possible they could be fine thread.5/16 X 24 ,I think.

 

[bankerjohn]

Re: 1996 Evinrude 9.9 Flywheel Question

Re: 1996 Evinrude 9.9 Flywheel Question

I went to the hardware store and took my new flywheel with me ... to try metric 8mm bolts. Tried both M8-1.25 (coarse) and M8-1.00 (fine) and neither screwed in any further than the 5/16"-18 and the 5/16"-24 bolts did.

If I'm not mistaken, the motor was made for Evinrude by Suzuki ... so I'm now leaning toward a metric size.

I guess I'm going to have to break down and visit my l local Evinrude dealer, just to be 100% sure I have the right size ... surely they will know what to use!

 

[bankerjohn]

Re: 1996 Evinrude 9.9 Flywheel Question - ANSWERED!

The correct size is 5/15"-24 ... flywheel off, electric start kit installed ... tested and working like a champ! Now my wife can start the motor ....