Any Ideas?

[Bry21317]

I have a buddies 1990 Johnson 200 hp, that we are working on. The stator is fried, from something looks like a wire came loose or something and fried one of the coils on it. <br /><br />The other thing that I found is that the Key that holds the flywheel on, looks to be sheered off. It is very flat, and doesn't sit in the groove on the flywheel now, because there is not enough of it left to. We have tried to get it out and can't get it to budge. We have sprayed with PB Blaster, Hammered it in either direction with and Ice Pick. Drilled a hole in the key to try to get more leverage to bring it up out of the hole. It still doesn't want to budge at all. Does anyone have any ideas?<br /><br />Thanks,<br />Bryan Cox

 

[wilde1j]

Re: Any Ideas?

I would try driving it downward (and out) with the largest punch that fits the keyway. You don't want to get the crankshaft or the keyway buggered up b:c you're looking at major big $'s if you do.<br /><br />Sounds like someone may have had the flywheel off and didn't torque it to specs when replacing it. That's the only cause I can think of for a sheared woodruff key.<br /><br />If the flywheel bore or the crankshaft taper is scored at all, you will need to lap the two to a really good contact fit.

 

[splasher]

Re: Any Ideas?

The woodruff key is there to locate the flywheel<br />in the correct position for timing. You could file it flush to shaft and refit flywheel eyeballing keyway and old key and make sure they stay in line whilst torquing fly wheel nut!<br />Good luck

 

[JB]

Re: Any Ideas?

Well, you could, but it would be a very bad idea. Timing would last about 5 revs. <br /><br />I agree with Wilde One. You might try heating the shaft with a heat gun or hair dryer before you take the punch and the 3lb hammer to her.<br /><br />Good luck.

 

[12Footer]

Re: Any Ideas?

Now don't laugh,y'all! But I found that a pulley puller,WD40, and an electric engraving tool, and soaking time werk. I had to purchase a new puller, as I shattered my other one in an attempt to remove a flywheel. So I got my engraving tool out,and started engraving my name into the arm of the puller.After I got done, I turned to put the engarver up.I heard, "TINK!", turned back around, and the flywheel gave up the fight!<br />I've used it once since then, and the vibes seem to have an adverse effect on a flywheel's determination...No,I aint smokin nothin. Try it.

 

[splasher]

Re: Any Ideas?

JB, its the taper that locks and holds the flywheel in place not the key.Give it a try cost nothing will do no harm.

 

[JB]

Re: Any Ideas?

With respect, Sir, the taper fixes vertical position. The key fixes phase relationship to the crank.<br /><br />I've replaced too many sheared keys to try mounting the 'wheel without one.<br /><br />Cheers.

 

[wilde1j]

Re: Any Ideas?

Pay attention to the voice of experience, JB. He knows whereof he speaks.<br /><br />By the way, I put a new crankshaft into a '73 Evinrude 135 a lot of years ago and the crank was $635 then. And that's just the part, no labor. Be real careful you don't end up trashing the crankshaft.

 

[Hooty]

Re: Any Ideas?

You may end up grinding the old key out with a Dremel tool. It's sorta slow but with care it can be done.<br /><br />c/6<br /><br />Hooty

 

[poppopfishes2002]

Re: Any Ideas?

if the engraving tool dont work which i think is a good idea as im a machinist try to get a hand held grinder with a thin cut off wheel and cut down the middle of it hope this helps

 

[Bry21317]

Re: Any Ideas?

Thanks guys.<br /><br />We got it with a drilling a second hole in it. Then soaking it some more with PB Blaster. We then hit it a few times with a punch and out she came. So that part is over now.<br /><br />Thanks for all the input though.<br /><br />Bryan Cox