how to remove flywheel? 200hp johnson v6

[floffshore]

hello,

i have a 90 v6 200hp outboard. i was out fishing today and i went to start it up and heard a horrible sound. turned out to be some large magnet fragments stuck between the flywheel and the starter. it was a long ride home using my 5hp kicker but i made it in eventually.

i was looking around online for a manual or instructions on how to remove the flywheel. i'm hoping to just be able to replace the magnets.

i'm somewhat mechanically inclined. i have rebuilt a few motors in my life, both 2 and 4 stroke, but i'm not an expert on outboards. can anyone offer any advice/suggestions or link to some instructions?

i have a seloc manual but it just says "remove the flywheel", lol.

thanks in advance.

 

[tashasdaddy]

Re: how to remove flywheel? 200hp johnson v6

PULLING FLYWHEEL

you need a harmonic balancer puller, you need 3 - #8 harden bolts, that fit the 3 holes in your flywheel. standard hardware store bolts will strip out, causing more problems. loosen the flywheel nut, leaving it on so it protects the thread. thread the bolts in 7/16 of an inch. then tighten the puller, adjust so it has a straight pull. now tighten the puller, rap the center bolt with a hammer, then tighten some more. you may have to let it sit over nite, and repeat in the morning. this is a compression fitting, it will eventually POP!!. do not loose the woodruff key that goes in the groove of the flywheel and the crank shaft. then installing the flywheel, it has to be totally clean, no oil, woodruff key in place. then torque the nut to the specifications for your particular motor. if you do not do this, the woodruff key with shear, and you will be repeating these steps.

 

[daselbee]

Re: how to remove flywheel? 200hp johnson v6

Loosen the large flywheel retaining nut in the center of the flywheel about 2 turns. Don't take it all the way off, as it will keep the flywheel in place when it pops up.
Go get a harmonic balancer puller from autozone, a good heavy one. YOU HAVE TO GET A GOOD STOUT PULLER.
Affix it to the flywheel using 5/16-24 grade 8 bolts. Three holes are already tapped in the top of the flywheel. Thread the three puller bolts in at least an inch. You may need to chase the rust and paint out of them.
Hold the flywheel, tighten the puller center bolt, very tight, and whack that center bolt top with a hammer.
You gotta get it tight, very tight. We're talking breaker bar tight. If it does not pop, tighten the puller center bolt a bit. Whack it again. You may have to soak some penetrating oil on it, you may have to wait a day with the pressure on...just keep tightening it, and give it a whack every now and then. It will eventually pop.
When it pops, the flywheel nut will keep it on the crankshaft and it will not sail across the garage.

Search "flywheel remove" on this site for plenty on stories and methods.
Get your magnet repair kit(s), and fix the flywheel, checking for other damage that probably occurred under there.

Replace, making sure the key is correctly installed in it's keyway, and torque to 140-150 ft-lbs. Very important to keep from shearing the flywheel key later.

 

[floffshore]

Re: how to remove flywheel? 200hp johnson v6

you guys are awesome. thanks.

 

[floffshore]

Re: how to remove flywheel? 200hp johnson v6

i dont have a socket that size!

the biggest socket i own is a 30mm i use to remove the clutch basket from my dirt bike. that wont even cover that nut.

anyone know what size socket i need so i can run out and pick one up on the way home today? thanks.

 

[daselbee]

Re: how to remove flywheel? 200hp johnson v6

i dont have a socket that size!

the biggest socket i own is a 30mm i use to remove the clutch basket from my dirt bike. that wont even cover that nut.

anyone know what size socket i need so i can run out and pick one up on the way home today? thanks.

1-7/16 socket, or a 38mm will fit also. I use the 38mm.

 

[floffshore]

Re: how to remove flywheel? 200hp johnson v6

i just got back from sears with a shiny new 1 7/16" socket.

but it's too large. the outer diameter of the socket is even too large to fit inside the recess of the flywheel where the bolt is. is there another common size (smaller) it could be?

thanks

 

[James R]

Re: how to remove flywheel? 200hp johnson v6

Take that back to Sears. I think it is a 1 5/16 that you need. Not absolutely certain but the motors I have been working on take that size.

 

[daselbee]

Re: how to remove flywheel? 200hp johnson v6

Oh crap...very sorry. In my 1996 200 looper OMC book it specifically states
1 7/16. Re-reading I see you haave a '90.
Very sorry.

 

[ezeke]

Re: how to remove flywheel? 200hp johnson v6

It is 1-7/16. Put your socket on an extension and grind it down on the edge until it fits. You are supposed to use a thinwall socket but the one you have should work that way.

Don't strike or heat the flywheel, or you will be replacing the rest of the magnets.

 

[ocdb]

Re: how to remove flywheel? 200hp johnson v6

When removing the flywheel and putting back on do you need to do any timing adjustments or watch out for anything that could mess your timing up?

 

[daselbee]

Re: how to remove flywheel? 200hp johnson v6

Nope. Just put it back on, making sure you align the key properly.
The magnets in the flywheel tend to pull it around a bit, moving it where and when you don't necessarily want it to move, but align the key. Clean crankshaft nose and flywheel taper very well. Torque to 140-150 ft-lbs.

 

[floffshore]

Re: how to remove flywheel? 200hp johnson v6

thanks everyone.

no worries on the size. your input/advice is worth more to me than one extra round trip to sears!

i'll grab a 1 5/16 and give it a shot. if it doesnt work, ill pull out the roto zip and get to grinding down the fancy new $18 socket.

one more question... can someone point me to somewhere online where i can buy the magnet kit? gracias.

 

[wilde1j]

Re: how to remove flywheel? 200hp johnson v6

Any BRP dealer.

 

[floffshore]

Re: how to remove flywheel? 200hp johnson v6

the 1 5/16 fits in the recess, but is too small for the nut.

looks like a ground down 1 7/16th socket it is!!

 

[daselbee]

Re: how to remove flywheel? 200hp johnson v6

I am surprised. I just went to Sears and bought an off the shelf 38mm, 1/2 in. dr. socket and it fits.
You are not using an impact socket, or a 3/4 in.dr. are you?

They must have increased the diameter of the flywheel recess in 1993.

 

[floffshore]

Re: how to remove flywheel? 200hp johnson v6

I am surprised. I just went to Sears and bought an off the shelf 38mm, 1/2 in. dr. socket and it fits.
You are not using an impact socket, or a 3/4 in.dr. are you?

They must have increased the diameter of the flywheel recess in 1993.

i was looking for a 38mm but all they had was <= 36mm.

i'm going to swing by one last time tomorrow and take another look.

 

[daselbee]

Re: how to remove flywheel? 200hp johnson v6

i was looking for a 38mm but all they had was <= 36mm.

i'm going to swing by one last time tomorrow and take another look.

Well, just goes to show ....I went to the shop to verify exactly what I use, and sure enough, it is NOT 38mm, but it is a 36mm. That's what I get for trying to do this from memory...
I have the Sears number etched into the side of the socket, AND THIS IS RIGHT....#50752, 36mm, 1/2 in dr., 12 pt., $8.79.

1-7/16 = 1.4375
36mm = 1.4173

which is .020 smaller, but it works for me.

I use it on my 1994 - 1998 V6 loopers. This time the info is correct. Sorry.

 

[floffshore]

Re: how to remove flywheel? 200hp johnson v6

no problem, thanks for the follow-up.

i actually got back from the "made in china" cheap tools hardware store a little while ago today. i bought a 4,000 piece 3/4" drive set with 18 ratchets, 32 extensions, 183 breaker bars and a lifetime warranty for $3.

no, but seriously, i got a 21pc 3/4" set for like $50. i took the 1 7/16" and started grinding down the sides a bit until it slid easily in and out of the recess. i managed to get the bolt loose already and now i'm working on trying to pop the flywheel off with my craftsman puller.

how do you guys normally keep the flywheel from spinning when youre loosening that bolt?

i just put about 18" of my stern line into one of the cylinders so it wouldnt be able to spin freely, but wondering how other people do it as well.

thanks again for all the help/info guys.

 

[bankerjohn]

Re: how to remove flywheel? 200hp johnson v6

i managed to get the bolt loose already and now i'm working on trying to pop the flywheel off with my craftsman puller.

how do you guys normally keep the flywheel from spinning when youre loosening that bolt?

i just put about 18" of my stern line into one of the cylinders so it wouldnt be able to spin freely, but wondering how other people do it as well.

To keep the flywheel from turning, I installed my harmonic balancer puller ... then wedged a BIG screwdriver between two of those bolts.

When you say you're going to use your "craftsman puller" ... I hope you don't mean one of this 2-armed bearing pullers! If so, you may very well warp the flywheel using it ... you need to use a harmonic balancer puller, with three grade 8 bolts screwed into your flywheel.