replacing timing belt on 1976 merc 500/50hp

[dub1620]

I have a 1976 2 stroke mercury 500 outboard. The timing belt recently broke, and i am in the process of replacing it. I have the large flywheel and stator removed, but cant for the life of me get the lower flywheel that sits above the pulley on top of the scrankshaft to budge. I have a pulley puller, it doesnt seem to work on it, and im not sure that it should b/c the bolt in the center seems to be attached to the pulley.

Without removing this pulley, i cant get the belt into position because the endcap is too close. I cant seem to remove the end cap either, which would eliminate the need to remove the above mentioned pulley. NOt sure which way to proceed any info would be greatly appreciated.

thx

 

[dub1620]

Re: replacing timing belt on 1976 merc 500/50hp

here are some pics hopefully it will help.

 

[Moody Blue]

Re: replacing timing belt on 1976 merc 500/50hp

Hope you marked the orientation of the outer flywheel relative to that center hub before removing it.

Usually remove the two pieces as one assembly. No need to separate the outer and inner flywheel parts, but that's already done.

A Merc flywheel puller will do the job nicely. Takes me all of 10 seconds once the nut is removed. Since you most likely don't have one then a 3-jaw gear puller should do the trick.

Position the puller on the hub, tension up the center bolt ( not super tight or you may distort the hub) on the crank then whack the center bolt of the puller with a hammer. The hub should pop off the tapered crankshaft end.

 

[dub1620]

Re: replacing timing belt on 1976 merc 500/50hp

I didnt mark the orientaion unfortunately, what can i do to figure out the proper alignment once it is completed?