Suzuki DT 75 Flywheel Stuck

[let0927]

Hey guys,

I have a stuck flywheel on my powerhead. The powerhead is removed already and I'm in the beginning stages of replacing the piston rings, bearings and crank bearings (expensive). I have significant mechanical experience and mediocre experience on outboards plus I have a self experienced vet on outboards from Tampa helping me out. (We are currently in Raleigh)
Here is What I've tried:
1) Harmonic Balancer/Steering Wheel puller
A. Doesn't work, starts to bend when I put too much torque on it (tried two different ones)
2) Two Arm gear puller
B. Same thing but starts bending the top of the flywheel up.

I'm thinking about getting a three arm hydraulic gear remover from harbor freight

(link here) http://www.harborfreight.com/5-ton-three-jaw-hydraulic-gear-puller-95326.html

but I'm afraid the same thing will happen. I have soaked the threads in Penetrating oil (PB blaster). I also have the manual and have done everything it says.

One of my questions is, does the flywheel have a cover or something I need to remove? I do not see any other screws or bolts on top. (and yes, I have removed the lug and washers from the top)

Any suggestions, past experience is grateful,

Thanks

 

[99yam40]

Re: Suzuki DT 75 Flywheel Stuck

I am not familiar with the DTs, but does the manual name a special puller for that motor?
Some motors need a puller that threads into a recessed area around the shaft with a threaded bolt running through the middle of it

 

[let0927]

Re: Suzuki DT 75 Flywheel Stuck

The manual has a part number for the puller that is outdated. I found one that is the equivalent for $77 with no pictures. I just wander what is so special about that one?

Edit: actually, the part they call for costs over $200. What do you think about this one?

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=280592491986&viewitem=#vi-content

Its for a motor cycle but not sure if it would work. Don't have the engine readily available so can't tell if there are threads on the inside of the flywheel hole.

 

[robert graham]

Re: Suzuki DT 75 Flywheel Stuck

Have you tried applying some heat to the flywheel while you tighten down on your puller? Tighten, apply heat, tap with a small hammer will usually break one loose! Good Luck!

 

[mphelle8vld]

Re: Suzuki DT 75 Flywheel Stuck

+1 to the last post although you might need more heat and a smack with a large hammer to the end of the puller, also, loosely replace the flywheel nut to keep things from flying when it does break free. Not sure what you consider expensive for the parts and labor to rebuild but here's a backup if you find it more cost effective. (especially if you haven't found out how many exhaust cover bolts will twist off during disassembly)

I believe it's an 88.
http://cgi.ebay.com/ebaymotors/Suzu...3985269QQptZBoatQ5fPartsQ5fAccessoriesQ5fGear

 

[99yam40]

Re: Suzuki DT 75 Flywheel Stuck

The manual has a part number for the puller that is outdated. I found one that is the equivalent for $77 with no pictures. I just wander what is so special about that one?

Edit: actually, the part they call for costs over $200. What do you think about this one?

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=280592491986&viewitem=#vi-content

Its for a motor cycle but not sure if it would work. Don't have the engine readily available so can't tell if there are threads on the inside of the flywheel hole.

That is the style I was thinking of, but I do not know if that will fit your motor or even if your motor is set up for that. You will have to look and measure hole size and threads and see.might call brownspoint and ask. I have heard they are very helpful.
Some of these flywheels are not made to be pulled with the old style of puller, they are not made of strong enough metal to be pulling from the outside edges. They have magnets glued to them and you do not want to hurt that with too much heat, and most of the bearings do not tolerate hitting on the puller like in the old days

 

[Silvertip]

Re: Suzuki DT 75 Flywheel Stuck

DO NOT use a two or three arm gear puller on a flywheel unless you really want to buy a new one. Use only a puller that bolts to the flywheel. Tension the puller bolt tightely then give a sharp rap on the puller bolt. tighten a bit, rap again. Let soak, repeat. With stuck parts "patience" and plenty of any of the rust-breaker liquids is required. Impatience breaks things.

 

[let0927]

Re: Suzuki DT 75 Flywheel Stuck

Awesome responses. As to the heat, I'll try that, the only issue I was thinking about is the block is aluminum. Any problems there. mphelle8vld, I'm gonna buy that one. The parts to rebuild is over $1,000 from Brownspoint. I still need to pull the flywheel bc the one doesn't seem to have one. Thanks

 

[let0927]

Re: Suzuki DT 75 Flywheel Stuck

I purchased a flywheel puller from amazon that looks promising. I think what I am going to do is when it comes in, attach it, apply the pressure with my nifty 18v Porter Cable impact wrench, let stand, turn again, maybe a few light whacks with the hammer and repeat until it comes off. Sound good?

 

[James R]

Re: Suzuki DT 75 Flywheel Stuck

If this motor has been in salt water it may only work with heat. You will need a whole bunch of parts and possibly stator parts. I use the three pole harmonic balancer puller with hardened cap head bolts. Be careful not the damage the crankshaft end. Use the tapered tip in the grinding center of the shaft.I use an impact wrench and it works.

 

[let0927]

Re: Suzuki DT 75 Flywheel Stuck

Finally got her to pop. We took the powerhead off to replace the other one and took the powerhead to a local tire shop where we used their impact wrench, came right off.