trouble removing bolts and flywheel...help!


bluemonster1 said:
becoming a little difficult disasembly.The torgue limiter hex bolts gave me headaches.Had to grind the head with 2 straight edges to put 1/2 inch wrench on it and got it to turn,Need a new bolt for there.Then the bracket for the limiter,the 2 hex bolts on the 2 halves of the cases wouldn't move either.Used a little heat and got one to turn,stripped the other one.But at least can split cases with the one bolt removed.
On to the flywheel end nut.Which way to turn to undo it...clockwise I assume.Have to use impact,but there is no way of holding the damn shaft from turning.Don't want to damage the crank or bearings with impact movement more then neccessary.What is the trick here.Have that feeling it is going to get harder yet.If I can't remove the nut and flywheel,then the seal are staying put and I will only complete top end.... :o| #$%&*
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Another means of holding the crankshaft from turning when loosening the flywheel nut is to use a piece of rope placed into a spark plug hole. Not too long that it ends up into a transfer/exh/int. port, but enough to fill combustion chamber causing the piston to top out before TDC. Bring the piston above open ports, stuff the rope down the plug hole, turn the crank 'til it stops.

Of course if the cylinders are off this won't work nor would I recommend it for clutch removal.
 
going to get some case sealant today,will stop by the dealer.What is the procedure now that the cases and crank are out ...the cleaning procedure.Do I simply use brake fluid and clean the bearings and crank ..then dry off with air.Same with the cases....Don't want to start using towels or rags and leaving lint behind.
 
Clean the bearings with carb clean and use air to remove cleaner and debris. Do not spin bearings with air though. After cleaning of crank is done lubricate bearings of crank with some 2-stroke oil. I use an old mustard bottle for positive placement of the oil. With the cases clean I spread a very thin layer of loctite where the brearings of the crank are going to sit on both case halves. This VERY thin layer with fill any TINY voids or incorrect alignment of the cases. The permatex sealant you described earlier in this thread will work just fine. Just spread a thin layer on both case halves wait a minute and carefully assemble cases. Make sure that the crank is fully seated in upper case half before setting lower case half on. torque all bolts in sequence and to the correct torque of 19 ft/lbs. I do it in three steps also. 10-15-19. Also put sealant in the grooves where the mag and pto seal will sit. Hope this helps you out.
 
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haven't pu any Yamabond yet..I can get my hands on threebond,if Permatex is silicone base,don't want to use it.Waiting for all my parts to come.That will be in about 2 weeks..so no rush to find the right sealant.
I want to de-glaze the cylinders with my tri-stone honing device and wash cylinders good.Probably put it thru the DW cycle.
 
The tough part is getting the flywheel off. Its really on there. I used a 3 bolt puller as most do. Mine was so "on there" that it bent the puller and just about snapped. I had to put an oxy-acetylene flame on the inner hub of the flywheel to get it to break loose.
 
sxr-x said:
Clean the bearings with carb clean and use air to remove cleaner and debris. Do not spin bearings with air though. After cleaning of crank is done lubricate bearings of crank with some 2-stroke oil. I use an old mustard bottle for positive placement of the oil. With the cases clean I spread a very thin layer of loctite where the brearings of the crank are going to sit on both case halves. This VERY thin layer with fill any TINY voids or incorrect alignment of the cases. The permatex sealant you described earlier in this thread will work just fine. Just spread a thin layer on both case halves wait a minute and carefully assemble cases. Make sure that the crank is fully seated in upper case half before setting lower case half on. torque all bolts in sequence and to the correct torque of 19 ft/lbs. I do it in three steps also. 10-15-19. Also put sealant in the grooves where the mag and pto seal will sit. Hope this helps you out.
Click to expand...
all great advise , just wanted to add don,t forget to add some 2 stroke oil to the waterpump/oil pump shaft cavity right before you bolt the halves together.
 
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