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techtalk:ref:engmech01r [2019/05/21 02:48] hippysmack created |
techtalk:ref:engmech01r [2019/05/21 04:15] hippysmack [Disassembling the Crankshaft / Flywheel Assembly] |
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====== REF: Engine Mechanicals - Sub-01R ====== | ====== REF: Engine Mechanicals - Sub-01R ====== | ||
====== Disassembling the Crankshaft / Flywheel Assembly ====== | ====== Disassembling the Crankshaft / Flywheel Assembly ====== | ||
+ | Article by Hippysmack \\ | ||
+ | This is a 91-99 flywheel assembly but the process is basically comparable for 03 and prior flywheel assemblies. \\ | ||
+ | The table is a 3/4" piece of plywood hinged to the wall with a 2x4 stood up under it. \\ | ||
+ | To make it easier, no measuring of the holes was done. \\ | ||
+ | A 2" hole saw was used to bore a hole for the pinion shaft to sit down in. | ||
+ | The size of the hole isn't really critical as long as it's bigger than the shaft. \\ | ||
+ | The 2" hole just gives some leeway to position the wheels to drill for the holding pins. \\ | ||
+ | Then a 3/8" drill bit was run into the holes to the board to mark the hole locations. \\ | ||
+ | |||
+ | |{{:techtalk:ref:engmech:homemade_flywheel_torque_jig_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:engmech:homemade_flywheel_torque_jig_2_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:engmech:homemade_flywheel_torque_jig_3_by_hippysmack.jpg?direct&300|}}| | ||
+ | |||
+ | The location can be adjusted if needed before drilling the holes. \\ | ||
+ | Once the holes are drilled, run 2 pieces of 3/8" x 12" threaded rod into the holes with nuts and washers on top and bottom. \\ | ||
+ | Make sure they're tall enough to go through the holes in the top wheel. \\ | ||
+ | Then set the wheel over the all-thread (or holding pins). \\ | ||
+ | |||
+ | |{{:techtalk:ref:engmech:homemade_flywheel_torque_jig_4_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:engmech:homemade_flywheel_torque_jig_5_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:engmech:homemade_flywheel_torque_jig_6_by_hippysmack.jpg?direct&300|}}| | ||
+ | |||
+ | Use a 1-5/16" socket wrench to remove the crank pin nut on the sprocket side. \\ | ||
+ | With the crank nut off, lower the all-thread below the top wheel and retighten the nuts. \\ | ||
+ | You'll be knocking the top wheel sideways next to loosen it from the crank pin. \\ | ||
+ | |||
+ | |{{:techtalk:ref:engmech:homemade_flywheel_torque_jig_7_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:engmech:homemade_flywheel_torque_jig_8_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:engmech:homemade_flywheel_torque_jig_9_by_hippysmack.jpg?direct&300|}}| | ||
+ | |||
+ | Double check that the holding pins are below the top wheel. \\ | ||
+ | |||
+ | Do not attempt to hit the hardened flywheel with a steel hammer alone. \\ | ||
+ | You need to use a soft metal hammer (brass, lead etc.) to keep from exploding the flywheel into your body parts. \\ | ||
+ | A sledge hammer hitting a block of aluminum against the wheel was used below (a rubber mallet will do you no good in this instance). \\ | ||
+ | |||
+ | Hit the top wheel 90º to the crank pin hole on the outside edge to knock it sideways and loosen itself from the crank pin taper. \\ | ||
+ | Basically hit the outside edge in the vicinity of the holding pin hole. The soft metal will not hurt the flywheel. \\ | ||
+ | |||
+ | |{{:techtalk:ref:engmech:homemade_flywheel_torque_jig_10_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:engmech:homemade_flywheel_torque_jig_12_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:engmech:homemade_flywheel_torque_jig_11_by_hippysmack.jpg?direct&300|}}| | ||
+ | |||
+ | It takes a pretty good whack to move it and swing it off to one side.\\ | ||
+ | At this point, you can lift the top wheel off the assembly. \\ | ||
+ | |||
+ | **Note**: Use a short piece of pipe (O.D. no bigger than the bearing cage) over the crank pin and against the top bearing cage. \\ | ||
+ | (else the small bearings will fall out and scatter when you pull the rods up) \\ | ||
+ | That was not done here and bearings did scatter. \\ | ||
+ | Then remove the connecting rods. \\ | ||
+ | |||
+ | |{{:techtalk:ref:engmech:homemade_flywheel_torque_jig_13_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:engmech:homemade_flywheel_torque_jig_14_by_hippysmack.jpg?direct&300|}}| | ||
+ | |||
+ | The bearings and parts will go everywhere so it's best to have a storage container of sorts to keep them in until you're ready for reassembly. \\ | ||
+ | |||
+ | |{{:techtalk:ref:engmech:homemade_flywheel_torque_jig_15_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:tools:small_parts_storage_1_by_hippysmack.jpg?direct&300|}}| | ||
+ | |||
+ | Next, the jig has to be drilled to accept the crank pin and allow the bottom flywheel to sit over the holding pins. \\ | ||
+ | The wheel was placed over the pins, leveled and the crank pin location outlined. \\ | ||
+ | |||
+ | |{{:techtalk:ref:engmech:homemade_flywheel_torque_jig_16_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:engmech:homemade_flywheel_torque_jig_17_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:engmech:homemade_flywheel_torque_jig_18_by_hippysmack.jpg?direct&300|}}| | ||
+ | |||
+ | Then another 2" hole was made into the outline for the crank pin. \\ | ||
+ | Lower the wheel into position and the nut can now be removed with the 1-5/16" socket. \\ | ||
+ | |||
+ | |{{:techtalk:ref:engmech:homemade_flywheel_torque_jig_19_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:engmech:homemade_flywheel_torque_jig_20_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:engmech:homemade_flywheel_torque_jig_21_by_hippysmack.jpg?direct&300|}}| | ||
+ | |||
+ | Then, knock the pin out with punch and hammer (make sure there is something soft under the crank pin for it to land on). \\ | ||
+ | Again, it'll take a good whack to dislodge the crank pin. \\ | ||
+ | |||
+ | |{{:techtalk:ref:engmech:homemade_flywheel_torque_jig_22_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:engmech:homemade_flywheel_torque_jig_23_by_hippysmack.jpg?direct&300|}}| | ||
\\ | \\ |