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--- techtalk:ref:engmech01r [2019/05/21 02:55] – hippysmack
+++ techtalk:ref:engmech01r [2019/05/21 04:46] (current) – [Disassembling the Crankshaft / Flywheel Assembly] hippysmack
@@ Line 2: / Line 2: @@
 ====== REF: Engine Mechanicals - Sub-01R ======
 ====== Disassembling the Crankshaft / Flywheel Assembly ======
+See more [[techtalk:ref:tools103#reftools_-_103|crankshaft / flywheel tools]] in the tools section of the Sportsterpedia. \\
+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|}}|
-|{{:techtalk:ref:engmech:homemade_flywheel_torque_jig_10_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:engmech:homemade_flywheel_torque_jig_11_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:engmech:homemade_flywheel_torque_jig_12_by_hippysmack.jpg?direct&300|}}|
+Double check that the holding pins are below the top wheel. \\
-|{{: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|}}|{{:techtalk:ref:engmech:homemade_flywheel_torque_jig_15_by_hippysmack.jpg?direct&300|}}|
+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|}}|

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