Trouble pulling mag flywheel

[Onemorecast]

So i have entire top end off and motor is out of ski, im trying to remove this rusted POS, have new wheel, magneto housing, rectifior, everything....I have the proper puller and cant seem to get this pig off. Its been soaked with PB for hours and as of tonight I mixed up a batch 1:1 of ATF and acetone as i've heard and seen its a great rust buster. Any tips to get this thing off would be great. Right now i have old crummy flashlight jammed jn opening for starter to prevent wheel from spinning (ignition housing is being replaced so not worried if it gets wrecked) this thing is on there GOOD!!! Also drilled
Out mag housing screws to take off and give puller more threads to grab but that didnt want to budge, but thats why they are missing if you are wondering.

 

[Onemorecast]

Nvm 4' cheater bar plus more "weasel piss". THANK CHRIST!!

 

[Sportster-2001-951C-Stock]

"I mixed up a batch 1:1 of ATF and acetone as i've heard and seen its a great rust buster. "

You aren't supposed to broadcast that secret recipe, PB Blaster will send an unmarked white van to your house!

 

[Onemorecast]

Ahhaha after using a can of PB w/ ZERO effect I was extremely happy to stumble upon this old mechanics mix, im sure a few like myself have never heard about it before. If it saves somebody from the aggravation I had from this rust bucket....let them send all the white vans they want

 

[Sportster-2001-951C-Stock]

While we're broadcasting recipes, my rust preventor is 1/4lb of melted paraffin wax poured into 1qt of mineral spirits and one tablespoon of motor oil. Place this in a spray bottle and go to town with it on anything you want to coat in paraffin and wait for the mineral spirits to evaporate out.

 

[Onemorecast]

While we're broadcasting recipes, my rust preventor is 1/4lb of melted paraffin wax poured into 1qt of mineral spirits and one tablespoon of motor oil. Place this in a spray bottle and go to town with it on anything you want to coat in paraffin and wait for the mineral spirits to evaporate out.

Ive heard good things about a paraffin mix, will just have to mix up a batch. Nothing like looking like a meth lab when I'm out pouring liquids into jars w respirator on. Why I have ya on here, I know it isn't best pic, but does that woodruff key look ok. Not sure if its supposed to stick out more or how it is is correct.

 

[Sportster-2001-951C-Stock]

I'd say you did a great job getting the flywheel off without ruining the snout. The key looks fine to me, don't really need it anyway except to get the correct initial position b/c it's the taper-fit once torqued that keeps the alignment.

Straight up Rotax spec on that ignition timing is good, we just want to ride around not break speed records.

I'd clean up the taper surfaces with acetone (don't get it in the crank seal) and put the lock-tite red back on there.

Are you going to pressure test the crankcase or let it ride and see how it goes?

 

[Onemorecast]

Well after removing old ignition housing....no gasket (great) already have housing and gasket and oil seal in mail heading here. I have no way to pressure test case so, ride/pray.

 

[Mekanix]

Had one like this a while ago. Managed to get it off with a harmonic ballancer puller and a heat gun.

Set the most tension I could by hand without snapping bolts and then left the heat gun on it.
5 minutes later... PUAAANG...
Thing just flew off

 

[Sportster-2001-951C-Stock]

I bet it works out just fine with the new crank seal.

 

[Bnelson]

Had one like this a while ago. Managed to get it off with a harmonic ballancer puller and a heat gun.

Set the most tension I could by hand without snapping bolts and then left the heat gun on it.
5 minutes later... PUAAANG...
Thing just flew off

That idea there is goin in the piggy bank.... Thanks

 

[sookati]

I just had the same issue with a rusted flywheel on my '96 GTI. I had an ungodly amount of pressure with a 4' cheater bar on my puller plus PB Blaster, nothing.

I took it to my shop (I'm a sales rep), and a mechanic put a big air impact on the puller and had it off in 2 minutes. I think having all the torque centered on it really helped.

 

[Sportster-2001-951C-Stock]

That's easy, it's a tape measure!

 

[Onemorecast]

Well since no ignition housing gasket, top end got done

 

[Onemorecast]

I just had the same issue with a rusted flywheel on my '96 GTI. I had an ungodly amount of pressure with a 4' cheater bar on my puller plus PB Blaster, nothing.

I took it to my shop (I'm a sales rep), and a mechanic put a big air impact on the puller and had it off in 2 minutes. I think having all the torque centered on it really helped.

After this "miracle concoction" I wont use canned stuff again, except maybe kroil, craps expensive though. The ATF/acetone was the trick, along w using cheater bar. I had rusty nuts rofl sitting in the mix for an hour, they look brand new! Ratio is 1:1 dirt cheap and works WORLDS better

 

[Sportster-2001-951C-Stock]

Not to mention the rusty nut behind the wheel.