WOW! Ring gear/rotor nut is tight! Help!

[justy_123]

Hey all.
Been trying all day to get the nut off the ring gear/rotor assembly. Its so so tight. :ack: I've tried heating it , soaking it in wd-40 and using a 1.5ft breaker bar. I'm scared I'm gonna break something expensive! The engine is still mounted in the jet ski and its a 2004 XPdi. Read in the manual that this nut is done up to 85 ft lbs.:redface: real tight!

Any ideas? Could I use a rattle gun?

Also, I'm using rope inside one of the cylinders to lock the crankshaft up. Is that ok or is there a better way?

Its a fairly long story, but the reason I am taking the ring gear off is to get to the starter bendix drive. Ever since I bought the jet ski a few months ago the bendix drive has been playing up. So thought I would change it.

It's been a big job so far. Exhaust bolts hard to get to and seized! Lost count on the things I have undone or loosened to get access to the exhaust etc. Found things that need replacing eg. oil pump cable which is about to break :ack:

Opened the front mag cover and the reason the starter bendix has not been working that well is the fact that all inside the ring gear, magneto and starter bendix area is water and gooey rusty sludge! Somehow water has made itself inside. It aint pretty! Bugga.

But I really need to get this nut off so I remove the ring gear/rotor assembly, remove the old starter bendix drive, clean the whole area out and put a new bendix drive in.

Thanks guys. I need help!

 

[Dr Honda]

Just use a BIG impact on it. It will blow the nut off quick and easy. Also... if you use a big, twin hammer rattle gun... it can probably knock the nut off without holding the engine with any mechanical means. (just grab the flywheel)

 

[justy_123]

Thanks Dr Honda. Will give it a go. Hopefully it will move!
Cheers

 

[justy_123]

Just bought a rattle gun. Only a cheapy. Says max torque of 250ft lbs.

Should I leave the rope in the cylinder and keep the crankshaft locked whilst I try and undo the nut? Or should I take the rope out and put the spark plugs in?

I'm a bit worried about causing damage to the engine internally with this force that the rattle gun is gonna put on this nut.

Any ideas? :cheers:

 

[Dr Honda]

You can try it with the spark plugs in... but if it's a cheap gun... it may not do the job. BUT... to help your self... hook it to your compressor with a 3/8" ID hose, and don't use any quick connectors. Even though you may have 80 PSI in the line... once it goes though the fittings, and a small hose... you may only have 40 psi internal of the impact gun.

When I go something like this... I use an IR twin hammer rated to 750 Lb/ft. It pops the nut off without even spinning the engine.

Oh... if you have a strap wrench... put it around the ring gear to hold it while hitting it with the gun.

 

[justy_123]

The nut is off! Yay!

The impact gun worked. It took a few seconds and then it went.:rofl:

However, my next hurdle is to pull off the flywheel from the crankshaft:ack:

I have a puller that should work. But I can't get the screws out that attach the rotor and flywheel assembly together. There's about 6 screws. They are tight also. Probably all the rust that is in the area. I have 'rounded' out 2 screw heads already trying the unscrew the screws.

Not too sure what Sea Doo were thinking using those useless star shape internal heads!

I would leave these screws in, however, I need to attach my puller to something. At least 3 of these screws.

Any ideas guys?Any other ways to remove the flywheel?

 

[justy_123]

Just done some research and I think the best bet is to buy the Sea Doo crankshaft puller for this engine.

P/N 420 976 235.

Looks like it just screws on to the crankshaft and pulls it off from there. Sounds too easy.

Off to my Sea Doo dealer tomorrow to spend more money!

 

[seadooya]

imprevise

http://www.shopsbt.com/jetski_repair_tools/80-104.html