Engine Disassembly Question

Discussion in '2-Stroke Engines' started by rcjunkie, Apr 21, 2007.

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  1. rcjunkie

    rcjunkie Guest

    I need help figuring out how to remove the clutch, the flywheel, and the small gear that drives the flywheel/clutch assembly. I'm talking apart my engine to replace a cracked side case. Any help would be appreciated. I have the small circular tool but haven't figured out where it goes.


  2. azvinnie

    azvinnie Guest

    good luck to ya, l tried doing the samething and l didn't have the correct tool to take off the flywheel. mine is still sitting in the box, am going to take it to someone and see if they can do anything with it. other than that sorry l couldn't help. maybe someone here will be able to help ya....
  3. rcjunkie

    rcjunkie Guest

    I just need to know how it is removed. Is it press fit and removed with a gear puller or it is screwed onto that shaft. THe gru-bee website pic and my eyesight are neither any good.

    I'm not going to take it to a motorcycle shop; I prefer to do itmself. Plus, I've replaced motorcycles clutches lots of time but those were wet clutches and much easier to remove than this thing. All I need is a little help to "crack the code"on this engine.

  4. Guest

    Guest Guest

    I may not be much help here, but do you have a gear puller?

    Why did it crack?
  5. rcjunkie

    rcjunkie Guest

    The clutch assemgly is press fit onto the shaft which has a woodruff key in it. To remove it, spray some penetrating fluid onto the area and use a propane torch to heat the entire assembly. Once it is warmed up, quickly spray a little more penetrating oil onto the shaft and using two screwdriver's gently the flywheel out. You may have to rotate the flywheel several times and use repeated heat but it will pull out.

    FYI, There isn't very much clearance to use a gear puller.

    Splitting the case is a PITA and can easily damage the case and cause it not to seal properly when reassembled. I used a wooden hammer handle as a wedge. I first sanded the hammer handle so that the tip was angled. I then hammered the wooden hammer handle into the case to keep pushing it apart. As I worked around it, I also gently hammeredm using a wood block, the clutch assembly shaft, on the clutch side to push it out.

    Special Tools needed to completely disassemble the engine:
    Propane Torch
    Impact screwdriver (an aboslute must)
    Previous experience tearing an engine apart
    Permatex Right Stuff as gasket maker (better than paper or cork gasket for the crank)
  6. Guest

    Guest Guest

    Good tips RC!