Feed: Small Engine Repair – How Do I Remove the Flywheel - AggScore: 18.1

Small Engine Repair – How Do I Remove the Flywheel on My Go Kart?

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pWe have been talking about ignition systems and their repair, but one important component is flywheel removal. Especially if you have an engine with points. Typically the points are underneath the flywheel, and when they go bad, the flywheel must be removed.ppYou will discover that flywheels have illusive retention devices, in particular the rapid rewind systems that include ball bearings.ppYou will also discover that once you figure out how to remove the rapid rewind cog system that the flywheel is fixed pretty hard on the crank shaft.ppThis article is aboutpp How to first of all remove the rapid rewind cog system. br Secondly how to remove the stubborn flywheelbr And finally how to put it all back together again.ppIt should be noted that the flywheel has fins on it. If any of these fins become broken, the engine will become out of balance and vibrate intensely. If the fins are broken, the flywheel is junk, so be very careful around the fins.ppTo remove the rapid rewind cog use a pipe wrench and a screw driver. The pipe wrench is put on the rapid rewind cog and the screw driver is inserted in between the cast iron fins. Note there are aluminum fins, stay away from them, they will breakppRotate the crank shaft so that the screw driver is pressed against an immovable object. Another method which is more forgiving, is to wedge a piece of wood this works best when the engine is mounted to the engine mounts on the go kart under the flywheel. This acts like a wedge brake.ppGently press down on the pipe wrench. Excessive force is not needed here. The rapid rewind cog generally comes off rather easily then.ppA note with respect to the rewind cog unless you like chasing ball bearings all over the floor, keep in mind that typically a screen covers the rewind. Remove the screen, BUT put the retention screws back in place right away. This makes the rewind cog stay together, and also be accessible to the pipe wrench.ppNext the flywheel is stuck on the crank shaft with a press fit. Actually the flywheel is press fit using a cone shaft aperture on the crankshaft. The object is to pop the press fit. To do this generally a shock needs to be introduced into the system.ppThere are two methods that work best. First shock the end of the crank shaft with a very hard piece of wood and a mallet. Note do not use steel on steel, the end of the crank shaft will become mushroomed over and become unusable. Repair is usually not doable.ppThere are tools available that you put on the end of the crankshaft, but even they can damage the crankshaft. So be careful to use minimal blows on the crank. And in case I did not make myself clear, the blows are normal, or perpendicular, or axial to the crankshaft, not to the side of the crank, but to the end of it.ppSometimes that does not work. If the engine has been sitting around for years, or is over 10 years old, the crank may have rusted partially to the flywheel.ppUse a little penetrating oil at the flywheel, crank interface.ppThen pry the back of the flywheel, very gently, and evenly with a flat head screw driver, or even a prybar. Very light action is needed. If you are reefing on the screw driver, there is something wrong. something else is holding the flywheel on!ppThe flywheel should pop off right away, so be sure to catch it before it flies off and falls on the floor. I suggest having a catch system such as rags or cardboard.ppTo reinstall the flywheel put it back together the same way it came apart. Use the pipe wrench and the screw driver method to tighten the rewind cog.ppAgain, do not over tighten the rewind cog. Also take note that the washer was put back in place.ppJust as a side note, the only real reason a flywheel should be removed on modern magneto style engines is if the key way sheared. If the key way sheared you should be looking at other areas on the engine for damage...ppThe Go Kart Guru is a Go Karting Design, Fabrication and Performance specialist. Topics ranging from Turbo Charged Go Karts to Wood Go Karts, the Go Kart Guru has something to say that will help you! about it. Visit a targetnew hrefhttpGoKartGuru.comhttpGoKartGuru.coma for more details.ppAnd for those with Vertical Lawnmower Engines, there is a special section just for you! Dont throw away that vertical engine just yet!p

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