1997 xp pto flywheel. PLEASE HELP

[E9sling]

new member here please help. i have a 1997 xp im trying to remove the pto flywheel. the flywheel appears to be 2 pieces. i can get the part with the "ears" to turn but the flat piece between it and the case does not. i need to get this off. what do i do?

 

[SeadooBOB Square Pants]

First, are you removing it because of damage? It sounds like the piece with the "ears" or coupler is rounded off in the PTO. If it is similar to the PTO on my XP I had to remove the pump and drive line to get the rest of the PTO assembly out. Once you get the drive line/pump pulled then you will be able to better get to the PTO. I left my engine in but this made a huge PIA, you can use a chain wrench 14" or larger or a pipe wrench but if you are keeping the PTO remove the grease nipple so you don't damage it. Any other info on the ski would be great. Can you spin the impeller without the crank turning??

 

[E9sling]

sorry i didnt get into more specifics. the engine is out. engine destroyed rod bearing. i pulled an engine from a 96 xp that i am going to put in the 97 xp. the pto flywheels are different. the one from the 96 has the grease fitting and can use an impeller to remove. http://www.monstermarketplace.com/p...oo-clutch-flywheel-pto-800-cc-xp-97-420958096
the pto on the 97 looks like the one on this link. this is the one i can not get off. any suggestions? thanks

 

[LouDoo]

Try this, honestly I haven't done this myself, but Dr Honda has recommended this method.

Get some cotton rope, like clothes line rope, and run it in one of the spark plug holes. Turn the motor over until it makes contact with the rope. This will lock the motor without destroying the piston. Put your pipe wrench on the smaller part or the flywheel, see if you can pop it loose, if it doesn't move try a little heat, like your wife's hair dryer.

Lou

P.S. What are you going to do with the 96XP? I've got one I just bought and might be interested in some parts, specifically the upper hood.

 

[E9sling]

i did that to get the pto off the 96 and it worked perfectly. on the 97, i had already taken the jugs off so rope is out of the question. i was able to wedge a pry bar to keep the crank from turning. i put a pipe wrench on it and the smaller part turned, but the larger, flat piece and the crank did not

 

[SeadooBOB Square Pants]

Watch the SBT video about removing a PTO flywheel he uses a chain wrench, but I tried this method with a lower end model wrench and it failed but the guy on the video makes it look easy. The one in the video however is working on a brand new engine not an old one that has been sitting.

The link below has some videos I have watched on carb cleaning, etc. pretty helpful videos.
http://www.shopsbt.com/forum/f23/

 

[SeadooBOB Square Pants]

Try this, honestly I haven't done this myself, but Dr Honda has recommended this method.

Get some cotton rope, like clothes line rope, and run it in one of the spark plug holes. Turn the motor over until it makes contact with the rope. This will lock the motor without destroying the piston. Put your pipe wrench on the smaller part or the flywheel, see if you can pop it loose, if it doesn't move try a little heat, like your wife's hair dryer.

Lou

P.S. What are you going to do with the 96XP? I've got one I just bought and might be interested in some parts, specifically the upper hood.

If you use heat keep in mind that too much heat might deto your crank seals then you are in a different boat now having to do a new bottom end as well.

 

[ltdyfz99]

Bump this thread, did you ever get the PTO off having the same issues.

 

[E9sling]

If your jugs and cylinder heads are still on, feed some rope in to the cylinder through the spark plug hole. If your jugs are off, you'll have to use something to stop the crank from turning. You will have to use a chain wrench to break the pto loose. Once you break it loose, it should just spin off by hand. If you need more help, just let me know. Chain wrench is the key. I worked for days trying to get that pto off, then I borrowed the wrench and had it off in 5 minutes

 

[Minnetonka4me]

I just delt with one this week...


#1 YOU HAVE TO USE A CHAIN WRENCH (24" chain) ON THE BIG PART OF THE PTO!!! If you spin the coupler part, you need to install some pins to hold the coupler to the PTO. If you do not pin it, it will slip and have to come all apart again.

#2....you better read #1, b/c these flywheels are SUPER hard to find and must be fixed if you spin the coupler.


Also on holding the motor...put the rope (i use a bungee with the end cut off) in the PTO plug hole. I have about 20 cradle brackets so I modified one to go on backwards to give full access to the PTO, and mounted a long bar on cradle bracket. I slide the bar under something heavy to hold the motor steady, then the PTOs pop right off.

 

[E9sling]

How do you fix the pto if you spin the coupler? Before I was able to get mine off, I found a new one online for around $100 so I went ahead and bought it just in case.i used the new one before I got the old one off, but I would like to fix the old one

 

[Minnetonka4me]

Drill two holes through the coupler and into the PTO. Use some 1" SS allen bolts and drill the coupler so the allen heads countersink. Then, tap the PTO. The coupler is aluminum, but the PTO is hardened, so you better have good tools.

 

[ltdyfz99]

I heated mine up good so I assume thats why it started to spin. I am going to do the pin mod just in case that was some really good advice, thank you.