Flywheel Removal And Installation - Mercury 40 Service Manual

Flywheel Removal and
Installation
REMOVAL
1. Remove flywheel cover from engine.
WARNING
Engine could possibly start when turning fly-
wheel during removal and installation; therefore,
disconnect (and isolate) spark plug leads from
spark plugs to prevent engine from starting.
2. Disconnect spark plug leads from spark plugs.
3. While holding flywheel with flywheel holder
(91-52344), remove flywheel nut and washer.
a - Flywheel Holder
4. Install a crankshaft Protector Cap (91-24161) on
end of crankshaft, then install Flywheel Puller
(91-73687A2) into flywheel.
5. Hold flywheel tool with wrench while tightening
bolt down on protector cap. Tighten bolt until fly-
wheel comes free.
a
a - Flywheel Puller
NOTE: Neither heat nor hammer should be used on
flywheel to aid in removal as damage to flywheel or
electrical components under flywheel may result.
2A-22 - ELECTRICAL
6. Remove flywheel. Remove flywheel key.
7. Carefully inspect flywheel for cracks or damage.
8. Inspect crankshaft and flywheel tapers for worn
or damaged key ways.
9. Check for loose or damaged flywheel magnets
(outer rim and center hub). Replace flywheel if
necessary.
INSTALLATION
1. Install flywheel key in crankshaft slot with outer
edge of key parallel to center line of crankshaft.
a - Flywheel Key
2. Align slot in flywheel center bore with flywheel
key and install flywheel onto crankshaft.
3. Install washer and nut.
4. Hold flywheel with Flywheel Holder (91-52344);
torque nut to 125 lb. ft. (169.5 N·m).
a - Flywheel Holder
55333
a
90-852572R1 JANUARY 1998