Aero engine take down, to be rebuilt

[Fishman43]

I finally recieved my handi-dandi magnito puller I ordered off of Fleabay in the mail yesterday. Had to work an unusual Saturday so waited until this afternoon to start in on the Aero rebuild again. I threaded in the larger piece into the magneto as deep as I could without over tightening it. Threaded in the center bolt to push on the crankshaft end, grabbed my chanel locks for the outer part and my ratchet for the center bolt and started cranking... f*** ME that magneto is on there tight! So I twist a little harder (I had already bent two head bolts trying to unstick the years of heat cycles that had stuck that F'er on). I feel a little give... OH JOY, I finally have this thing off and I can continue my build. Twist a little harder and guess what pops off... Oh no it isn't the magneto I am trying to remove, it is the head of the bolt in the magneto puller tool.

Much cursing and tool banging ensued for a few minutes.

So I think dang it all, I will pull the tool out and get an easy out for the center bolt upgrade to a grade 8 bolt and be good to wrench away at it again. Yuh think it is going to be that easy at this point! Instead I find the center bolt has tightened enough to thouroghly locked the main large piece into the threads of the magneto... f*** AGAIN!

So now I am looking closer and what do I see, when I had threaded the head bolts in to try pulling it the first time I had over tighted them right into the copper coils on the inside of my magneto. Did I just kiss them making a little mark but no real harm, take a guess at this point in the story...

Didja guess... Nope I tightened the F'ing things so tight it cut right through two wires. Much more cursing ensues....

So now I get to the help I am needing.

1. How do I get the magneto tool out of the magento?

2. How do I get the magento off of the dang ol engine?

3. Does anyone have a functional magneto untit for an '86 Aero for sale (mine has cut wires )?

Thanks!

[mousewheels]

Argh, that hurts

I'd bet the guys here will have ideas for the puller,
Two I have are thread a nut over the bolt stub and weld it. Maybe an easy out.

[Fishman43]

Thanks Mouse, easier said than done with no welder at Mi abode. I stopped at the local hardware store on my way to work this AM and picked up an easy out. Fingers crossed it works! Any other thoughs out there?

Follow up question. Would an Elite magnito fit an Aero? I have an extra one of those from a parts scoot.

[mousewheels]

Follow up question. Would an Elite magnito fit an Aero? I have an extra one of those from a parts scoot.

I looked at stator compatibility a while back. The only plug and play option for the 85-87 Aero was87 Elite SE. But by splicing in connectors, it expanded to 88-93 Elite SA50.

More details herehttp://www.hondaspree.net/phpBB3/viewto ... 83&#p91883

[Fishman43]

REALLY! The only plug and play is from an '87 SE50?

Well if that is the case then of all the Gin joints in all the world, that is the very engine I have available for parts. How * lucky for me... of course I still need to extract the mag. puller, and the magnito before I can even get to the stator. But finally a break in the clouds!!!

Now, anyone have a suggestion on how to break loose the dang-ol magnito?

[CharlotteSpreeRider]

Now, anyone have a suggestion on how to break loose the dang-ol magnito?

I use a steering wheel puller. I use head bolts threaded into the holes on the flywheel where the plastic fan blades were at (not much further than the thickness of the flywheel, for reasons you've already discovered). Then I thread the large center puller part in, and off pops the flywheel with ease. Never really had a problem with getting it off. Apparently, it's the remembering to torque it back on part that I forget sometimes.

[Fishman43]

I have tried the steering wheel puller with no success, I only managed to cut two wires and bend two head bolts.

Update on where I now stand. I drilled a hole in the push bolt and put in the easy out, started twisting on that trying to get it loose and out and only succeded in breaking the easy out off in the bolt, f***, f***, f***!!!

So feeling completely frustrated and like I had nothing to loose any longer (can't put it all back together as is since the stator has broken wires now). I put a big ol screwdriver through one of the vent holes in the magnito, a giant cresant wrench on the flywheel puller and used my feet to step on the tools. That was enough to get the flywheel puller unthreaded... FINALLY!

I spent the better part of another hour trying to get the center bolt out of the puller with no luck. Tried drilling out the bolt from the other side, no luck. Tried an easy out from the other side, you guessed it, NO LUCK.

Of to Fleabay I went again and ordered a new flywheel puller. So now I sit waiting for the new tool, and still don't know how to free the magnito from the crankshaft.

[Wheelman-111]

Greetings:

I used one that looks like THIS. Note that I have no idea whether or not this particular tool will fit the Elite, but showing you this link to illustrate only.

I forget where exactly I purchased mine, but it sure beats trying to line up the steering wheel puller bolts. Screw in, pop off.

ChevyGuyJay had once posted a video of a crude-but-effective process, especially dedicated to your humble contributor. You unscrew the flywheel nut almost all the way off. Hold the flywheel in one hand, with the engine suspended an inch or two from a soft landing. Then beat on the nut with a BFH until the flywheel pops off its taper. Finally unscrew the nut all the way off and pull off the flywheel. Be sure to identify and save the Woodruff Key for reinstallation.

[Fishman43]

Greetings:

I used one that looks like THIS. Note that I have no idea whether or not this particular tool will fit the Elite, but showing you this link to illustrate only.

That looks close enough to the one I had to be the same idea. I broke the center bolt off, broke the easy out inside of that, and now have an exspesive fishing weight. I ordered a new tool to try again, but no idea how I am going to get the magnito to let go of the crankshaft at this point. I am trying top avoid beating on it excesively in the off chance I wack the crank out of true. I tried a little heat via a propane plumbing torch, that didn't break it loose either.

Edit: Just got the email my new puller tool is on the way Priority Mail. I am still open to ideas for how to break loose the mag. from the crank... Pretty, pretty please

[Wheelman-111]

Greetings:

Since the mag/flywheel appears to have welded itself to the Right half of the crankshaft, there is no danger of whacking the crank out of true. Forces are confined to the same side. There is a danger of messing up the threads. Also of dropping the block onto the other end of the crank, which will jeopardize the crank.

[Fishman43]

I might just have to get out the motivator then... rubber or metal?

For the threads, I was thinking of modifying the pointy deal that goes on the end of the steering wheel puller to fit into the mag puller and over the threaded push bolt. Maybe tighten down the new mag puller tool to slightly tighter than snug, then start wacking in hopes that the added presure of the puller tool with the percusive force of the motivator will crack the bond.

[Wheelman-111]

Greetings:

My wheel just jumped off with a couple of solid Whacks with a generic Wheelman household Rock. Then again, mine wasn't welded to the crank as yours appears to be. In that case Rubber won't do it, but there is the little matter of buggering up the threads. If you can, find a second nut to thread on behind the first, then tighten them together firmly. This will spread the percussive load across a greater surface area of threads. (Or mess them all up completely...!) A proper puller is still preferred but you've already broken one. I like your idea of steady pull plus percussion.

[Fishman43]

Checked the shipping status of my new replacement tool through the USPS trackign system this AM... Could it be delivered today!?! The status shows it as passing through my closest sort facility (in MA, not NH), so maybe I will get lucky and have a replacement before leaving work today. Then that magnito is coming off come * or high water. At this point, what do I have to lose pounding on the F'er anyway!

[Wheelman-111]

Greetings:

For those without one coming, THIS ONE looks an awful lot like mine. Should work. Not mine, YMMV.

[Fishman43]

So with the new tool in hand and more than a little nerveous I set upon my Aero engine again. Tool threaded in carefully, center bolt (new 10.5 from the hardware store) threaded in to the crank shaft end, lightly tightened on. I get out my wifes little motivator (I didn't have the garbonzos to use mine that is big enough to drive a 16 penny in one or two whacks, the wifes is better for hanging pictures in dry wall). Tap, tap, tap, tighten, thighten lightly, tap, tap, tap, tighten, tighten, tighten (reaching my comfort level of tight now), tap, tap, tap. Nothing, not a budge, nothing. F'it this thing either has to come off or the engine is toast anyway. whack, whack, whack, still nothing... WHACK, WHACK, WHACK, POP! OH S**T, did I break it... Nope, the dang thing finally let go!!!

Thank god, now I can continue the build.