HowTo: Splitting Crank Case AND NOW: Reassembly

[dem0nk1d]

Tools Need

2 Old Head Bolts
2 Old Variator
1 Steering Wheel Puller
1 Rubber / Plastic hammer to help break the crankcase seal

Parts minus a the rubber/plastic hammer



--/ Bolt everything up like the following.---/---------------------



Once you put some tension on the puller it doesn't hurt to tap the case with the hammer. This will help to break the seal



Start cranking steering wheel puller bolt, you'll know it's pulling as you'll hear a slight knocking sound



Now just remove the side flywheel side of the case




Done, now go drink moar!!! beer!!!


This is the best method i've found to work. I've hear other methods, but have failed. I hope this will help plenty of the noobs and the old guys too. Work smarter and not harder. =) I'm still working on a method to get the crank pressed out with some kind of Macgyver tool. More to come.

[Wheelman-111]

Greetings:

Great job, Kid!

[Wheelman-111]

Greetings:

My Flash IV Begins thread in Scooter Builds depicts my new Tusk crank assembly tool from eBay. As of this writing, there were several sources around the US offering this tool for around $60 - some with shipping and some not, so shop around. Here's one example.

E4TuskTool1.jpg (208.8 KiB) Viewed 21767 times

The chromey looking nut nearer the flywheel is part of the tool. The black nut already on the crank end is one of 2. The smaller nut fits the alternator side of the crank

E4TuskTool2.jpg (195.96 KiB) Viewed 21765 times

The long threaded stud with the cylinder then gets threaded onto the chromey nut, which traps the black nut. Now the big cylinder affair slides onto the bolt and the pin on the smaller cylinder engages a notch in the bigger one.

E4TuskTool3.jpg (220.51 KiB) Viewed 21766 times

Now by tightening the pressure nut over on the right, there is a means to pull the crankshaft into its case bearing without hammering the opposite end of the crankshaft. We've seen how that can cause the crank to wander out of true. I'll post again when I get ready for Final Flash Four assembly.