1994 Sportsman 400 ,No Spark, Flywheel Removal
#1
1994 Sportsman 400 ,No Spark, Flywheel Removal
I have a 1994 Sportsman 400 been a great machine. I was Pulling starter to replace the bendix drive and found the seal behind the flywheel was leaking. I proceeded to put puller on flywheel using 3 hardened bolts when one of the bolts snapped off.
Does anyone know of an easier way to get flywheel off ? Then I can get bolt drilled out hopefully. Can I use a torch to heat center of flywheel without damaging the stater in behind.??
next problem My 400 would run a bit and then die. . We tried new plugs. That didn't help it would run 4-5 minutes then die.I started by trying to check for spark because I can't see any spark@ plug. I was testing it w/ recoil rope because starter didn't want to engage. Hence i ran into problem above.SHould I just shoot it or is there hope for repairing this without buying it twice?
Does anyone know of an easier way to get flywheel off ? Then I can get bolt drilled out hopefully. Can I use a torch to heat center of flywheel without damaging the stater in behind.??
next problem My 400 would run a bit and then die. . We tried new plugs. That didn't help it would run 4-5 minutes then die.I started by trying to check for spark because I can't see any spark@ plug. I was testing it w/ recoil rope because starter didn't want to engage. Hence i ran into problem above.SHould I just shoot it or is there hope for repairing this without buying it twice?
#2
1994 Sportsman 400 ,No Spark, Flywheel Removal
The way you were doing it is how, do you have a regular puller with the three bolts and a larger one in the middle?, When it gets tight you should hit the large center bolt with a hammer, dont use a torch cause there is electrical wirees behind it, the spark problem is probably the stator which is also behind the flywheel, the service manual will tell how to check it.
#3
1994 Sportsman 400 ,No Spark, Flywheel Removal
Yes that is the type of puller I was using.How about if I tried a jaw type puller and put jaws in the 2 half inch big holes on either side of center shaft. I have never seen such a hard flywheel to come loose. There isn't any other boltss attached underneath is there ? like a collar over the seal that could be holding it on?
#4
1994 Sportsman 400 ,No Spark, Flywheel Removal
Kerbbirds is right, tighten the puller up, then smack it with a hammer - it may take tightening, smacking, tightening, smacking - several times before it comes off.
Some of the 400's had 6mm threaded holes, some had 8mm threaded holes - we have found that on the 6mm threaded holes to drill them out and tap them to the 8X1.25 mm size - gives more strength in the pull.
Since you only snapped off the bolt, you should be able to get it out easily enough, maybe even working it with a small center punch and hammer - unless you crammed a wrong threaded bolt into the hole.
The service manual is a great tool, and there are tests that can be done with a multimeter set to Ohms to determine the cause for lack of spark - the Pulse (or Trigger/Pickup) coil for the stator could be one of the culprits.
Some of the 400's had 6mm threaded holes, some had 8mm threaded holes - we have found that on the 6mm threaded holes to drill them out and tap them to the 8X1.25 mm size - gives more strength in the pull.
Since you only snapped off the bolt, you should be able to get it out easily enough, maybe even working it with a small center punch and hammer - unless you crammed a wrong threaded bolt into the hole.
The service manual is a great tool, and there are tests that can be done with a multimeter set to Ohms to determine the cause for lack of spark - the Pulse (or Trigger/Pickup) coil for the stator could be one of the culprits.
#5
1994 Sportsman 400 ,No Spark, Flywheel Removal
I had to replace the pulse coil on mine when I first got it, the flywheel was tough to get off, I did like the other guys said, smacking the center with a hammer and I used a jaw type puller because that was all I had at the time but it was a pain in the ***. if you can use an ease out to remove the broken bolt i would, then try again with the regular flywheel puller.
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