Pro Tips: Removing Chainsaw Flywheel Made Easy

Table of Contents

1. Introduction
2. Step 1: Removing the Recoil
3. Step 2: Accessing the Spark Plug
4. Step 3: Using a Piston Stop
   1. Option 1: Metal Piston Stop
   2. Option 2: Nylon Rope
5. Step 4: Locking the Piston
6. Step 5: Removing the Flywheel Nut
   1. Do's and Don'ts
7. Step 6: Using a Flywheel Removal Tool
8. Step 7: Removing the Flywheel
9. Step 8: Reinstalling the Flywheel
10. Step 9: Torquing the Flywheel Nut
11. Removing the Flywheel without a Tool
12. Conclusion

How to Properly Remove a Flywheel for Small Engine Repair

Introduction

In small engine repair, knowing how to properly remove a flywheel is essential. Whether You are working on a chainsaw, two-cycle equipment, or four-cycle equipment, the process remains the same. This step-by-step guide will provide you with the knowledge and tools required to remove a flywheel safely and without causing damage.

Step 1: Removing the Recoil

To start, you need to remove the recoil from the equipment. Locate the small screws (Torx or Phillips) that secure the recoil and carefully remove them. If you are working with Stihl equipment, you will typically encounter T27 Torx screws. Additionally, remove the covers to access the spark plug and ensure that it is removed.

Step 2: Accessing the Spark Plug

Once the recoil is removed, you can access the spark plug. This step is crucial to prevent any accidental Ignition during the flywheel removal process. Make sure to remove the spark plug before proceeding.

Step 3: Using a Piston Stop

Using a piston stop is essential to lock the piston inside the cylinder and prevent it from rotating while you remove the flywheel. There are two options you can choose from: a metal piston stop or a nylon rope.

• Option 1: Metal Piston Stop

A metal piston stop, like the one shown in the demonstration, is a reliable tool for this task. Screw the threaded piston stop into the cylinder until it stops the piston from rotating. Ensure that the piston is positioned above the exhaust port and other ports to avoid potential rope damage.

• Option 2: Nylon Rope

Alternatively, you can use a nylon rope to stop the piston from moving. Insert the rope into the cylinder, being cautious not to let it get caught between the piston and the ports. This method requires extra care to prevent damage to the rope and the engine.

Step 4: Locking the Piston

Once the piston is securely held in place with a piston stop, you can proceed to turn the flywheel.

Step 5: Removing the Flywheel Nut

To remove the flywheel nut, use a 13mm socket (the size may vary depending on your equipment). Attach the socket to a ratchet and securely fasten it to the nut. Give the ratchet a firm tap to loosen the nut. Remember not to use an impact tool, as it could potentially damage the flywheel.

• Do's and Don'ts

Always resist the urge to use an impact tool when removing flywheel nuts, as it can cause damage to the flywheel or the key embedded in it. Exercise caution and remove the nut manually.

Step 6: Using a Flywheel Removal Tool

To safely remove the flywheel, it is recommended to use a flywheel removal tool. One such tool, depicted in the demonstration, is the Stihl flywheel removal tool (part number 599 308 L1). This tool is not only compatible with Stihl chainsaws but also with many other chainsaws on the market.

Screw the tool onto the shaft by turning it as far as possible by HAND. Then, back off the tool by half a turn or more.

Step 7: Removing the Flywheel

It is essential to wear safety glasses before proceeding with this step. While holding the chainsaw (or equipment) slightly elevated, strike the flywheel removal tool with a brass hammer. This will Apply force to loosen the flywheel. Give it a few firm taps if necessary.

As the flywheel becomes loose, proceed to remove the nut completely, and carefully pull out the flywheel.

Step 8: Reinstalling the Flywheel

When reinstalling the flywheel, Align it correctly and position it back onto the shaft. Place the nut back onto the shaft and tighten it by following the recommended torque setting. Using a torque wrench is recommended for achieving the correct torque.

You can leave the piston stop in place while reinstalling the flywheel, ensuring that the flywheel nut is securely torqued. This prevents any accidental rotation of the piston during the process.

Step 9: Torquing the Flywheel Nut

Use a torque wrench to apply the recommended torque setting to the flywheel nut. This step is crucial, as it ensures the flywheel is securely fastened to the shaft. Following proper torque specifications helps prevent any issues or damage during the engine's operation.

Removing the Flywheel without a Tool

In situations where you do not have a flywheel removal tool, there is an alternative method to remove the flywheel. By leaving the nut flush with the shaft or slightly above it, you can protect the nut and shaft with an oil drain plug or similar object. Carefully strike the flywheel to loosen it, ensuring safety precautions are observed.

This method requires extra care to avoid damaging the shaft Threads or the nut. During the demonstration, no damage was observed on the threads or the nut, indicating that this method can be effective if performed properly.

Conclusion

Removing a flywheel in small engine repair is a task that requires precision and proper technique. By following the steps outlined in this guide, you can safely remove a flywheel without causing damage. Employing the recommended tools, such as a flywheel removal tool and a piston stop, ensures a smooth and risk-free removal process. Remember to observe safety precautions and wear protective gear throughout the procedure.

Highlights

• Properly removing a flywheel is crucial in small engine repair.
• Use a piston stop or nylon rope to lock the piston in place before removing the flywheel.
• Avoid using an impact tool to prevent damage to the flywheel or key.
• Utilize a flywheel removal tool for safe and efficient flywheel removal.
• Always wear safety glasses and exercise caution during the removal process.
• Reinstall the flywheel following the recommended torque setting to prevent issues.

FAQ

Q: Can I use a nylon rope instead of a metal piston stop to lock the piston?

A: Yes, a nylon rope can be used as an alternative to a metal piston stop. However, extra caution must be taken to avoid damaging the rope or the engine.

Q: Is it necessary to use a flywheel removal tool?

A: While it is not mandatory, using a flywheel removal tool ensures a safer and more efficient removal process. The tool provides better control and minimizes the risk of damage.

Q: Should I wear safety glasses during flywheel removal?

A: Yes, wearing safety glasses is essential to protect your eyes from any potential debris that may fly off during the removal process.

Q: What torque setting should I use when reinstalling the flywheel?

A: It is recommended to consult the manufacturer's guidelines or specifications for the correct torque setting. Using a torque wrench will help achieve the desired torque.

Q: Can I remove the flywheel without a flywheel removal tool?

A: While it is possible to remove the flywheel without a specific tool, it requires extra caution and the use of alternative methods, such as protecting the nut and shaft while striking the flywheel.