Proper Flywheel Installation? - Merc 402

I want to make sure I put my flywheel back on properly. I removed it because I wanted to see the condition of the wires connected to the stator (Original Problem: http://forums.iboats.com/showthread.php?t=272210).

Model: Mercury 402 (2cyl, EL - Electric Start, Long-Shaft)
Serial Number: 7102322
Year: 1977

First off, I didn't remove it properly (no flywheel puller - rookie ignorance). Basically, I removed the bolts in the flywheel to get it off. I didn't smash it with a hammer or anything.

1. I removed the main nut/washer connected to the crankshaft.
2. I tried to pull up using my hands. Wasn't going anywhere.
3. Then I removed the bolts in the center of the flywheel. I started on the outside (I only removed two and was working on the third when i realized it was loose). I just lifted the flywheel off. I discovered that the stator also had sealed wire connections and no terminals, so I simply put the flywheel back on.

I bought a torque wrench and tightened the nut to 75 ft lbs (as per manual). I can't find the torque specs for the other bolts I removed on the flywheel. Any suggestions for torque on these ones?

The reason I'm concerned, is that there seems to be vertical "play" with the flywheel. The nut/washer is tight to the flywheel (ie. there isn't a gap on top or anything). It's just that the whole things moves up/down a little bit. Video below shows what I mean.


Flywheel Up/Down movement
http://www.youtube.com/watch?v=vpZHOAZeS7g

Motor Running
http://www.youtube.com/watch?v=OOhDu5F7Tow


Thanks,

-Cambo

Re: Proper Flywheel Installation? - Merc 402

Hi Cambo,

There should be vertical movement of the crankshaft. It should be between 4 and 12 thou.... and it's called 'end float'....

The torque on the flywheel nut is 75ftlb. The smaller bolts aren't listed in the manual because there are never intended to be removed.... I'd just do them up 'snug'.

Cheers,

Chris........

Re: Proper Flywheel Installation? - Merc 402

Interesting achris- (actually mine is a 40hp 79 but almost the same)I am going to test that on my motor, never realized that movement. I recently replaced the upper end cap and stator on my 79'(same motor) and never noticed that movement of the flywheel. So, I did remove the flywheel( a few times actually, u will see why). I had the unfortunate luck of purchasing my motor and having to replace the stator. The replacement cause of the first stator was unknowingly finding that the screws that held down to the stator(scew into the upper end cap) had wear beteen them and the space that they screwed into on the upper end cap. The stator that was on the motor when I bought it shook loose and damaged the stator. So I bought another stator, then replaced it and tightened in down to the upper end cap and added lock tight. But being new to that motor I did notice that the screws weren't 100 tight, but I figured with lock tight they would be ok. WRONG!!! stator shook loose and the screws from the stator to the upper end cap came loose an bored the holes to the upper end cap out, causing the stator to shake loose and become damage after rattling against the flywheel.

Solved the problem by replacing the upper end cap, which I foumd on ebay for $10(normally about $170). Rebought the stator(new$130, normally close to double the price) and new screws(4). Now the motor runs like a champ. Turns out that the damage was before I bought the motor but I was a newbie and didn't know that the cause of the stator shaking loose before was because of the loose threads to the upper end cap. I did save myself a ton of money though my doin the repair myself, Not bad for a college boy. Replaced the upper end cap, new screws(4), and another staor. All together a total of about $160,. I think I saved myself close to a thousand dollars in parts and labor.

Re: Proper Flywheel Installation? - Merc 402

Hi Chris,

I'm not sure what you mean by "It should be between 4 and 12 thou". Could you explain?

Just to confirm, what I'm seeing is normal right (end-float)?


Thanks again,

-Cambo

Re: Proper Flywheel Installation? - Merc 402

As long as the flywheel is not moving on the crankshaft, the amount of movement, up and down, (of the flywheel and crankshaft as a single unit) should be between 0.004" and 0.012".

The movement is actually the crankshaft moving in the engine block.

Chris..........

Re: Proper Flywheel Installation? - Merc 402

Perfect, that does appear to be the case.

Thanks you again.