Shift cable stuck in Flywheel during install

[Derbytime1]

I see there are a posts from a few years ago on this. The answer seems to be to turn the motor back by hand, so I'm at that point with plugs removed. I have the plugs out and still am not able to budge it using the bolt on the balancer. I tried to turn it forward as well, but the bolt just turns out. Any other thoughts on how to turn the motor back? Maybe some type of a puller on that pulley?
Thanks!

 

[Alumarine]

You don't say what motor but don't use the harmonic balancer bolt.
If that breaks off in the crank you'll have bigger problems.

You could remove the starter and with use a screwdriver on the flywheel teeth to turn the motor.

 

[achris]

I've successfully used a square section bar across the screw heads on the water pump pulley to turn engines. Using the crank pulley bolt is a big NO-NO!

Too late now, but you should have either tired a pull cord to the end of the old shift cable BEFORE you pulled it out, or removed the inner and reinserted it into the cable from the engine end, then pulled the cable or, leaving the inner in place as a guide for the new cable... Getting a new cable in without a guide or pull cord isn't fun. Often requires the engine to be pulled to get it right...

Chris...

 

[Derbytime1]

Thanks for the replies!

This is a Mercruiser 5.7 Alpha 1 Gen II on a Glastron 249. Very tight quarters in the back of the engine. I did have a guide tied to the old cable, but it broke pulling it back through. If I cannot pull it back plan B was to cut it as short as I could and let the starter do with it what it may.

It has been very frustrating to say the least. The amount of time I've spent on it, I could have easily had the motor lifted if I had the proper equipment.

Would surely like to get the family on/in the water this weekend with the sweltering heat.

Thanks again!

 

[Rick Stephens]

For me the easiest way is to pull the balancer pulley off, then use a pair of little longer bolts in those holes and a prybar against them. Makes it super easy to turn either way.

 

[Derbytime1]

Thanks for that tip! Using a little longer bolts in which holes? I had actually thought about using longer bolts in the puller holes with balancer on, and pry on those, but thought there would probably be too much leverage for length and size bolts. Thanks again!

 

[Rick Stephens]

On the bolts that attach the pulley to the harmonic balancer. Just need a couple inch long max.

 

[Derbytime1]

I did not realize that the pulley came off the balancer. Thanks again!

 

[achris]

Yep, remove the centre bolt. Then the 3 'side' bolts and it falls off... When I put mine back on, I replaced those 3 mild steel bolts with 316. It'll make them easy to remove in future. You need to retain the steel centre bolt as it's high tensile.

Chris...

 

[Derbytime1]

Just wanted to say thanks again for help on this! Using bolts on balancer I was able to back the flywheel up and the cable came loose almost right away. Was able to get routed properly and got back on the water last weekend.

 

[Bt Doctur]

A helpful tip for you budding mechanics. Get a control cable from a shop, usually free. Use the solid core as the guide, it never breaks

 

[Searay205]

I never got my stuck but only because of shear luck. I ran weedeater line down the old cable for a new guide. In the end I had three ends LOL. A $15 boroscope that uses your phone is priceless. Then as the cable comes through the transom you can see how to catch with a coat hanger and force it in the right directions. The cable goes straight to engine coupler where it needs to make a 90 degree turn. My Weedeater line never worked, i was so pissed i just kept raming it in there and eventually i pushed the weedeater line into the coupling, how I didn't get cable stuck was a miracle. If I had to do again I could get it in 3 minutes with horoscope. Cheap on amazon. Actually take pictures with it also.