Fixing up new '85 250sx

[beastybaconman]

The puller works just as you described, a threaded "Bolt" is screwed into the flywheel and pushes on the end of the crank.

I can't remember which engine, and which front axle bolt, but there was a machine where the front axle bolt has the correct thread to thread into the flywheel and push it off. It's worth a shot to check on yours. Be sure to grease the threads.

Oh and the pilot thing, it was just a hobby (didn't do it for a living) and it's been a long time since I went up... but it's always been something I loved doing and hope to again once life lets me.

I pulled my axle out real quick and tried it but it’s too small. I did find a puller on amazon though for like $10. Should get here by this Saturday


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[beastybaconman]

Alright so I got my flywheel off with the puller, got the crankcase separated, and removed just about all the transmission parts. The only things left in the case are the crankshaft and the output gear case.

I’ve run into another problem though, I was trying to remove the output gear case but I can’t pull out the top bolt. I tried to just loosen it but once it broke free it would just spin like maybe I broke the bolt. So I tried to just pull it out but after about a 1/4” it gets jammed up and I can’t turn it or pull it out any farther. Any idea what could be causing this?

And even though I got the other two bolts out and it seems like this bolt has a broken shank, I still can’t pull off the output gear case. Is there any special way to press it out or something?



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[beastybaconman]

Managed to get that stuck bolt out and it looks like the threads did shear off the end. The threads are just stuck in the crankcase so they should t prevent me from getting the output gear case off.

I’m still having trouble pulling off the output gear case though, anyone have any tips to get it off?


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[beastybaconman]

Fixed my problem lol. I just took the longer bolt and put it in the hole where the other bolt sheared and tapped it with a and that got it to move a little. A little more tapping and prying and I managed to get it off. I think my problem was the thing was wicked corroded.

After I got that out I pressed out the crankshaft so now the engine is completely torn down. All I have to do now is replace some bearings, clean and inspect some parts, and slap her back together!

Any tips or tricks I should know for reassembly?


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[beastybaconman]

Here’s some pics of that output shaft




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[beastybaconman]

Well I finally started putting everything together, transmission and everything went back together no problem with all new bearings and seals. I’m working on getting my clutches put on now but I’m having trouble torquing them.

For the manual clutch I think I can make a holder easy enough but I’m not sure how to keep the centrifugal clutch from spinning while torquing it. I did find the holder they recommend in the manual online but it’s like $100. How do you guys go about holding the centrifugal clutch when you’re torquing the nut?


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