Phazer PZ50 engine repair

[Hubert]

I don't know if this belongs here, but I'll try anyway. I'm beginning the process of repairing a '09 Phazer MTX engine, pz50. It was hit by a truck on the clutch side. I took the engine off and starting to look it over. The drive gear that is connected to the clutch needs to be replaced and the bearing that is connects to, I've taken that off. What I'm trying to do is to pull the gear that turns the balancer gear. The gear I'm talking about is the one that is connected to the crankshaft. Is this gear part of the crankshaft? Do I need to remove the cam drive chain off first?
Thank you in advance!!!
Hubert

 

[Mooseman]

Don't know if you saw this thread, shows the teardown very well.
http://www.ty4stroke.com/viewtopic.php?t=73643

 

[Hubert]

Thanks for the link Mooseman!! On picture 025.. the balancer drive gear is attached at the end of the crankshaft or maybe it was machined that way?. Its the gear with broken piece. If it does come off then is it a special puller or maybe pound the heck out of it.
Again thanks!!!

 

[3-UP]

Just looked at a microfiche and it shows its removable too bad its over $500.

 

[cannondale27]

I never did remove that broke gear from crank shaft but its a bolt holding it on.Not sure if its also pressed on.I will give it a try if really needed but just start by removing the bolt and see if the gear slides off.

 

[Mooseman]

Expensive probably because they come as a set for the reduction gear as well. If it suffered a direct hit right on that gear, I'd be afraid of the structural integrity of the block itself, including the crank bearing saddles.

How did the rest of the sled fare? A lot of damage?

 

[Hubert]

I took the bolt off and it didn't slide out. So I put the bolt back on but not tight and tried a 2 arm puller.. using the bolt head to put the center of the puller to push against. So I might try it again and maybe tap it this time. Unless there is a special tool like a clutch puller? Thanks for all your suggestions. If I get lucky and get it out, I'll post so at least if someone should wonder it will be here.

 

[cannondale27]

Here you go.Its on a splined shaft.As you know the bolt is lefthand threads.Is a slight press fit just at the end.A good gear puller should have no trouble.It is timed with one spline being cut out and one being filled in so will only go back on one way.

 

[cannondale27]

I agree with Mooseman.It would be safest thing to inspect the main bearing by the reduction gear.I did not see any damage to the mainbearings on this one.But I did not Plastigage them either though so your call.Lot more work to split the case.

 

[cannondale27]

I would NOT tap on that puller either.Use a 3 jaw or better a press.

Hubert if you have a camera pics would be very helpful.

 

[Mooseman]

I went through the repair manual supplement and to remove the drive gear, it doesn't mention using a puller at all. It just mentions that the bolts are left hand thread. Other than that, info is sparse about it. Maybe a gentle rap with hammer or a gentle pry will get it off. A three jaw gear puller would probably work if you can get the jaws behind it.

 

[Hubert]

Wow.. Thank you all!!! Pictures really helped, Cannondale27. Points well taken Mooseman about the bearings. Main damage was done to the primary sheave gear drive bearing.. so most components are probably impacted as well. This was struck in an angle. I'm going to turn the crankshaft and see how smoothly it turns.. if not than find another engine and use this as parts. Again Thank you for all your help!! I really do appreciate it. I'll get a 3 arm puller since the 2 arm may not be centered.

 

[Hubert]

Yea!! Pulled it out!!! It was pretty tight! I'll see if can post some pictures. The tunnel is dented in where the track rubs, but I think I can pop the dent out and it would fine. The crank case cover needs to be replaced.
Again thank you for all your help!!

 

[leonar57]

same issue, but different reason...

I too am trying to pull the reduction gear off my phazer's crank and am using a small puller, but not having much luck. What did you use for a puller set-up to get the gear off the spline?

 

[leonar57]

I answered my own question with a good 3 prong puller and about 60 ftlbs of torque. Now, for removing all that metal...