Flywheel hub removal & installation

Flywheel hub removal & installation

Watch the walkthrough

Watch on YouTube ↗ · JETSURF Service Tutorials #13 (titled "shaft coupling" on YouTube, but the video and its description cover the flywheel hub). Timestamps in the steps below follow the video's on-screen counter (0:05–1:54).

This is the standalone flywheel hub job — the same procedure as the first part of Crankshaft removal & installation, without splitting the cases. You need the puller set and a heat gun. The hub is single-use once heated.

Tools & supplies

• Flywheel hub holding tool + flywheel puller set (with backing "special tool")
• Torx T6 driver
• Heat gun
• Green Loctite (hub-to-crankshaft mating surface), blue Loctite (hub bolt)
• New flywheel hub
• Woodruff key — reusable if it isn't oxidized or rusty

Removal

1. 0:05 — Secure the flywheel hub with the holding tool and unscrew the flywheel retaining bolt from the crankshaft with a Torx T6.
2. 0:30 — Attach the flywheel puller. Set the special tool under the puller bolt, resting it against the crankshaft.
3. 0:37 — Tighten the puller down as far as it will go.
4. 0:51 — Heat the flywheel hub with the heat gun until it releases from the crankshaft.
5. 0:56 — Draw the hub off with the puller. Do not reuse the flywheel hub — heating damages the magnets.

Installation

6. 1:25 — Insert the woodruff key into the crankshaft.
7. 1:36 — Apply green Loctite to the mating surface between the flywheel hub and the crankshaft.
8. 1:54 — Fit the new hub and tighten it with the Torx T6 bolt and washer — always with blue Loctite on the bolt.