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Unread 03-28-2017, 01:58 PM   #1
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Default 2004 G22 engine pulley removal

I recently purchase this car from an auction. It was missing a starter generator which I installed and it cranked right up! It ran maybe 50 yards before it started making a clanking noize in the engine and then it ceased up. Oil was up to normal levels before I ran it.

After taking the engine out and pulling the piston cover I found the piston arm had snapped at the rod. Any idea what could've caused this. The rod looks to be in good condition. I am now trying to get the engine pulley off and I've tried everything from a puller to a longer bolt to pull it and even wedging shims behind it. I have noticed a hex head screw deep in the shaft. Is this the solution?

Thanks in advance!
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Unread 03-29-2017, 08:06 AM   #2
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Default Re: 2004 G22 engine pulley removal

There is a special pulller bolt to remove the primary clutch sheave!! About 40 bucks!!

Or take it to a Yamaha dealer, and have them remove!!
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Unread 03-29-2017, 02:11 PM   #3
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Default Re: 2004 G22 engine pulley removal

this
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Unread 03-30-2017, 07:16 AM   #4
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Default Re: 2004 G22 engine pulley removal

Got it off with a make shift puller, pb blaster and a rubber mallet. Does anyone know what the small pump looking device is inside the block is. It has a a single wire coming out of the block. It wasn't connected and I'm thinking that's what caused the piston arm to break. I think it goes to the starter generator.

Thank you for the response!!
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Unread 03-30-2017, 09:10 AM   #5
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Default Re: 2004 G22 engine pulley removal

If it's the blue wire, it's for the low oil level switch. All it does is turn on the light.
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Unread 03-30-2017, 10:56 AM   #6
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Default Re: 2004 G22 engine pulley removal

That's it....any other ideas why the piston arm would break around the shaft? I'd hate to get it together and it do it again....
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