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Old 03-26-2011, 06:55 PM   #3
GMB74
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Yamaha
 
Join Date: Jun 2009
Location: Heluvabump,VT
Posts: 623
Default Re: G1 Oil Seal Replacement- Fan Side

Let's get started.
1) Remove the battery to give access to the fan side of the engine. Disconnect the wires going to the ignition coil and the links going from the carburetor to the exhaust butterfly valve, if so equipped. You do not have to remove the whole link, just unclip the carb end and the exhaust valve end, everything will come off with the fan shroud. Remove the screws holding the fan shroud in place. Some engines may have a deflector bolted over the air intake. Removing the shroud screws will remove it as well. The bottom screw (at about 7:00 in the image) can be difficult to see and access in the buggy.
2) You may need to hold the crankshaft to remove the nut holding the fan and flywheel in place. Pictured are two homemade piston stops that screw into the sparkplug port and hit the piston, keeping the engine from turning. Alternatively, you can set the piston about halfway up the cylinder and feed rope or clothesline into the cylinder through the sparkplug port. The rope will fill the combustion chamber, jam the piston and keep the engine from turning.
3) Remove the big nut in the center of the fan/flywheel. If you have a compressor and an air impact wrench you can zap the nut off. Otherwise jam the piston as described and use a socket and breaker bar.
4) Set up a puller as shown. Pullers can be purchased from Harbor Freight, autoparts stores, and some hardware stores. The three bolts that thread into the flywhell are metric, 8mm. Do not thread them into the flywheel too far and damage the coils underneath, just far enough to fully engage the threads in the flywheel. Tighten the center bolt to put tension on the flywheel and pull it off the crankshaft taper. If the flywheel does not come off, rap on the center bolt of the puller with a hammer. Give it a good smack squarely on the bolt head with a metal hammer to jar the flywheel loose.
5) You should now see the ignition coils, probably caked in dirt. Clean them up and they should look like this. Note that the two mounting screws on this engine at 11:00 and 5:00 have torx heads, indicating this engine has been apart before. Original screws are phillips head. Do not remove them yet.
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