81
Repair instructions
Gear ring, replacement
(Flywheel removed)
1
Drill 1–2 holes in the gap between two teeth on the
gear ring.
Split the gear ring across the drilled holes, using a
hammer and cold chisel.
2
Brush the mating surface of the flywheel with a wire
brush.
3
Heat up the new gear ring in an oven, or with a weld-
ing torch, to max 180–200°C.
WARNING. If you use a welding torch, take
great care to ensure that the gear ring is evenly
heated, and not spot heated, which would
cause annealing. To check the heating
process, polish the gear ring bright at several
places before heating it. Stop heating when
these surfaces become blued.
4
Put the heated gear ring on the flywheel and tap it
into place with a soft punch and hammer.
Allow the gear ring to air cool.
5
Clean the mating surfaces on the flywheel and crank-
shaft. Check the location dowel in the crankshaft
flange and the rear crankshaft seal. Replace
if necessary.
Install the flywheel. Tightening torque is 190 ±10 Nm
(19 ±1.0 kpm).
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