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Flywheel breaking Jonsered keeps breaking the key way off the flywheel. It's bolted down tight. What's happening?

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If you aare sure the securing nut is tight, then it has to be a problem with the taper on the crank, it is the taper on the crank that holds the flywheel, the key is just to align the ignition timimg.

Posted on Oct 17, 2013

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When you replace the key, the flywheel attachment nut has to be really tight so that there is absolutely no slop in the flywheel connection. Give it another try. Don't strip the threads, but also, don't be afraid to pull on the wrench.

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I have a 1975 Yamaha dt400 it has a points ing. In it how do I set the timing and what is the settings for it? ?


Take off left sidecover,......Remove flywheel nut and washer. You'll probably need to put the bike in 4th or5th gear and get someone to stand on the rear brake as you remove flywheel nut and washer.......Screw the japanese flywheel removal tool into the flywheel.....tighten the center bolt of the tool till it firmly butts on crankshaft......Strike the center bolt of the flywheel tool semi-hard with a hammer to "shock" the tapered fit of the flywheel and shaft...... Tighten the center bolt of the tool a little and repeat till flywheel is dislodged......Gently remove flywheel. There are powerful magnets in the flywheel so hold onto it tightly as you gently draw it off the shaft......You'll see the points and condenser....... Remove them but when you put the new points in, the little washers must go on precisely like they were on with the old set of points,otherwise the points will be shunted to ground and you'll never get any spark......After you've installed the points gently replace the flywheel on the shaft being careful to make sure you're not smashing the rubbing block part of the points......Oh yeah there's a flywheel key imbedded in the shaft. It insures proper location of the flywheel in relation to the piston. Sometimes they'll shear or get deformed. Replace it if it needs it. The bike may still have spark if it is sheared, but it will be at the wrong time........Put flywheel on and tighten flywheel tight.. I mean tight. If you don't you'll shear the key. Don't strip-out the threads though......The points are adjusted thru the windows in the flywheel.. It's kind of a hassle until you've done it a bunch of times but what you do is rotate the flywheel and make sure the points are closed at the low part of the ramp on the flywheel. Slowly rotate the flywheel and you'll see the points opening. The goal is to have the points break open at the same time the marks on the flywheel line up with the reference point on the engine.. The points have a little slot usually that helps you open and close the point gap. Basically the larger the gap=advances the timing.......the smaller the gap= retards the timing........ Good Luck

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1 Answer

Replace flywheel


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The fly wheel bolts will not line up unless you turn the flywheel one hole at a time The arrangement is so that the balance of the flywheel in relation to the crank shaft is maintained . So offer up the flywheel and see how many holes line up . turn it one hole at a time and more holes will line up . Keep going until all the bolts screw in finger tight . If you have a tight one then move the flywheel again as all the bolts have to fit finger tight and not need force to turn

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Flywheels are either doweled in place or the bolt holes are not symmetrical. That means that of all the holes one will not line up properly to allow you to insert the bolt. Keep turning the flywheel on the crank until all the bolts go all the way in finger tight . If you have one that is a bit tight start again turning one hole at a time .until you achieve them all finger tight.

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It sounds as though you may have a sheared flywheel key. The keys are made of aluminum and shear easily if the flywheel is not tight. Remove top cover and flywheel retaining bolt/nut. Examine key for location with slot in crankshaft. If sheared, orient the flywheel slot and crankshaft slot so that a new key fits. Be sure flywheel and crankshaft mounting surfaces are clean and free of oil/grease. Tighten crankshaft retaining bolt/nut to 90 ft lbs. Flywheel posisition is maintained by friction between it and crankshaft.

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Removing a flywheel can be a aggravating process if you do not know the tricks. The nut which holds the flywheel is on very tightly, and can only be removed by blocking the rotation of the crank shaft with a wrench holding the nut on the blade or by blocking the rotation of the blade. Do not try to hold the flywheel by sticking a crowbar in the teeth, or they might break off. Once you have remove the nut which holds the flywheel in place you will need to gently pry off the flywheel with a crowbar. Keep rotating the flywheel until it can be lifted off easily. Now put the flywheel key somewhere safe. When you want to put the flywheel back on make sure that the key is in the right direction. It is usually marked in some way. :)

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1 Answer

My jd 318 wont start and back fires,i replaced the shaft key did it brack agein


It sounds like it did break again. Check the key and ensure that the flywheel is installed dry onto the shaft and the bolt in the end of the shaft is tight enough.
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