Author Topic: fll250 bottom end  (Read 1480 times)

lillezlie

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fll250 bottom end
« on: July 10, 2008, 09:42:01 PM »
how do you pull the bottom end apart to put new gaskets and maybe replace crank

PilotHawK

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fll250 bottom end
« Reply #1 on: July 11, 2008, 12:34:22 AM »
You have to pull the engine out of the machine first. The hardest part of the rebuild will be getting the clutch off. You will have to have a puller to remove the clutch. Remove the clutch bolt, then you will see that the clutch has internal threads. The threads are 7/8 national fine thread. Place an old deep well socket into the hole and then thread the bolt into the threads. Use an impact wrench on the "puller bolt" and the clutch will pop off after a little bit of effort. You will have to have a helper hold the clutch while you are using the impact wrench or make a clutch holder out of a piece of flat stock with bolts small enough to just barely fit into the holes in the clutch cover to hold the clutch still. After that it is fairly straight forward. You can find the rest of the procedure in the manual.

I would recommend doing a leak test on the engine before pulling it apart though. You can build one out of parts from home depot of a good hardware store for under 30 bucks or you can buy one ready made.

http://www.aftershockmotorsports.com/detail/airleak.html

Here is a link to the factory service manual.
http://g2buggy.g2-innovations.com/gentech/manuals/fl250manual.zip