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  1. #1

    ULTRA 250x Drive Coupler Removal

    I am in the middle of disassembly of a Ultrs 250x with a cracked head. I need to get the entire motor apart to remove all the milky oil and sea water. Also to check the condition of the shell bearings.
    At the moment I am trying to reomove the drive (PTO) coupler.I mad up a tool to hold the crank at the front end of the motor, similar to the tool in the manual. But everytime I try and loosen the coupler all that happens is the little pin on the starwheel keeps shearing.
    From what I can see the thread on the coupler is a righthanded.
    Anyone have any pointers on how to remoave this coupler


  2. #2
    Banned User
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    Yep buy the proper tool. Use and impact and heat.

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  4. #3
    Go Kawasaki's Avatar
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    And if that doesn't work....cut it off.

  5. #4
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    wow thats a new one. heat and air impact gun always gets them off, use the rods to hold the shaft not the timing gear.

  6. #5
    Quote Originally Posted by nicjak View Post
    wow thats a new one. heat and air impact gun always gets them off, use the rods to hold the shaft not the timing gear.
    sorry to bring it back from the dead, can we use rope in the cylinder?

  7. #6
    nicjak's Avatar
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    yes you can try that if you havent already removed the head.

  8. #7
    you would have to find the correct crank position so there are no open valves, or you will bend them
    Quote Originally Posted by DR2006RXP View Post
    Quote Originally Posted by nicjak View Post
    wow thats a new one. heat and air impact gun always gets them off, use the rods to hold the shaft not the timing gear.
    sorry to bring it back from the dead, can we use rope in the cylinder?

  9. #8
    Just bought me a 1400psi knocker hahaha im doubtful but wishful thinking and maybe ill get lucky, 500psi laughed at me with zero results......

  10. #9
    GZA's Avatar
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    I cheated a little when i did mine. Un-did the whole short shaft off the end of the crank and removed it out of the rear housing with the coupler intact. Used a pin through the two middle conrod small ends, pulling down on a block resting on the case.
    Not endorsing this though - the book doesn't say to do it this way...

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  12. #10
    No one likes that book anyway, good on you!

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