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Ray70, From my experience, swapping a motor requires the full tear down of the whole set. For separating the rotor from the fly wheel, you'll need to disassemble the generator section as well. I was only able to get to the 5 bolts with an offset wrench. The spacing is too tight to get a socket...

I've started re-assembling a good generator from all the best parts. The flywheel and rotor assembly I went with was the original one that caused me to start this thread. I thoroughly cleaned the flywheel and rotor before re-assembly and even used some steel wool to polish some rough spots...

VICTORY!!!!! While explosives and tug of war were both great ideas and very satisfying entertainment wise I just couldn't get over the risk of potential energy turning into kinetic energy and launching a heavy piece of something to somewhere it shouldn't go. After a few days away from...

I appreciate the help Guyfang in reaching out. I've reached out to all my Army buddies and everybody is as baffled as I am. Its even stranger to have the same problem on two sets that clearly are from different batches. I did buy them in the same auction lot though from the same place... so...

Diesel Addict, That is an interesting idea. Sadly I don't think there is a way to implement it. 1, there isn't a hole in the adapter plate other than the bolt holes. 2, There is a void between the problem adapter plate and the fly wheel, but I don't know how big it is and where it is if I...

Well.... a brother and a niece helped me tear down my 2nd 802 set. Sadly, same problem/issue. I haven't beat on it as much yet, but I've exhausted all "normal" means of separating the two. This one has a black painted adapter plate with white lettered part numbers. So... its obviously a...

the most common suggestion amongst my co-workers is a tie between explosives and a 5-ton tug of war approach. I must admit, that if I'm stumped by the 2nd set these suggestions will get pretty appealing. I should have more to report this coming week. Several of my brothers will be in town, so I...

I've spent several days trying all sorts of tactics with out success. This latest attempt had the rotor standing vertical in the air so that the fly wheel was horizontal. We then flooded the problem joint with 50/50 acetone & ATF for several days. Threaded in a bolt in the end of the rotor and...

I had a few moments today in the shop to give it another try. Got the slide hammer setup with a 3 jaw puller and put that over the bearing on the end of the rotor. The whole thing put up a fight, but I at least got the bearing off which needs to be replaced anyways. Still no movement at all from...

Well once I get the time to try the slide hammer I'll report back. In looking at my rotor, I'm not seeing how the exciter coils or mail coils would slide off the main rotor shaft. I also don't see any pictures in the manual referencing that. Is that something the bigger gensets let you do but...

The whole goal is to replace the engine so I don't really care about all the other stuff. That being said, I re-read your comment about just removing the flywheel and I'm not seeing how that is possible on the 802. According to pictures and the manuals I've looked up on the 802, you can't get...

Here is a picture of the situation. The problem is the red plate won't come out of the tan fly wheel. All 5 bolts holding the red plate into the fly wheel have been removed.

guyfang, I'm doing all this to replace a bad engine with a rebuilt one. I didn't anticipate all this trouble. I currently have a strap around the main rotor section( not the exciter rotor ) and have lifted up the whole thing( rotor, motor, skid ) to try and let gravity do the work. It hasn't...

Guyfang, in your picture I can't get part 25 to separate from part 42. I have removed bolts 16. I haven't tried heat yet because I don't see a good way to get heat to the area of the fly wheel that I need. Additionally there is soo much fly wheel mass my thought is that 1, it'll take for ever...

went at it with a dead blow hammer and still nothing.

I've thus far been beating on it with a rubber mallet on the main winding lobes. Perhaps it is time to move up to a dead blow hammer.

I'm working on replacing the engine on my 802 which requires a full tear down of the generator. I've gotten everything taken off but am stuck at the stage of removing the rotor from the fly wheel. I've been working on getting it removed for several days now and have used copious amounts of PB...