trainzkid88 wrote:

might be lucky and not damaged the other gears have them crack tested to be safe. 

I imagine my options are
1) Rebuild the Mag, assuming I can find parts in tollerance
2) Buy a used mag and hope it is in tolerance when it comes and not damaged itself
3) Install an electric start with means of heating intake manifold and likely a different generator (which will be "fun" given my gen also powers the aux hydro)

By "damaging the other gears" you mean the large one this interfaces with? I haven't turned it over to see if there are any issues with it yet as I didn't know where the teeth of this one ended up and didn't want to damage it further.

yes there is 4 gears in that gear train the mag gear, the cam gear, the idler gear, and the pinion shaft gear, also check the crankshaft.

you have 3 choices rebuild the pony which is easier if your in the states as more 2nd hand parts are available.

convert to direct start
or do what im doing and adapt another engine to do the job of the pony.hindsight it would have been the same cost to rebuild my pony.

remove the pony and find those teeth they are probably in the pinion shaft oil well. use a borescope camera to find them all. there is several bungs to drain that housing.

Drained the flywheel housing from the lower plug, then pulled the plate down there to find the stuff on the shop towel. I don't think we ever pulled this before. This explains why I have to hold the pinion starter knob (since I have in seat starting) the whole time while turning over the main motor ... Not sure what the brass looking thing is ... I suspect a seal for something in the pony? 

Going to pull the pony today since I didn't find any teeth in the housing with a magnet. 

The main problem with oil clutches and starting engine systems is owners would grind the pinions all the time and all that metal would get into the clutch pump and wear them out.

Was "fun" today loosing the pony ... the engine isn't in the parts book as the number of nuts / bolts was different. The one in the back wasn't too hard to get to but the bolt was an odd find given it was very hard to reach with fingers alone ... going to be more "fun" putting it back on.

Couldn't get it off though ... going to try a come along tomorrow since I don't have a chain wench and my climbing gear wasn't working out too well.

How much does the motor weigh? It seems kinda light given I can lift one side up easy.

from memory about 60kg.

there is a couple of dowel pins that locate it it could be stuck on them. use a prybar on each side to lever it up evenly

Hi There,
There are sis nuts under the pony motor and 2 bolts at the back of the pony motor that needs to remove then the top water hose connections then tilt forward flywheel side and lift off.

Regards

trainzkid88 wrote:

there is a couple of dowel pins that locate it it could be stuck on them. use a prybar on each side to lever it up evenly

I ended up doing something similar ... used a pivy bar to lift up each side to confirm it was free ... I think it was just how I had the rigging setup as I had a 5:1 configured but the rope I was using I believe might be too thick for the devices I was using to lift it.