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Cummins/Onan 4.0BF-1R/9500 — Flywheel Removal

For the Cummins/Onan 4.0BF-1R/9500.

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Before you start

  • Do not use a screwdriver or similar tool or pry behind the flywheel against the gear case. The gear case cover is die-cast material and will break if undue pressure is applied in this manner.

Procedure

  1. Turn the flywheel mounting screw outward about two turns. Do not remove the screw completely since it acts as a restrainer when the flywheel snaps loose.
  2. Install a puller bar on the flywheel.
  3. Turn the puller bar bolts in, alternately, until the wheel snaps loose on the shaft.
  4. Unscrew the puller from the flywheel, remove the flywheel mounting screw and washer and pull the flywheel off the shaft. Take care not to drop the wheel.

Tools required

  • Puller bar

Source: manual:965-0515 Onan 4kwBF RV Genset Major Service manual (09-1973).pdf. Figures and steps are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.