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  1. #1
    PWCToday.com Is My Home Away From Home nightrider05's Avatar
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    Removing PTO Coupler on 787 XP Engine Questions

    Ok...so we are trying to remove a PTO coupler on a 787 Engine and it is not coming off. I used an old driveshaft and bent it to use as a removal tool. We put rope down the PTO side cylinder to "lock" the motor up. We have heated the pto, and even put a breaker bar on the makeshift tool we made and its a no go...How hot do you have to get these things? Also how much force does it take to get these off?
    Last edited by nightrider05; 05-03-2009 at 09:28 PM.

  2. #2
    PWCToday.com Is My Home Away From Home JasonZE's Avatar
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    Re: Removing PTO Coupler on 787 XP Engine Questions

    I usually need a 5 foot bar to break them free,
    currently riding sxr or what ever has gas in it!!

  3. #3
    Top Dog Landworks's Avatar
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    Re: Removing PTO Coupler on 787 XP Engine Questions

    I heat mine up with map gas, put the driveshaft tool in, and wack it good with a rubber mallet. Works every time for me, and i don't lock up the cylinder, i use a tool i made that goes in the starter hole and holds the flywheel. I didn't want to bend a rod if i hit it too hard.


    3 96 XP's
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  4. #4
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    Re: Removing PTO Coupler on 787 XP Engine Questions

    Here is the flywheel lock Landworks mentions.
    Attached Images Attached Images

  5. #5
    Top Dog Landworks's Avatar
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    Re: Removing PTO Coupler on 787 XP Engine Questions

    And here is a pic of one i made from some scraps laying around.



    3 96 XP's
    2000 XPL
    2002 XPL 67mph GPS
    twin pipe build up link
    http://www.pwctoday.com/showthread.php?t=204126

    If you want more inches STROKE IT!

  6. #6
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    Re: Removing PTO Coupler on 787 XP Engine Questions

    Landworks, are you concerned that only one or two teeth are actually engaging the flywheel?

  7. #7
    Top Dog Landworks's Avatar
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    Re: Removing PTO Coupler on 787 XP Engine Questions

    I have been using it for a couple years with no issues. Have probably used it 75 times. I made sure when i made it that the teeth engage all the way in.


    3 96 XP's
    2000 XPL
    2002 XPL 67mph GPS
    twin pipe build up link
    http://www.pwctoday.com/showthread.php?t=204126

    If you want more inches STROKE IT!

  8. #8
    Top Dog lotsofspareparts's Avatar
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    Re: Removing PTO Coupler on 787 XP Engine Questions

    You will need about 300 degrees to break the loctite bond, but be quick about it cause to much heat can damage the crank seal, that is unless you are rebuilding it.
    96 XP 800
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  9. #9
    PWCToday.com Is My Home Away From Home nightrider05's Avatar
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    Re: Removing PTO Coupler on 787 XP Engine Questions

    Thanks for the replies guys..and the problem is that we are trying to save the crank seal. I have a good lower end but it has the wrong PTO on it...it needs the coupler PTO like on a 97 XP.

  10. #10
    Tech Guru PWCToday.com Is My Home Away From Home Watercraft Magic's Avatar
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    Re: Removing PTO Coupler on 787 XP Engine Questions

    I use a ton of heat on some of them that are stubborn. A good impact from a hammer will break them loose.

    As for only using two teeth or whatever, think about this, all of the strain is on that small woodruff keyway and key in the mag flywheel.

    It only takes a minute to remove the head and use a solid wooden block on top of a piston.
    email Chris at Watercraft Magic cdofixr1@live.com

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