Here is exactly what happened

[EuropeanAM]

Good job, Leon. That explains why the "symptoms" mimicked irratic CPS input!

Permanent loctite and torque flywheel nut properly to specifications- should be fine.

[lpugh]

In further thought to cause of this. I believe it should have a concave heat treated washer that functions like torque to yield head bolts and a flange lock nut to help keep clamp force applied to the flywheel. Would be interesting to know if the newer motors have changed in this regard?
Over time this washer concaved the wrong direction!

[EuropeanAM]

That's supposed to be a pretty thick washer... makes me wonder if it was ever tight.

[tomloans]

I think you are right Leon. This washer has been updated and likely for this reason! Click on the picture for a larger view. Capture.JPG

I don't know when it was updated but it would be good to know and replace it if your motor fell into the "older-washer-model" of the Optimax models. I don't want what happened to me to happen to others. Take heed! It is only about $10.00 for a new washer and bolt as well. Totally worth it.

[EuropeanAM]

Tom- I highly doubt that to be the case... and I've not seen even one (1) "bent or cupped" flywheel washer/nut. Not discounting yours might have been, but I do feel quite confident that if it were happening with any consistency at all, we would have seen or heard it quite regularly.

Parts supersede quite regularly. Sometimes for a new supplier, sometimes for a change to the components (and sometimes the change is simply to make one part suitable for use on multiple products, rather than just one particular series).

I know this has been asked in several of your posts- but after scanning 5 pages I still don't see your serial number here in this thread:

If you would, please review the Announcements at the top of the Forum, and be sure to provide the REQUIRED INFO (serial number) when you open a post. Thanks!

[tomloans]

Thanks Don for clearing that up. Maybe it is just a new supplier. I didn't know that. Here is what I missed in the beginning of all the craziness. Excuse me please, I usually don't forget to post it...

1B737378
FEB 2009
PRO XS L

I also edited the first post as well. Thanks again Don!

[Bryanmc57]

Tom... Have you considered buying a lottery ticket?

[tomloans]

Tom... Have you considered buying a lottery ticket?

Good Idea! LOL You know in hindsight, I would have taken it in earlier if I had known Leon was doing this type of work. I just didn't know so I booked a local guy for Feb 7th then found another for Jan 6th, so I kept banging my head against the wall with it until I learned of Leon. Anyways, he would have probably knocked it out overnight. Oh well, it is always an adventure and everyone learned a lot and we had some good laughs along the way as well.

[Bryanmc57]

The amount of knowledge gained was well worth the price of admission.

[1ranger487vs]

Remember eliminate the basics first. Pulling that flywheel to check the key way is something I’ll remember. Did I miss something. Timing fixed the no start but what was the noise that started this

[EuropeanAM]

Timing fixed the no start but what was the noise that started this

My money is on a loose flywheel... and the resulting (incorrect) timing.

[tomloans]

Remember eliminate the basics first. Pulling that flywheel to check the key way is something I’ll remember. Did I miss something. Timing fixed the no start but what was the noise that started this

Yes the timing was so off that injectors and spark was firing at odd times. Occasionally it would act like it was going to start then back to coughing. The flywheel was moving slightly from time to time I think. It was like a ghost as it would come and go. In regards to the horrible knock, I think what was happening is the flywheel was shifting from time to time and spark was firing at the wrong time causing the spark to fire too early in some positions of the flywheel and causing a knocking sound ( we use to called it pinging in our carbureted engines back in the day ). I have no idea, how I managed to run for hours that day at 4500 to 5800 RPM. I have no idea why I didn't suddenly here a massive metallic clunk and have a piston or two go flying out the back of the motor. Likely because at higher RPMS, flywheel likely shifted in the rust it was sitting in to a more aligned position. Talk about fortunate! Bryan, thinks I should go out and buy a lottery ticket. Just might do that.

[EuropeanAM]

Buy TWO.

[eagleman55]

Sounds like mine did just before lower unit came apart.