There is a reason that using the rope sheave for a flywheel puller is no longer listed in the service manual. It is because it only works under ideal circumstances. Many outboards are used in less than perfect conditions, and can be "Serviced" by individuals who don’t know what end to stick in the water. Failure to properly torque the flywheel nut can lead to disaster. Too lose can lead to a sheared key and scored crankshaft. Too tight can virtually weld the flywheel in place. Longtime storage in a damp, salty atmosphere can do the same. Aluminum does not have the strength to pull the flywheel under these circumstances. That is the reason OMC designed there flywheel puller, and why they encourage it’s use.
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