How To: Kawasaki Jet Ski PTO Coupler Removal
Channel: Andrew Crocker - Fixin2Ride
Date: 2020-10-28

Welcome Back my Friends! 

 In today's video I quickly made a tool to remove the PTO Coupler off of my 2000 Kawasaki STX 900 engine after finding out after my first test ride that there was a crank seal leak. The PLugs looked a little lean from front to back getting less lean towards the rear cylinder. 

SO I made a tool to fit into the coupler to remove it out of some 1/4" x 1" Flat stock and a 1-1/8" Nut. WORKED LIKE A CHARM!!! 

 Check out the Video and let me know what you think... 

Some of the Tools I used in this Video....

TOOLS USED:
- Campbell Hausfeld 60g Single Stage Air Compressor
- Campbell Hausfeld Impact Gun and Socket set
- 1/4" x 9/16" flat stock steel and 1-1/8" Nut
- 4.5" Craftsman Angle Grinder, cutting wheels and flap disc assortment
- Stanley Fat-Max tape measure (or similar)
- Lincoln Easy MIG 240v 180amp welder with .035" Vulcan Flux-Core Wire
- Carbide Tipped Metal Scribing Pen
- LG OPTIMUS G7 Smartphone
- UBeesize Adjustable Cell Phone Tri-Pod

TOOL CREATION PROCESS:
1. Cut two 3"- 4" long pieces of 1/4" x 9/16"
2. Place one piece in the coupler and hold it in.
3 Place the second piece across it in the coupler and scribe the bottom piece using the edges of the top piece.
4. Cut the bottom piece on both lines and keep the outer portions to weld
5. Prep the edges of the long center piece as well as the ends of the two smaller pieces by beveling ends and edges to allow a flat weld after grinding.
6. Place all pieces in the coupler and tack weld into place making sure the fit is tight.
7. Remove and complete all welds and grind flat, while ensure a slip in finger tight fitment. You shouldn't have to force the tool in with a blunt object.
8. With the tool in place, tack weld the 1-1/8" nut to the center of the tool, leaving room for an impact socket on all sides. 
9. Remove and completely weld nut onto tool making sure no welds create an obstruction.

CONGRATULATIONS!!! You've made your very own PTO Couple removal tool!!! 

- Lincoln Easy Mig 180 Welder:
https://www.amazon.com/MIG-Welder-Handheld-208-230VAC/dp/B003TS8D2M/ref=sr_1_2?dchild=1&keywords=Lincoln+easy+mig+180&qid=1603739154&sr=8-2

- Vulcan 10lbs Roll of Harbor Freight .035" Fluxcore Welding wire:
https://www.harborfreight.com/0035-in-e71t-gs-flux-core-welding-wire-1000-lb-roll-63494.html

- UBeesize Phone Tripod:
https://www.amazon.com/gp/product/B06Y2VP3C7/ref=ppx_yo_dt_b_asin_title_o01_s00?ie=UTF8&psc=1

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Sincerely, 
Andrew C.