I pulled my rear stat gear to replace the worn out O-ring, and it wouldn't go back in. WTF! I didn't move the rotors or anything at all!

Now I've tried rotating the crank by hand to see if it will mesh, but no joy whatsoever.

How can you get it back in short of rebuilding the engine?

 

Give it a few taps with a rubber mallet. It'll go in.

 

I tried tapping it... but I've already turned the crankshaft several times so I might have fudged up royally.

Also, when I turn it several times in one direction, it seems to get stuck, which is WTF to me.

They're not going to mesh unless it's slap-dead perfect, I think. What I don't get is why it wouldn't go in the first time, before it turned at all.

Oh well, I guess it's time for another engine refreshing... maybe I'll port it this time :p

 

If you turned the e-shaft more then a degree or two, you're going to have issues. Without the stationary gear the rotor is allowed to rotate "freely". It won't move more then a few degrees obviously because of the geometry of the engine, but you will now have a real bear of a time getting the stationary gear back in.

You can try lifting the e-shaft up a little at the back as it will probably fall slightly due to bearing clearances. Then have someone rock the engine a bit while you try to slip in the gear. Lube the gear, bearing, shaft and inside of the rear iron.

 

Rock it how? Do you mean I should wiggle the e-shaft?

I hadn't though to lube it all up... but the clearances seem to be so tight that it has to be 99% perfect or no joy.

 

Remember that the stationary gear have some teeth that fits into the rotor gear. If they are not well aligned they will no fit. The stationary gear need to be placed without any disaligment or it will not came in place.

 

Hence why I probably need to crack it back open... technically not a rebuild, just a disassemble/reassemble and maybe a port job if I feel like it.