Yanmar KM2-A Disassembly and Cone Lapping
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- Опубліковано 22 сер 2024
- This video shows how to Dissemble a Yanmar KM2-A transmission and lap the shift cone. This transmission is from a Yanmar 2GM engine. The Yanmar 2GMF, Yanmar 2GM20 and Yanmar 2GM20F, and Yanmar 1GM series engines all use this transmission.
The Yanmar SD 40 and SD 50 also use a clutch cone.
How to service a Yanmar clutch cone.
Hey, just wanna give you a shout out for your videos. I tackled my slipping Kanzaki gearbox with your video as a reference. It's working better than at any point in the 4 years we've owned her. Massive thanks
Thanks for watching. This is why I wanted to make this video!!!
Gotta say, if you had a cameraman to get in close step by step you’d have the best transmission rebuild video I’ve seen on UA-cam! Great video man.
Thanks! I have the ONLY KM2A transmission video on UA-cam!
This type of gear box is made in India and costs around $350 in US dollars.
Very Helpful. Thanks for taking the time to make it. Well done, and priceless to someone with this Trans. Looking to do this soon.
Cheers
Awesome job. I'm sure this will get a ton of views, as you mentioned there are next to nothing for video resources for this. On my gearbox, reverse was working correctly, but forward would make a slipping and banging unless pressure was kept on the shifter lever on the gearbox. I'm hoping that lapping the cone and flipping the shifter like you did will resolve my issues. Thanks again for the excellent video.
Yes, My transmission did the same. It would go into gear in forward, but then when I increased engine RPMs from idle to 1000 ish RRMs I got no additional speed. When I increased RPMs to 2000 the transmission would bang into gear. I learned this is happens because the shift cone gets glazed and needs to be lapped. Lapping my shift cone solved the issue. I did this 2 seasons ago and my transmission has been working perfectly!
@@sonofneptunesailing917 Happy to hear this. My boat is on the hard till April 1st, so I have a project.
OOO hello, another Marine page.. Awesome stuff. These have the same clutch as the PRM boxes like the 120 / 125 Although PRM coat their cones.
I'm following this to the tee as I rebuild mine... Hopefully just need to Lapp it and don't need to replace the cone
Can you link the other video of the lapping process that you used?
Great video, thanks for taking the time to put it together. I am about to attempt this job, assuming that it is just a case of refacing the cone and gears, are there any parts I need to pre order, gaskets, seals etc that get damaged during the process? Thanks again very informative, Phil
Great video, thanks
Bravo, thanks!
Hello, I just had a friend contact me about a small boat with a Yanmar engine and transmission. It goes into reverse instantly. If you shift into forward it seems to be slipping but if you rev it up a good bit it will engage. Sounds like this is the answer? Thanks for the great video. Too bad they don't make a lapping oil to put in run and drain....LOL. So the symptoms this fixes are slipping correct? Thanks Again.!!!!!
Yes lapping the cone sounds like the answer. I would just make sure the transmission is a cone type and not a clutch plate type.
Thanks for watching!!!
Lol, love the opening to the video!
Very nice video!! Thanks
Jim D - great video! I’ve read that it’s really difficult to remove the transmission from the motor- what did you do
I had no issue removing my transmission. I have had people comment that they had issues removing their transmission…
What size gear puller did you end up using? Looks like it might be a 6" or 8"... Planning to rebuild our transmission and need to get this tool, so hoping you might be able to share what you used.
Jim - would you be kind enough to list the main tools I would need to do this job!?
Hello, thanks very nice explain video, but can you describe the symptoms of the engine, to be sure that’s the problem is the cone?? Thanks
At low speed my transmission would go into gear. As I increased RPM the boat would not increase speed and the transmission make a noise like a washing machine. When I would increase RPM more to 1,000 ish the transmission would make a Bang sound and the boat speed would increase.
Can you send me the link for the seals and bearings please? Great video, thank you.
I don't still have the numbers for the parts I used. I just went to a Yanmar dealer with my service manual and they cross referenced and ordered the parts.
@@sonofneptunesailing917 got the parts. $60US for the seals, o ring and nuts. Not bad. Did the rebuild yesterday. Great instructions. Thank you. Torqueing that final coupling nut was not easy to get 80ft/lbs. no where to hold the trans. Will recheck once I install back in the boat. Also, the shifter adjustment is critical. Thanks!
@@Saylor-Rob61 I hope it works!!!
Great video. I did this task about a year ago and need to do the same on my other engine (note only ~1300 hrs before gear started slipping). I recall the hardest part was the first step removing the output shaft nut. After grinding the chiseled divot (chalk mark in the nut) it was difficult to loosen the nut while trying to hold the unit firmly. Did you use the 'special tool'? (#177075-09050) or perhaps bolt a piece of steel to the coupling to brace it against the vice or floor?
Thank You!
I think put a pin in the output shaft flange to lock it so I could loosen the nut. I did this project 2 years ago.
Thanks for making this video!! I think I might have to do this on my gearbox as well. When I put the lever forward, it doesn't immediately go into gear, when it does eventually kick in, it vibrates a lot until I rev it up a bit. When i put it in reverse, there doesn't seem to be any issues. Do you think that might be the symptoms of worn off cones ?
Yes sounds like the forward side of your cone is glazed. I got a lot of good advice from a yanmar owners Facebook group
Very helpful! Thank you! What are the dimensional specs of the cone? At which point is it worn too much and a replacement is in order?
The manual says to replace the cone on the KM2A when the amount of wear on the tapered contact surface of the cone is less then 24.1mm. I would recommend downloading the service manual there is a section on Inspection and Servicing that gives all the dimensions and tolerances of various parts and places to look for wear. There is a Facebook group called Yanmar owners that I believe has down loadable versions of the service manual.
The common issue with these shift cones is not that they wear, it is that the oil between the cone and tapered surface of the forward gear heat the oil and create a "glazed" oil surface that prevents the cone from locking into the gear. It is similar to the "seasoning" on a cast iron frying pan. The point of "lapping" the cone is to remove this layer. I believe this transmission needs to shift fast and not have too much oil. Slow shifting and too much oil can cause the cone to glaze and the transmission to slip.
Thank You for watching!!!
Sir I want to know more about gear box of yanmar then tell me about it
You Rock plain and simply demystifies the process if I wasn’t such a chicken shit I’d attempt it well I need tools I don’t have Or own but fantastic job thank you
Can anyone suggest a cost effective place online to buy Kanzaki parts? My local Yanmar guy here in NZ is very expensive
One final question - in putting the 300 ml oil into the transmission do you screw the dipstick all the way down to check the right level or only put the dipstick in and not screw it down to check the mark on the dipstick? Know what I mean? Thanks.
I think you screw it down. The Yanmar owners Facebook group is a good source of information like that. I remember reading posts about your question. I don't remember the answer.
@@sonofneptunesailing917 I’ve read both ways but like other dip sticks screwing down makes sense
Love this video❤️ Would a kanzaki km4a be much the same?
I am not sure. I know they changed the shifting mechanism after the KM2A. I don’t know if the km4a is a cone clutch or plates. There is a really good yanmar owners group on Facebook.
My springtime project, I have absolutely no reversing power at all, makes for very tricky docking,,,
Typically, a glazed clutch cone is a forward gear problem. Not having reverse may be a different issue. Gool Luck! There is a Yanmar Owners group on Facebook that typically gives good information.
What is your background (normal job) looks like you’re pretty well set up there
Actually, I am a health care worker. My Dad owns the marina, a dock building business, and scuba charter boat.