Maintenance & Technical > KX500 Original
Repeatedly shearing flywheel key
martyestes:
Hey y'all. First time lurker here. I've been rebuilding a '96 K5, and it just came back from a mechanic who replaced the crank bearings, seals, etc. Low hour bike, but was drinking trans fluid at a rapid rate and smoking like crazy! Since it came back, on initial start-up, ran for about 1-2 seconds, then died. Then really strange backfires, kickbacks, but wouldn't start. Searching here - figured it was woodruff. Correct. Replaced it. And the EXACT same thing happened. Two things at work here: Bottom end work and I also installed a Steahly flywheel weight. Pretty sure I installed it correctly...but dunno. Not sure if the timing is radically off BEFORE I started it both times, or only after the key sheared. Looking at the stator vs. pictures of other bikes, etc...it isn't radically off visibly.
Possible my guy installed a flywheel off another bike or is there a way to do the crank wrong and have it be off? Any ideas?
Thanks, I'm scratching my head here. And yes - I searched first! :-D
kxpegger:
I'm just guessing but either the key slots are out of spec or it's a poor quality key. You may be able to find an oversize key and file it down for a nice snug fit?
Motorrad:
--- Quote from: kxpegger on April 27, 2012, 01:18:45 PM ---I'm just guessing but either the key slots are out of spec or it's a poor quality key. You may be able to find an oversize key and file it down for a nice snug fit?
--- End quote ---
flywheel key doesnt hold on the flywheel.. the taper does... Keyway is just for alignment.
Lap your flywheel to your crank.. Valve lapping compound works great.
martyestes:
Thanks. I have been searching all over and think that I probably did not have the assembly on secure enough. Both times. I will try once more, then break out the lapping compound. Thanks for the replies.
alward25:
Torque is key, it must be torqued to spec. Use oem keys too, one that looks good enough will not be.
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