Maintenance & Technical > KX500 Original
Water Pump Drive Gear Snapped Off Crankshaft!
kxpegger:
Is this a common failure point? The engine was assembled by Service Honda!
The last few rides I was experiencing quite a bit of pinging but thought it was bad gas. Then I noticed it was puking about 150cc of coolant per ride. I pulled the rad cap and saw that there was no coolant flow.
Hope I didn't roach the top end too!
Also after I pulled the clutch cover my exhaust valves would barley move. Had to use a mallet and gently tap on the actuator rod to move the valves! I thought it was way down on power but havent been on the bike for over six months!
Looks like I'll be pulling the top end apart for sure!
Looking for suggestions to remove the broken part of the drive gear from the crankshaft. I'm assuming some heat and an easy out but without damaging the crank seal.
I did have a little good luck too as there is no other damage in the clutch area.
http://www.youtube.com/watch?v=ZPalL_FM7Mc
Update! The micro fiche makes it look like the water pump spur gear is press fit into the crankshaft? Looks like I may have to drill a hole and tap it! Then maybe some heat and create some type of shield to keep the heat away from the seal? Screw a bolt into the hole I tapped and use a slide hammer to pull it out?
Sure could use some help on this one. I don't trust any locals around here to do it thats for sure!
81cr450:
Oh man that sucks.
The drill tap & slidehamer sounds like a good idea, might be a real PITA if that is hardened steel which I'd guess it is. When we weld the pick-up tube to oil pumps we use a rag soaked in cold water to try to keep the heat out of the pump, seems to work fairly well. I'd pull the gear & wrap directly on the crank though.
Thinking of that hardened steel if you cant drill & tap it you could drill a hole in a piece of plate & try welding it to the end of the nub thats left in the crank so you have something to grab it with maybe?
kxpegger:
--- Quote from: 81cr450 on December 15, 2012, 11:22:57 AM ---Oh man that sucks.
The drill tap & slidehamer sounds like a good idea, might be a real PITA if that is hardened steel which I'd guess it is. When we weld the pick-up tube to oil pumps we use a rag soaked in cold water to try to keep the heat out of the pump, seems to work fairly well. I'd pull the gear & wrap directly on the crank though.
Thinking of that hardened steel if you cant drill & tap it you could drill a hole in a piece of plate & try welding it to the end of the nub thats left in the crank so you have something to grab it with maybe?
--- End quote ---
One of my riding partners presently owns 5 different year KX500's and has had more than one for the last 18 years. I asked if he had ever experienced this? Nope! Just my bad luck!
Yeah! Definately going to have to keep that seal cool. I like your idea of a cool rag and then maybe some type of ice water drip onto the rag for some insurance? Cant tell by the micro fiche but it looks like it goes inside the crank at least 1/2".
sandblaster:
I have had my hands on many K5's over the years and have never seen that happen.
Sorry to see it.
I think it's just a fluke.
Anyone else seen that?
Larry Wiechman:
Can you post a photo?
If you use a welder, be careful where you place the ground clamp. Do not let current pass through bearings.
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