Maintenance & Technical > KX500 Original
Water Pump Drive Gear Snapped Off Crankshaft!
kxpegger:
I've searched cyberspace with little success.
Plan #1 is to have a friend of mine machine a drill jig on his lathe that will fit over the crankshaft end and allow me to drill a hole keeping everything centered. Tap the hole and place a grade 8 bolt in the broke off piece after tapping. Design a heat shield to keep direct heat away from the crank seal. I will also use welders heat sink to keep the heat away. I found some stuff that's called Cool Blue. I will try not to get temps above 275-300F by using a digital temp gun I can borrow from work. I will then use a slide hammer and hopefully it will pop out. I've researched what you need to drill and tap hardened metal.
Plan #2 will be to take it to a local machinist who is also a dirt biker and understands all of the concerns. Silver State Machine of Las Vegas.
Plan #3 is split the cases, heat the s**t out of crank end and use a drift to knock the broken piece out inboard because I think the inner bore of crank end is the same size all the way through the crank.
Plan #4 as an absolute last option is buy a new crank! :x
USMC 500:
I'm guessing you've already spoken with Service Honda on this since they supposedly assemble each engine piece by piece from OEM. Hence, why they are so expensive.
Klammer:
There are companies that specialize in broken bolt and screw extraction. They use a process called EDM. They can get your stud out and not heat up the seal. If you have problems locating this service, talk to machine shops. They often use these guys or know of a machine shop that has EDM.
kxpegger:
--- Quote from: Klammer on December 18, 2012, 12:20:58 AM ---There are companies that specialize in broken bolt and screw extraction. They use a process called EDM. They can get your stud out and not heat up the seal. If you have problems locating this service, talk to machine shops. They often use these guys or know of a machine shop that has EDM.
--- End quote ---
Thanks! Looking to see who in Las Vegas may be able to do this!
kxpegger:
--- Quote from: USMC 500 on December 17, 2012, 01:48:18 PM ---I'm guessing you've already spoken with Service Honda on this since they supposedly assemble each engine piece by piece from OEM. Hence, why they are so expensive.
--- End quote ---
Haven't contacted SH. I would be surprised though if they were building the crank assembly opposed to ordering them complete. I have established that the spur gear is a press fit though.
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