Maintenance & Technical > KX500 Original
Water Pump Drive Gear Snapped Off Crankshaft!
5hunrooster:
This is what happened to me when I bought my 500. I couldn't figure it out. I took it for a couple 10 minute rides, it would start pinging and would notice a trail of coolant following me back. I took the water pump cover off and the impeller was spinning freely. I tried drilling and tapping but the tap would not start into the shaft of t.he gear. So I had to drill it out as much as I thought was safe to not damage the crank and tried to put the new gear in but, it IS a press fit. I tried the heating the crank end and putting the water pump shaft gear in the freezer but it didn't work. So I was frustrated one night, and after having a couple of thirst quenching Budweisers I gently started it in with a small hammer, then hit it square a few good times with a sledge hammer and perfect, it went all the way in until the gear was flush against the end of the crank. Since then, it has worked great.
kxpegger:
--- Quote from: Larry Wiechman on December 15, 2012, 12:53:13 PM --- 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.
--- End quote ---
http://s155.beta.photobucket.com/user/peteegger/media/024_zps2c13489e.jpg.html?sort=3&o=0
http://s155.beta.photobucket.com/user/peteegger/media/023_zpse2da7a78.jpg.html?sort=3&o=1
81cr450:
--- Quote from: 5hunrooster on December 15, 2012, 02:04:02 PM ---This is what happened to me when I bought my 500. I couldn't figure it out. I took it for a couple 10 minute rides, it would start pinging and would notice a trail of coolant following me back. I took the water pump cover off and the impeller was spinning freely. I tried drilling and tapping but the tap would not start into the shaft of t.he gear. So I had to drill it out as much as I thought was safe to not damage the crank and tried to put the new gear in but, it IS a press fit. I tried the heating the crank end and putting the water pump shaft gear in the freezer but it didn't work. So I was frustrated one night, and after having a couple of thirst quenching Budweisers I gently started it in with a small hammer, then hit it square a few good times with a sledge hammer and perfect, it went all the way in until the gear was flush against the end of the crank. Since then, it has worked great.
--- End quote ---
So what your saying is that the hole in the crank is deep enough to swallow an extra stub, correct?
5hunrooster:
I'm not sure about that, I just tried drilling it out until it looked like it was all out of there
don46:
I had one that had teeth missing on an Ebay motor, so I was going to replace it, Icouldn't get the gear out so I set the crank aside and used a different one. I'm sure this is an interference fit and requires heat and cold to assemble, and if I could get it out I'd let you know.
to answer your first qquestion I have never seen one fail, the one I had surely had something go through it to cause it to lose teeth, and even then it didn't break.
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