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Engine Blows-up

RE: Re: RE: Re: RE: picture fordipsey

Acyr

don't disappoint me. get off your arse and find an engine reconditioner. put the word race in anything and you double your bill. come on fella! get that bloody Google search going if nothing else or just keep this thread at the top of the board till someone gives in and helps you!

regards

Taffy
 
RE: Re: RE: Re: RE: picture fordipsey

Acyr,
The fixing of the Key broach is a very common repair on industrial equipment. I would be willing to bet just about any machine shop can fix you right up in about 2 hours.
 
Since the gear failed and not the key (quite common) I would simply clean up the crankshaft area, install a new key, insure the nut is not bottoming on the crankshaft (consequently insuring all the force is being applied to the new gear) and get on with it.

Truth be told using a broached key as opposed to the earlier tapered shaft is only for the sake of saving money. Keys are not and never have been designed to transmit load. They are a locating device. Such is why the failure when the drive nut is not absolutely tight against the gear.

Dale

PS
Thank you for the detailed pictures.
 
So you are saying that with the nut tight on the gear and the gear properly tensioned tensioned between the nut and step on the shaft there will be no force applied to the key while running.
 
nsman said:
So you are saying that with the nut tight on the gear and the gear properly tensioned tensioned between the nut and step on the shaft there will be no force applied to the key while running.
Click to expand...

No.
I am saying it is a poor design to begin with and that insuring the nut applies force to the gear will "reduce" the instantaneous load on the key and broached area of the gear.

The primary drive truly should be of a tapered fit (pre 2001) or multi splined design.

For offroad with limited traction the present design is in my opinion borderline.
For a "hooked up" big bike it can be a problem.

Dale
 
Thanks Dale,
Given the limitations of this design,is there any other way to secure this gear that would be an improvement, over the recommended regular checks for nut torque..
 
nsman said:
Thanks Dale,
Given the limitations of this design,is there any other way to secure this gear that would be an improvement, over the recommended regular checks for nut torque..
Click to expand...

The gear most often explodes as the broached key-way is quite sharp inviting cracks.

Providing a radius to the broach and shot peening add a considerable safety factor to the gear.

For those with deep pockets and serious about racing their are some alternatives. Stitch welding with Tig, grinding a taper, etc.

Their is "GASP" Green Loctite. The later has not proved to be all that bad a deal. One must simply use a good quality puller and apply a bit of heat to the gear (via a heat gun) in order to remove.

Hope this helps.

Regards,
Dale
 
have seen this type of distruction to drive train gears many times.with a tapered seat the force from the taper is transfered to the gearcogg.any part that uses a key for alighnment has two right angles at the top of the key groove this is the week point in the casting.i am curently haveing my shaft splined and a gear made to fit thus eliminateing the problem will let you how it goes. cost is about £120 pound in total hear in england inc re balanceing
 
wesh155 said:
have seen this type of distruction to drive train gears many times.with a tapered seat the force from the taper is transfered to the gearcogg.any part that uses a key for alighnment has two right angles at the top of the key groove this is the week point in the casting.i am curently haveing my shaft splined and a gear made to fit thus eliminateing the problem will let you how it goes. cost is about Ł120 pound in total hear in england inc re balanceing
Click to expand...

Late model engines no longer make use of a taper. The tension between the gear, shaft and nut is all that separates the load from the key.

Not good.

Early tapered fit had little if any trouble.


Dale
 
Hole fixed! Can't wait to finish it up...!

Brian

welded!.jpg
 
that looks a beautiful job!

cross your fingers till it's running....

regards

Taffy
 
Thanks, the welder who did this is top notch (he welds rockets for a living). The rest is going together today & tomorrow - taking my time with it to ensure it's done right. Just picked up some more Loctite 271 for the main gear nut...so it does not come loose again and mess things up...
 

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