Broken Output Shaft !

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04 Feb 2007 19:52 #110267 by sbodi4d
Broken Output Shaft ! was created by sbodi4d
I was removing the engine from my 1980 KZ1000 Shaft, and when I pulled the front bevel drive I found the output shaft broken where the nut is, on the end. How big of a problem is this to replace? I wasn't planning on tearing the engine and tranny down completely, but I may have to now. I took a couple of pics of it.
Hope this works.


Post edited by: sbodi4d, at: 2007/02/04 22:52

Post edited by: sbodi4d, at: 2007/02/04 22:54
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04 Feb 2007 19:54 #110268 by sbodi4d
Replied by sbodi4d on topic Broken Output Shaft !
Well here is the other pic.



Post edited by: sbodi4d, at: 2007/02/04 22:55
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05 Feb 2007 04:44 #110292 by wiredgeorge
Replied by wiredgeorge on topic Broken Output Shaft !
You will need to split the cases and replace the output shaft with a new one.

wiredgeorge Motorcycle Carburetors
Mico TX
www.wgcarbs.com
Too many bikes to list!

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05 Feb 2007 08:15 #110334 by donthekawguy
Replied by donthekawguy on topic Broken Output Shaft !
Bummer. But look at the bright side-now you can have the crank welded and put a 1075 kit on!

Rathdrum Idaho
1971 Kawasaki g3ss
1972 Yamaha R5 350
1965 Suzuki Hillbilly
1964 Yamaha 125

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05 Feb 2007 16:35 #110438 by larrycavan
Replied by larrycavan on topic Broken Output Shaft !
donthekawguy wrote:

Bummer. But look at the bright side-now you can have the crank welded and put a 1075 kit on!


Optimism is a powerful characteristic that tends to turn bad situations into good ones!...now where the hell is the thumbs up emoticon?

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05 Feb 2007 17:36 #110447 by hwms
Replied by hwms on topic Broken Output Shaft !
If it were mine I would drill and tap the shaft and use a cap screw and lock plate.

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05 Feb 2007 18:33 #110457 by steell
Replied by steell on topic Broken Output Shaft !
If you could drill a straight hole in that hardened shaft by hand (without using a mag drill) you are a better man than I :)

KD9JUR

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06 Feb 2007 09:56 #110573 by hwms
Replied by hwms on topic Broken Output Shaft !
Are you sure that the center of the shaft is hardened and not just some depth into the surface?

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06 Feb 2007 10:07 #110574 by nads.com
Replied by nads.com on topic Broken Output Shaft !
Steel what the heck is a mag drill? Magnificent? And why do people think every hole has to be straigh? Can't it be a little crooked since it's just a cap plate? In other words "Without a ten ton Megatron laser you don't have a chance other than suicide, if it's the least bit crooked the earth is gonna shake trees are gonna fall on your garage.

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06 Feb 2007 10:22 #110577 by steell
Replied by steell on topic Broken Output Shaft !
Mag drill has a magnetic holder on the chuck end, it locks the drill in place. The cheaper ones are near $500, but the good ones that are programmable are well over $1000.00

I suspect the shaft is hardened all the way through and not just case hardened, but I have not checked to see if it is.

It's not that big a deal to just replace the shaft, so that's what I'd do.

KD9JUR

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07 Feb 2007 07:09 #110780 by wiredgeorge
Replied by wiredgeorge on topic Broken Output Shaft !
I don't know if the output shaft is hardened or not. I would replace it. It ain't that big a deal. Cases need to be split. Replace cam chain. A couple hours labor mostly in chasing out the thread in the case bolt holes and cleaning the thread on the bolts and cleaning gasket mating surfaces.

wiredgeorge Motorcycle Carburetors
Mico TX
www.wgcarbs.com
Too many bikes to list!

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07 Feb 2007 12:01 #110800 by sbodi4d
Replied by sbodi4d on topic Broken Output Shaft !
Thanks for all the replies, I don't know that I would trust myself to drill and tap the old shaft, so I will replace the shaft.

George, what do you mean chasing the thread in the case bolt holes? I mean I know what you're talking about, but is there a thread locking agent in there or something?

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