Broken Output Shaft !

  • sbodi4d
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Broken Output Shaft !

04 Feb 2007 19:52
#110267
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.
550


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

Post edited by: sbodi4d, at: 2007/02/04 22:54

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  • sbodi4d
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Re: Broken Output Shaft !

04 Feb 2007 19:54
#110268
Well here is the other pic.

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Post edited by: sbodi4d, at: 2007/02/04 22:55

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  • wiredgeorge
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Re: Broken Output Shaft !

05 Feb 2007 04:44
#110292
You will need to split the cases and replace the output shaft with a new one.
wiredgeorge Motorcycle Carburetors
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  • donthekawguy
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Re: Broken Output Shaft !

05 Feb 2007 08:15
#110334
Bummer. But look at the bright side-now you can have the crank welded and put a 1075 kit on!
Rathdrum Idaho
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  • larrycavan
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Re: Broken Output Shaft !

05 Feb 2007 16:35
#110438
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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  • hwms
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Re: Broken Output Shaft !

05 Feb 2007 17:36
#110447
If it were mine I would drill and tap the shaft and use a cap screw and lock plate.

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  • steell
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Re: Broken Output Shaft !

05 Feb 2007 18:33
#110457
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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Re: Broken Output Shaft !

06 Feb 2007 09:56
#110573
Are you sure that the center of the shaft is hardened and not just some depth into the surface?

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  • nads.com
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Re: Broken Output Shaft !

06 Feb 2007 10:07
#110574
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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Re: Broken Output Shaft !

06 Feb 2007 10:22
#110577
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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Re: Broken Output Shaft !

07 Feb 2007 07:09
#110780
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
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  • sbodi4d
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Re: Broken Output Shaft !

07 Feb 2007 12:01
#110800
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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