Broken crank dowel pin

  • Ojisan rider
  • Ojisan rider's Avatar Topic Author
  • Offline
  • Sustaining Member
  • Posts: 328
  • Thanks: 65

Broken crank dowel pin

27 May 2018 01:43
#784131
Aloha guys. I need help with what the title say.

I manage to break the coil pick-up side of the crank dowel pin because I was stupid. Never rush a job...................Anyway, here are some pictures of it.

[img

[img


Is there any way I can remove this pin? I just went through about 16 pages of search but couldn't find anything.
82' KZ750-R1 cafe racer style. Clip-on, Rear set, Fork-Brace, Mikuni Flat-slide (forgot the size), Kerker.
84' GPz750 (basket case). everything are in pieces.
89' ZX750-H1 (ZX-7 Ninja). Resurrection project are on going with my KZ750. Everything is stock.

Please Log in or Create an account to join the conversation.

  • Nessism
  • Nessism's Avatar
  • Offline
  • Sustaining Member
  • Posts: 7527
  • Thanks: 2886

Re: Broken crank dowel pin

27 May 2018 04:41
#784134
You can always drill it out. Work carefully and stay centered in the pin. The bits are small so be careful to not break them off. If you are not confident you may want to look for a machine shop to do the work for you.

Please Log in or Create an account to join the conversation.

  • 650ed
  • 650ed's Avatar
  • Offline
  • User
  • Posts: 15343
  • Thanks: 2829

Re: Broken crank dowel pin

27 May 2018 04:42
#784135
You may want to have it removed by a shop that has an EDM machine. See links below for info. Ed

brokentap.com/services/

electroarc.com/difference-mdm-edm/
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)

Please Log in or Create an account to join the conversation.

  • Scirocco
  • Scirocco's Avatar
  • Offline
  • Premium Member
  • Never change a running system
  • Posts: 4255
  • Thanks: 2114

Re: Broken crank dowel pin

27 May 2018 06:25 - 27 May 2018 06:28
#784147
If you can do an accurate centered bore/thread for a threaded rod you can pull the pin out with a sliding hammer.
Another option is a sliding hammer, (dent remover) with a dot welding electrode.

Attachments:

Last edit: 27 May 2018 06:28 by Scirocco.

Please Log in or Create an account to join the conversation.

  • Ojisan rider
  • Ojisan rider's Avatar Topic Author
  • Offline
  • Sustaining Member
  • Posts: 328
  • Thanks: 65

Re: Broken crank dowel pin

28 May 2018 20:45
#784284
OK. I manage to drilled the hole and tried to dig it out, but it's not budging. Even tried to screws and tap, Since this is not a threaded item, harder I push to get something in, deeper it goes (sounds kinky, isn't it?).

Anyway, thinking of using arc welder rod as puller material after it gets welded to the pin. Anybody have any experience in this? Any other good method of getting this thing out? I been looking at evilbay lately just in case, but if all possible, I would like to use this crank since I know the history, what it'll need such as bearing.

Help!
82' KZ750-R1 cafe racer style. Clip-on, Rear set, Fork-Brace, Mikuni Flat-slide (forgot the size), Kerker.
84' GPz750 (basket case). everything are in pieces.
89' ZX750-H1 (ZX-7 Ninja). Resurrection project are on going with my KZ750. Everything is stock.

Please Log in or Create an account to join the conversation.

  • 650ed
  • 650ed's Avatar
  • Offline
  • User
  • Posts: 15343
  • Thanks: 2829

Re: Broken crank dowel pin

29 May 2018 05:44
#784289
Sounds like you're quite determined to make things worse rather than better. Why not simply take it to a machinist and have them remove it properly? Ed
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)

Please Log in or Create an account to join the conversation.

  • KZB2 650
  • KZB2 650's Avatar
  • Offline
  • User
  • Posts: 1475
  • Thanks: 265

Re: Broken crank dowel pin

29 May 2018 06:35 - 29 May 2018 06:35
#784296
When I was tearing into my motor this is what scared me most (breaking or striping bolt holes so I was overly careful) ........I'd listen to Ed on this one...... you don't want to make that hole over sized and have problems with it coming loose down the line.
1978 KZ650 b-2
700cc Wiseco kit 10 to 1.
1980 KZ750 cam, ape springs, stock clutch/ Barnett springs.
Vance and Hines Header w/ comp baffle and Ape pods, Dyna S and green coils, copper wires.
29MM smooth bores W/ 17.5 pilots, 0-6s and 117.5 main
16/42 gearing X ring chain and alum rear JT sprocket.
Last edit: 29 May 2018 06:35 by KZB2 650.

Please Log in or Create an account to join the conversation.

  • slmjim+Z1BEBE
  • slmjim+Z1BEBE's Avatar
  • Offline
  • User
  • Enjoy Life! IT HAS AN EXPIRATION DATE!
  • Posts: 1266
  • Thanks: 768

Re: Broken crank dowel pin

29 May 2018 13:13
#784315
650ed wrote: Sounds like you're quite determined to make things worse rather than better. Why not simply take it to a machinist and have them remove it properly? Ed
Yep. ^That.^

We cringed when we saw "...drilled the hole...".

That pin is very precisely placed in relation to TDC. It's what sets the advancer's static position in relation to TDC of all cylinders. Get the hole egged out, the replacement pin might be a few degrees out. That would introduce a permanent error in timing that may or may not be able to be corrected by rotating the timing plate.

Good Ridin'
slmjim & Z1BEBE
A biker looks at your engine and chrome.
A Rider looks at your odometer and tags.

1973 ('72 builds) Z1 x2
1974 Z1-A x2
1975 Z1-B x2
1993 CB 750 Nighthawk x2
2009 ST1300A

www.kawasaki-z-classik.com
An enthusiast's forum focused exclusively
on all things Z1, Z2 and KZ900.

Please Log in or Create an account to join the conversation.

  • Scirocco
  • Scirocco's Avatar
  • Offline
  • Premium Member
  • Never change a running system
  • Posts: 4255
  • Thanks: 2114

Re: Broken crank dowel pin

29 May 2018 13:58
#784318
Like slmjim+Z1BEBE and 650ed say, only a machinist in a metal working shop is your last hope to get the crank pin dowel bored out precisely for a little tip!!!
Everything else is a wast of time and hardware.

Please Log in or Create an account to join the conversation.

  • wiredgeorge
  • wiredgeorge's Avatar
  • Offline
  • User
  • Posts: 5310
  • Thanks: 44

Re: Broken crank dowel pin

29 May 2018 14:36
#784323
I have done the same thing. Use a carbide drill bit and get a compression pin and tap it into the hole. It is always nice to drill a straight hole and it is a lot easier to do this with a carbide drill bit (I think I already mentioned it). I have fixed several this way and it works fine.
wiredgeorge Motorcycle Carburetors
Mico TX
www.wgcarbs.com
Too many bikes to list!
The following user(s) said Thank You: Scirocco

Please Log in or Create an account to join the conversation.

  • SWest
  • SWest's Avatar
  • Offline
  • Sustaining Member
  • 10 22 2014
  • Posts: 23197
  • Thanks: 2817

Re: Broken crank dowel pin

29 May 2018 14:49
#784326
Just be careful. At some point it should start spinning and you can pull it out while it does.
Steve
The following user(s) said Thank You: Nessism

Please Log in or Create an account to join the conversation.

  • Ojisan rider
  • Ojisan rider's Avatar Topic Author
  • Offline
  • Sustaining Member
  • Posts: 328
  • Thanks: 65

Re: Broken crank dowel pin

29 May 2018 14:58
#784328
Got it guys. I'll try take it down to machine shop and see how much it'll cost. Probably cheaper to get used crank off evilbay.

Anyway, wish me luck.
82' KZ750-R1 cafe racer style. Clip-on, Rear set, Fork-Brace, Mikuni Flat-slide (forgot the size), Kerker.
84' GPz750 (basket case). everything are in pieces.
89' ZX750-H1 (ZX-7 Ninja). Resurrection project are on going with my KZ750. Everything is stock.

Please Log in or Create an account to join the conversation.

Powered by Kunena Forum