Locating pin trouble

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22 Oct 2024 14:26 #905346 by Vietvet
Locating pin trouble was created by Vietvet
When I split the crankcases and removed the input and output shafts this is what I found. One locating pin sitting proud like it should be and the other has been pushed down flush with the mating surface. It is a solid pin which sits very tight. I thought a very strong rare earth magnet might lift it but to no avail. I heated the area and tapped with a hammer but still no go. It has had a good soaking overnight with RP7 but still no good. Drilling it looks like a hard job. Any ideas. 

Tantanoola South Australia.
1979 KZ 650

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22 Oct 2024 14:31 #905347 by SWest

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22 Oct 2024 15:20 - 23 Oct 2024 13:18 #905349 by Warren3200gt
Replied by Warren3200gt on topic Locating pin trouble
If you can't get to it from behind then drill it with a small size bit, tap a thread in it, screw in a bolt with a washer and nut tighten to the head to give you something to grip and pull it carefully out. 
You will be able to reuse it with a threaded hole down the center. 


Z1000J2 somewhat modified!

Last edit: 23 Oct 2024 13:18 by Warren3200gt.

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22 Oct 2024 16:11 #905350 by Vietvet
Replied by Vietvet on topic Locating pin trouble
The case is not broken on the other side, I was thinking at one stage I could drill a hole on the other side to see if I could leverage it up. I will consider drilling a hole in it and maybe using an easy out but it looks like really hard steel and it is only 6 mm diameter. Might have to take it to an engineering shop and let them have a go at it.

Tantanoola South Australia.
1979 KZ 650

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22 Oct 2024 17:58 - 22 Oct 2024 18:04 #905353 by TexasKZ
Replied by TexasKZ on topic Locating pin trouble
You could also check for a local shop with an EDM machine.

You could also buy one, learn how to use it, and we could all send our broken bits to you.......

portableedm.com

1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough
Last edit: 22 Oct 2024 18:04 by TexasKZ.
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23 Oct 2024 05:43 - 23 Oct 2024 05:45 #905368 by Injected
Replied by Injected on topic Locating pin trouble
It is important to get that fixed.

I would try to pry it up using a small sharp wood chisel against some thin scrap wood.

Your going to have to hammer into it then try to smooth out the gouge so it slips into the locating hole.
You just need enough length to locate the end cap as there is a small oiling hole in it that feeds the trans bearings (orifice #14)


 
Last edit: 23 Oct 2024 05:45 by Injected. Reason: info
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23 Oct 2024 07:52 #905375 by SWest
Replied by SWest on topic Locating pin trouble
Is that a 750 twin? Looks like it due to the counter balance bosses.
I had a broken crank journal because of the wreck in 86. It was a big chip that I had to have welded. Couldn't remember if the pin was straight through or if it had a flange to hold it in. I went back on my 750 crank thread to see if I had any pics there but nothing but dead videos. After reading the text I remembered I had to drill out the hole to make it round again. I thought I'd have to use a pin from a 630 chain but the pin fit good enough to hold the bearing in place. In your case I wonder if the pin was pushed into a oil galley to make it that low. Could be a flaw in the casting but in any event I'd check to make sure. The pin needs to be there even if you have to fill it to make it stand out.
Steve 
kzrider.com/forum/13-bike-related/597654...kaw?start=336#757073
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23 Oct 2024 12:51 - 23 Oct 2024 12:54 #905383 by Scirocco
Replied by Scirocco on topic Locating pin trouble
You can try a spot welder hook and pull hammer any good car body shop should have to remove dents.
It´s less invasiv in my opinion and a lot of heat to the case is your friend during the task....
Last edit: 23 Oct 2024 12:54 by Scirocco.
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24 Oct 2024 12:58 - 24 Oct 2024 12:59 #905410 by Injected
Replied by Injected on topic Locating pin trouble
It may be easier to drill a new second hole in the end cap and drill a new dowel hole on the case. Even a 3/32" split pin would be good enough to locate it in the correct spot.
Last edit: 24 Oct 2024 12:59 by Injected. Reason: sp

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24 Oct 2024 14:21 #905412 by SWest
Replied by SWest on topic Locating pin trouble
There is a very small oil supply hole in the oil galley spot. Any shift in placement of the race will starve it for oil. 

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24 Oct 2024 15:19 - 24 Oct 2024 15:25 #905414 by Injected
Replied by Injected on topic Locating pin trouble

There is a very small oil supply hole in the oil galley spot. Any shift in placement of the race will starve it for oil. 


 
Yes, new hole and dowel to the outboard edge on the same center as the flush pin. From the outer edge of case to the OD of flush pin its .348" so plenty of room to do such a thing (have bare 650 cases here)

This would be a last ditch effort after trying to pry it or the weld and pull (I don't own a welder)
Last edit: 24 Oct 2024 15:25 by Injected. Reason: info

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25 Oct 2024 19:11 #905457 by Vietvet
Replied by Vietvet on topic Locating pin trouble
Thanks for all of the suggestions, I ended up taking it to the bloke that does the vapour blasting in Mt. Gambier he has worked on many z900 since the early 1970's and he had done that particular repair job. He drilled a hole beneath the pin from the rear and tapped the pin back into position then filled the hole of a hard setting liquid metal. Not sure of what it is called but it is very solid, took him 20 minutes to do the job. He is a wealth of knowledge on all things old KZ and Z model Kawasakis  

Tantanoola South Australia.
1979 KZ 650
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