Mangled drive shaft splines

[breaze]

What started out as a simple loose belt has now become mangled drive shaft splines. I was experimenting with different belts trying to cure a loose belt whine from the drive case. After the first belt change the problem went from a whine to a shudder. That should have told me something.

Anyway, to make a long story short, I read through the forum and saw warnings about the splines and being careful with them. I knew I hadn't been, so I pulled the pulley and didn't feel good about what I saw. The splines are mangled and the inside pulley half spins freely with its grooves worn out. I'm quite the humbled noob.

This is tough to take. I was so close and it ran so well except for the whine. Now I guess I am looking at a major job ahead of me. Best I can tell, cracking the case, replacing the crankshaft (complete assembly from Honda is $170.00), and replacing the front drive pulley - although the outer side may be salvageable.

This is something I do for fun and I am trying to relax and find something positive about the experience. Best I can come up with is that if I go forward, at least I can say I cracked a case - bet it makes a * of a pop. Also, what a great opportunity to replace the bearings and seals. Already re-worked the top-end, gotta do the bottom to stay in balance.

I plan to start reading up and maybe not move ahead so quickly this time.

My biggest concern is not the project, but the cost. From my experience, the more money I throw in, the less fun I have. I've got several other no-peds and scoots to ride so I am in no hurry.

If anyone has a crankshaft at a better price...

Sorry for the novel, needed to vent a little.

[tw39515]

Is it a spree didnt happen to see what kind of scoot it is. if its a spree check out here. Or i hate to say dude swap in a dio.

[breaze]

Yes, an 84 Spree so that 85 engine would be a good fit. That is probably the smart thing to do but I hate to throw $100.00 at it (with shipping) without time to mull it over.

Great suggestion - thanks for pointing it out. But I think I'll step back and think this one through. My guess is that a new engine is going to be the most painless route, but I'm not a dio dude, more like a 53 year-old fart with 3 kids keeping himself busy with an excuse to drink cold beers out in the shop.

[odinxxix]

post a pic if you can. if they arent to bad you may be able to massage them back to life.

[breaze]

If nothing else, these can be used as examples of boneheaded endeavors:









When the pulley inner half is all the way on it spins freely - I actually thought of using JBWeld on the inner pulley (the outer pulley holds). I would never be able to take off the inside pulley but would still be able to change the belt and do maintenance...

[tw39515]

ouch.

[toboggan]

ouch.

agreed. I'm Sure someone has a crankshaft around here

[martynkim]

You MIGHT get away with a new pulley. Or not. A new pulley and a file might do wonders.

[Trafficjamz]

If nothing else, these can be used as examples of boneheaded endeavors:


When the pulley inner half is all the way on it spins freely - I actually thought of using JBWeld on the inner pulley (the outer pulley holds). I would never be able to take off the inside pulley but would still be able to change the belt and do maintenance...

The Inner pully is not splinned and should spin free.

[wiguy05]

CRANK

I still have the above crank if it helps!

[breaze]

Wow, so the inner pulley is supposed to spin freely, which means there is still hope. I assume if the outer pulley is seated properly and torqued properly, the pressure against the inner pulley keeps it from slipping... and it is the outer pulley which is driven by the shaft.

I am going to try to assemble the front pulley on the shaft without the belt and see if there is a chance it will hold - the pulley splines look fine. I'll see if I can work on the shaft grooves with a file first.

Who knows... after reading up on splitting the case, removing and re-installing a crankshaft, I really don't think I'm ready for that effort.

[CharlotteSpreeRider]

Wow, so the inner pulley is supposed to spin freely, which means there is still hope. I assume if the outer pulley is seated properly and torqued properly, the pressure against the inner pulley keeps it from slipping... and it is the outer pulley which is driven by the shaft.

I am going to try to assemble the front pulley on the shaft without the belt and see if there is a chance it will hold - the pulley splines look fine. I'll see if I can work on the shaft grooves with a file first.

Who knows... after reading up on splitting the case, removing and re-installing a crankshaft, I really don't think I'm ready for that effort.

In order away from the center of the crank it goes oil seal, washer, inner pulley with fins pointed towards center of of crank, outer pulley, washer, nut. Only the outer pulley engages the splines. When you have the outer pulley on, it should completely cover all of the splines, but just barely. If you leave off the inside washer, there will be splines visible, and when you put the outer washer on, you will crush them and ruin the crank. Your assumption is correct.

[Clivester]

Trafficjamz is right.

The pulley is a softer alloy than the crankshaft, so there is a good chance you could clean out the splines. They usually get damaged by a poorly torqued shaft nut that allows the steel front pulley gear to spin on them.

[breaze]

Wow - hope springs eternal - and here I am stuck at the office. I will work on cleaning and possibly filing the splines on the shaft when I get home. Also, I will check the splines on the front pulley for damage. Honda wants $63.00 for that front pulley piece. Assuming the pulley splines gave and the shaft splines are recoverable, anyone have the front pulley piece (called a gear by Honda)?

[odinxxix]

you might be able to use a file the kind that looks like a diamond from the side and file it down inbetween the slots and make it work. good luck and let us know if you repair or replace.