layshaft seal is easy to replace

[scott_araujo]

Ok, I made the tool and it didn't look that ugly.  It also didn't work too well   I made iy by grinding down an 18mm socket.  It fit nicely but when it came time to remove the nut, the prongs bent.  It was on really tight.  I ended up using a torch and and then a hammer and chisel to get it off.  It finally let go.  I managed to straighten the prongs enough to get the new nut installed.  It bent again and shredded one of the key ways a little.  I didn't realize the torque spec on those nuts is 52 ft lbs!  Next time I'll just buy the tool.

The rest of the repair was simple.  Cam pulley came right off, easy out with the old seal, easy in with the new.  All back together now and belts re-tensioned to boot.

Scott

[Dietrich]

Anyone care to post up an easy way to get that little clip off from behind the pulley?  I've done two bikes now and that little clip is the hardest part...takes longer than all other steps combined.

[Monsterlover]

what clip are you talking about?

I just swapped pulleys from one engine to another this past weekend and didn't notice any clips.

I even swapped over the plastic backing plates. . .

[Dietrich]

There was a wire clip in a groove on the shaft behind the drive pulleys that are removed to replace the layshaft seal.  My DS1000 motor and a friends Monster 695 both had 'em.

[Monsterlover]

ooohh kay.

gotcha

[scott_araujo]

That's called a Woodruff key. 

http://en.wikipedia.org/wiki/Key_(engineering)#Woodruff_keys

Two ways to get it out:
1) Tap lightly or press down on one end and if it moves freely the other end will lever up and you can grab it. 
2) Put a very small screwdriver under the front edge, tap very lightly with a hammer.  It may go flying. 

It's also a pain to get back in, tight fit.

Scott

[Dietrich]

I 'm not sure if the newer motors are different or what, but I know what a woodruff key is and besides the two of those there are on that shaft, there is also a circular clip that fits in a groove around the shaft behind the pulleys and in front of the seal.  No problem, I've managed to remove two of them...mostly pointing it out so people know what to expect when diving into this repair.

[scott_araujo]

Yes, sorry, that's there too.  I think that lies against a thrust washer deeper in to keep the camshaft located properly left to right.  I think it's just a spring steel snap ring with no ears to grab, tough to get  off.

Scott

[erkishhorde]

Ok, I made the tool and it didn't look that ugly.  It also didn't work too well   I made iy by grinding down an 18mm socket.  It fit nicely but when it came time to remove the nut, the prongs bent.  It was on really tight.  I ended up using a torch and and then a hammer and chisel to get it off.  It finally let go.  I managed to straighten the prongs enough to get the new nut installed.  It bent again and shredded one of the key ways a little.  I didn't realize the torque spec on those nuts is 52 ft lbs!  Next time I'll just buy the tool.

The rest of the repair was simple.  Cam pulley came right off, easy out with the old seal, easy in with the new.  All back together now and belts re-tensioned to boot.

Scott

I made a note of that in my tutorial. It's damn tight!

[scott_araujo]

I should have read your tutorial more thoroughly.

[erkishhorde]

Show's your an engineer. Reading is for schmucks. Try it yourself and learn by doing. Or as the Cal Poly motto goes: Learn by make the beast with two backsing up. 

[ducpainter]

Show's your an engineer. Reading is for schmucks. Try it yourself and learn by doing. Or as the Cal Poly motto goes: Learn by make the beast with two backsing up. 

Engineers just think they make the beast with two backsing know everything.

[scott_araujo]

Nah, we just never trust anyone else's opinion.