WOODRUFF KEY takes it's next victim...
Posted January 31, 2004 - 05:39 PM
I logged 2600+ miles in 2003 on my WR450 with NO problems. I didn't have the TSB performed and thought I was one of the lucky ones to not have the woodruff key failure. Well, it happened to me today and I was SHOCKED! Unloaded the bike and went to start it and it just wouldn't go. A couple of pops, sputters and the kicker starter was kicking back and then nothing. The starter was just spinning and I knew I had become an official victim. Took the bike apart at the parking area and called a buddy who was coming out later to pick up a new key at the Yami shop on his way out. Replaced the key, torqued it to spec and put 20 miles on it with no issues.
When I pulled the cover, the flywheel nut was about ready to fall off. I think this failure is my fault and I'll tell you why. When I pushed the flywheel onto the crank, I really had to pull hard to get it back off. So, I believe I have well-matched mating surfaces on the crank and the flywheel. The bike is jetted well and hasn't back-fired since I have owned it. What I have neglected to do is check the torque on the flywheel nut at regular intervals and I believe that had I checked it on a regular basis, I could have avoided this. Should I have to do this? I don't think so but with the shady history of the 03's and the flywheels I guess I will make this a monthly ritual from now on.
Will the 04 upgrade parts help this issue? I'm not sure but I will definitely mull it over. I will tell you this, though...I will be packing several spare woodruff keys in my fanny pack so I can fix it trailside.
Posted January 31, 2004 - 08:05 PM
Posted January 31, 2004 - 08:34 PM
Posted February 01, 2004 - 04:11 PM
Posted February 01, 2004 - 05:49 PM
Posted February 01, 2004 - 06:03 PM
Posted February 01, 2004 - 06:16 PM
Posted February 01, 2004 - 07:05 PM
Posted February 01, 2004 - 07:27 PM
Posted February 02, 2004 - 03:22 AM
Hey guys I'am in the process of having that bushing made to go in the side case. I'am going by the dimensions that INDY WR450 gave me, so don't order a new side case until we make sure this works. They should only cost a few dollars, that a lot better than $90.00 for a new case.
Once you have that bushing made and have verified that it's all good...would it be too much trouble and expense to have the machine shop guy build a few more?
Posted February 02, 2004 - 03:26 AM
The other thing I did was mark the crank and flywheel nut with a center punch. That way I can see if the nut is backing off.
That's an excellent idea!
Posted February 02, 2004 - 06:47 AM
Posted February 02, 2004 - 01:31 PM
Bum Hair! That sucks. I was hedging on whether or not I want to go through the hassle of upgrading to the '04 parts, but now that sounds like it may be mandatory rather
than optional. However, I'm not convinved the starter gear
assembly is the only problem. I have a feeling it exacerbates an insufficient crank/rotor taper that is borderline so it may or may not really "fix" it and that's a lotta coin to throw on a "maybe".
Time will tell I guess.
Posted February 02, 2004 - 02:14 PM
Posted February 02, 2004 - 03:50 PM