Broken crankshaft end cap. Help!

plivesey · Post by **plivesey** » Mon Jul 16, 2007 10:59 am

I had a CCT go on Thursday at 37000km

but it didn't lunch my engine which is good.

The valve timing did slip significantly however and I had to reset it.

Unfortunately, the crankshaft end cap in the alternator housing was in very tight indeed and sheared when I tried to remove it. I just removed the cover to finish the valve timing and the bike now runs a treat (or at least as well as it ever did). The only problem I have left is how to replace this end cap to make future spannering easier. A good sized chunk of metal came off meaning that a hex bit no longer fits. Any suggestions?

Thanks.

Stormin Ben · Post by **Stormin Ben** » Mon Jul 16, 2007 12:12 pm

Whip the cover off and weld an old socket to it?

Stormin Ben · Post by **Stormin Ben** » Mon Jul 16, 2007 3:33 pm

Next alternative

Drill 2 holes through it
Put a bolt through each
Put a bar/ tyre lever/ etc between the 2 bolts
Apply twisting force

Hope that works coz the next method involves hobnail boots and a hacksaw

Ben

Stratman · Post by **Stratman** » Mon Jul 16, 2007 6:18 pm

This part is made of cheese. I used a dot punch and got it to move that way, then replaced it, but why it is soo soft is beyond me.

plivesey · Post by **plivesey** » Fri Jul 20, 2007 12:27 pm

It appears that my previous post has gone missing, but hey ho.

I don't have the use of a welder at the moment so my first choice of welding a socket to it was out.

I tried a few methods. Drilled a hole and tried an eziout. Nothing. Tried a bigger hole and my biggest eziout. Nothing.

Two holes, bolts and a pry bar. Nothing. The bolts bent.

Finally I resorted to a cold chisel and a hammer. I took a good amount of metal off the end cap before it started to move.

It's now been replaced with a nice new one which also appears to be made of cottage cheese and cost Â£10 to boot.

Stratman · Post by **Stratman** » Fri Jul 20, 2007 2:59 pm

It's now been replaced with a nice new one which also appears to be made of cottage cheese and cost Â£10 to boot.

That'll be one of them there compooterised ones then will it ?

plivesey · Post by **plivesey** » Fri Jul 20, 2007 5:16 pm

Stratman wrote:
It's now been replaced with a nice new one which also appears to be made of cottage cheese and cost Â£10 to boot.
That'll be one of them there compooterised ones then will it ?

Very good

It took me a moment to get that!

RedStormV · Post by **RedStormV** » Fri Jul 20, 2007 6:10 pm

Bootiful, just Bootiful Stratman

Stratman · Post by **Stratman** » Fri Jul 20, 2007 6:38 pm

I do have a rather strange sense of humour. Ditto reality.

Back off to bed with Kylie now. Bye...........

ChunkyMonkey · Post by **ChunkyMonkey** » Thu Jul 26, 2007 9:30 pm

I've spent ages this afternoon trying to undo my alternator cap to time cct

Despite varius onslaughts with punches I ended up cutting a slot through it with my Dremmel and wedging a flat piece of bar in the slot.
Why do Honda make these parts from dog sh!t?