broken tach drive sleeve removal

[rustybronco]

Thanks for the replies and suggestions, see my responses below. I guess I'll just have to noodle with it some more... The offer for a visit is still open, I'm perfectly willing to compensate someone for their time.

I won't say that I cant, but the distance is a bit on the longer side for me.

Do you have access to a decent size air compressor just in case it has to be cut off ?

[Agemax]

To expand a bit maybe re Rusty Bronco's question re an air compressor. I have zipped off ball joint bolts on cars and 4 wheelers in seconds with an air chisel. Sometimes had spent many minutes with a hammer and chisel and just got more tired than ahead. I am thinking a couple of quick air chisel blows on the gear shaft housing / plug affair will force that whole assembly out the front of the head in seconds. Harbor Freight, for example, sell that stuff cheap. Just a thought. Twenty bucks http://www.harborfreight.com/catalog...t?q=air+chisel

Compressor: good for airing tires too. http://www.harborfreight.com/catalog...?q=compressors

Ten bucks for some hose and fittings. Anyway, good luck on this. I cannot imagine the frustration.

i would definately NOT use an air chisel, unless you have a spare head close at hand......

[eil]

AWW YEAH

[Dogma]

Gotta love the vise-grips and hammer! Glad to see you got it out.

[WShie]

Good for you! Like mine it was a hell of a fight.

[eil]

I was in a rush to post last night, but I also wanted the thank everyone who offered help in this thread.

In the end, it was all about patience. Something I've been lacking lately. Every time I clamped the vice grips on the shaft, the hammer would bang them off. So I just kept going tighter and tighter until I was afraid I was going to break either the vice grips or my hands and finally she budged.

Why was it stuck? Best as I can tell, it was cooked motor oil holding it in ahead of the seal. So this sleeve is something to take out and clean once in awhile. Or maybe run some kind of heat-resistant o-ring all the way down the sleeve before installing to keep crap out of there.

Unfortunately, the tach gear is pretty buggered but I have a new one on order through Z1. (Their price plus shipping happened to be much better than any of the OEM fiche sites.) Until then, I have a temporary cap thing rigged up to plug the hole, on the off-chance that I get the bike running before the gear arrives.

Thanks again! You guys rock!

[rustybronco]

I suspect a bit of trepidation was mixed in as well.

[1948man]

Happy endings are good. Good advice rocks.

[rustybronco]

Too bad he jumped the gun. I had a used one sitting in wait for when he needed it.

[eil]

Too bad he jumped the gun. I had a used one sitting in wait for when he needed it.

Tach drive gear, you mean? Unless I spaced out and missed where you said that, I didn't know you had one...

But thanks again for the advice. Hopefully we'll run into each other soon. (Figuratively speaking, of course.)

[DonL]

After looking at your picture I think this would work: Use a dremel to cut a groove in your tach gear perpendicular to it's axis about in the center just deep enough to capture a screw driver. Then using a hammer and screwdriver or drift to push the assembly out through the head using the gear as a pusher on the soft aluminum plug.

I was experiencing the same leaky stuck Tach Drive.
I did what you recommended. Let's just say, don't do it.
Resulted in the sleeve of the drive breaking off also.
So...I get to pull the Exhaust cam and bump the drive out also.
Cheers!!