Removing crankshaft woodruff pin TS250

[Gordon Harkness]

Any tips for removing a reluctant woodruff pin on the dynamo end of the crank?

Cheers

Gordon

[Ian Earl]

Hi Gordon , Not the best or easiest job to undertake me thinks ! , question is there must be some reason to remove it ? , I would attempt removal by trying to grip the pin with mole grips as tight as possible and tap out using a hammer , if that fails you could possibly weld a small nut to it and progress to a larger size to enable removal , just several thoughts that I would try myself , cheers.

[Derek Reynolds]

If it’s not worn and need replacing – leave it in there. At least it won’t fall out and cost you time searching the floor.

[Gordon Harkness]

Thanks both for your replies.

I’m rebuilding the engine and treating it to a new crank (new old stock bought for a great price a couple of years ago), new bearings, seal, clutch refurb and a 12v powerdynamo/vape kit.

I’m going to try locally heating the crankshaft around the key and see if I can remove it without damage. If not, I’ll do the obvious and source a new one…….

I’ve stripped the engine and it’s the only part that hasn’t come out easily……..although I’ve yet to press out the bearings. Been pretty impressed by how easy these engines are to work on. I bought a clutch removing tool for the clutch basket but have made do with my collection of drifts and 2/3 legged pullers (made by me during my apprenticeship….a long time ago!) from my toolkit for everything else.

Probably needs a rebore but that can wait to things free up after this bloody virus passes!

Cheers

Gordon

[Greg Moore]

Hello Gordon
A good way to grip something round like the pin in the crank is with a drill chuck. There may not be enough protruding, and smaller chucks with small jaws with a pronounced taper will give better access. I have an old chuck saved from a scrap drill that I use. I have removed more than one of these pins in the past and have not found them to be very tight. A little gentle wiggling and twisting while looking closely at the pin with a magnifier to see if it is moving should also help.

Greg

[Gordon Harkness]

Cheers Greg,

I’ll give it a go (I’ve also got a couple of old chucks that I can use).

Should be back in the garage this week after a little delay (Mrs GH suggested it would be good to finish decorating the bathroom).

Cheers

Gordon

[Greg Moore]

Hello again Gordon
I hope you have managed to remove the pin from your crank, but, if you have trouble, I have found I have a spare one if you are stuck.

Greg

[Gordon Harkness]

Hi Greg,

All done. A bit of heat and drill chuck worked a treat. Many thanks for your kind offer though.

New bearings, seals etc are now fitted, gear cluster back together, cases re-joined and clutch/primary drive in place. Should get the barrel, head and new Vape generator fitted in the next day or so.

I’ve got some work to do on the forks (new seals and oil) and I’m renovating an old front wheel fitted with a Honda TLS front break.

After that, need to replace all bulbs to 12v and fit an new battery……and see if she starts!

I will also post article and media of the rebuild

Cheers!

GordonH

[Gordon Harkness]

“Brake”. Bloody spell checker!

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