NYsledneck
New member
Ok guys , what`s the trick to getting those darn speedo keys out of the drive axle when they break? I thought i got it all out but the new key does not seat deep enough in the shaft. 
Should i try to drill it out with a small drill? I know i`m not the only one to go through this 
Should i try to drill it out with a small drill? I know i`m not the only one to go through this TJ500
Member
just did same to my driveshaft last week...
a drill bit wouldn't touch old key material that was jammed inside... ended up drilling through insert with a dremmel tool and tiny carbide dremmel bit...
then (because the shaft insert was now damaged from carbide), carefully drilled out insert with MANY PROGRESSIVELY larger drill bits and CUTTING OIL, until pressed insert pulled out...
bought a new insert from Yamaha and heated shaft a little before pushing new one in flush...
big pain in the butt... driveshaft had to come off...
new key and new insert about $15...
see micro fiche for insert I am describing...
a drill bit wouldn't touch old key material that was jammed inside... ended up drilling through insert with a dremmel tool and tiny carbide dremmel bit...
then (because the shaft insert was now damaged from carbide), carefully drilled out insert with MANY PROGRESSIVELY larger drill bits and CUTTING OIL, until pressed insert pulled out...
bought a new insert from Yamaha and heated shaft a little before pushing new one in flush...
big pain in the butt... driveshaft had to come off...
new key and new insert about $15...
see micro fiche for insert I am describing...
terret725
New member
ive used a small but like half the size of the key and drilled it out. it should take and pull the strands of the key out bit by bit if ur lucky. if not is a speedo realy all that importaint anyway. if u have time too look how fast ur goin in the trails then ur not goin fast enough to begin with.
Or you can try and punch the broken peice in far enough to get the new key in. Sometimes its only a litle bit left and you can use a small punch or nailset to tap the broken peice all the way in, this will give you enuff room to fit in the new one.
TJ500
Member
did without a speedo for two seasons... care little about the speedometer but certainly look forward to the trip odometer once again!
hope the punch thing works for you...
try diameter of drill bits and punch and dremmel carbide or any other tools you are going to use into an unobstructed shaft insert first... the back half of the insert is press formed to accept the square key and is much smaller than front half....
hope the punch thing works for you...
try diameter of drill bits and punch and dremmel carbide or any other tools you are going to use into an unobstructed shaft insert first... the back half of the insert is press formed to accept the square key and is much smaller than front half....
NYsledneck
New member
I`m hoping i can get something figuired out without having to pull the shaft again. And i agree , don`t care about the speedo but sure miss having my trip meter!
PZ 1
Member
- Joined
- Mar 12, 2005
- Messages
- 987
If it isnt too far from going in all the way, you could grind some off the key.
NYsledneck
New member
yeah i tried the grinding down the key but then it still wouldnt work.
J.B. Weld it in.
Had the same problem so I cut my key in half and then used J.B. Weld to secure it into the insert. Been running it like that for 3-seasons (about 1,200 miles). I did it this way because I didn't want to take the drive shaft out. I have to this fall to replace the track so I am going to take it to a machine shop and have them bore the insert out and replace insert and key with new parts.
Mills
Had the same problem so I cut my key in half and then used J.B. Weld to secure it into the insert. Been running it like that for 3-seasons (about 1,200 miles). I did it this way because I didn't want to take the drive shaft out. I have to this fall to replace the track so I am going to take it to a machine shop and have them bore the insert out and replace insert and key with new parts.
Mills