How to rigg speedo key after snaping off inside shaft

[lakes of north]

Had a bearing failure on my Yamaha SXR 600 sprocket drive shaft.Speedo key fits into the end of the shaft.The key broke off inside the end of the shaft.I've gone through three metal specific drill bits to try and extract as much of the broken key as possible out of the end of the shaft.I can get the new key in about 3/8" of an inch which isn't all the way in, but I also round the edges of the shaft hole in the process of trying to drill out the broken key parts.The key has 4 flats and is about 3" in length.I tried using JB weld to hold the key in place inside the shaft, work for about 50 miles but the torque on the shaft finally wore it out.The JB weld worked but is to brittle to last.Does anyone know a product that would hold and be more pliable as to be able to handle the torque on the shaft?Can't find an e-z out that small of a diameter to fit in the end of the shaft to get remaining pieces of broken key out.Didn't take shaft out to drill, used compact right angle drill.There has to be some way to rigg this to make my speedo work again.Doesn't have to be pretty. FIXED IT! RESPONSE IS THE LAST ONE BELOW.

 

[skeeter2010]

have you tried a Dental Pick and Liquid wrench, kryol, or pb blaster or any other ust penatrant. Maybe you can get in alog side of it and get it to move

 

[mnguy]

Use what skeeter said and try an air blast. Sometimes that will dislodge loose bits. Be sure to wear eye protection though.

To save your sanity I would start looking for a used cross shaft.....it's usually cheaper than a dozen drill bits and four hours of your time.

 

[toddspolaris]

Alot of those yamahas have an isert that is drove into the end of the shaft and that insert can be removed, its not all that easy but can be done. check with your dealer for specific year

 

[syscokid4]

i had to remove the hole shaft to get the insert in the end of the shaft out its pressed in

 

[toolie]

mnguy is right on the money. either find a used one or bring it into a machine shop that has an EDM and they can weld it up and burn it out which may not be cheap.

 

[skutr]

Try straighting out a fish hook and pick it out with that.

 

[lakes of north]

Found a fix to fit a square key into a round hole. I raided my wife's sewing kit and used about 6 seamstress pins; not needles. Placed key into sprocket drive shaft hole I accidentally created, and then started placing the pins around the key until it became wedged. It ain't pretty but I put a 130 miles on it last weekend and the speedometer is still working. JB weld wouldn't work due to the brittleness of the material.The pins allow for some flex with the key when I pin the accelerator.

 

[doomsman]

Good red neck engineering in snow country.

 

[dakota]

Is the Yamaha key like the ones Polaris uses, (a piece of stranded wire that is pressed square)? If so I've used a very skinny wood screw to go into the hole to bite into the wire speedo key and pull it out. Use a good quality steel screw not brass as the brass one will not bite into the hard wire. Depending on what is left in the hole you may have enough of the square hole to then hold the new key.