Question about 2003 Yamaha TT 600 R

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Ive got a yamahaTTR600 2003 (9000km) thats sheared a balance shaft woodruff key causing the crank rod to colide with the balance weight. Im told its a common fault with this model. When I rebuild the motor I wondered to prevent this from occurring again could I machine-off the balance weight leaving the balance shaft without a weight. Im told this has been done before without noticable effects to the engine. thanks Paul Naumann/ New Zealand

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I would not get rid of a balance shaft you will have premature bearing failure. I would machine a spacer or caterpilller makes a great compound just for that, cant think of the name of it right now but a cat dealer can help you find that compound

Posted on Nov 09, 2013


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Posted on Jan 02, 2017

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SOURCE: engine rebuild

send a message to JUNIOR hes the resident gearhead tot heforum btw

Posted on Nov 10, 2008

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From memory I believe there are a couple of dots on the balance shaft drive gears, the dots line up together

Posted on Aug 23, 2010

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SOURCE: have a apachi 100cc quad

Losing power as the engine warms up is often caused by a sticking ring on the piston. This mostly happens on the exhaust side of the piston due to a lean mixture of air/fuel. Lean means too much air. what does your plug look like ? white+ashy? You may benefit by simply re-ringing the piston. It's easier than crank seals.

Posted on Dec 08, 2010

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SOURCE: kawaskia atv. 400.bayou engine woodruff

I don't know the year of your ATV but you probably have electronic ignition. I assume the cam chain has not been disturbed. Based on that, just install a new woodruff key and go riding. The timing is pre set. Please rate my answer. Thanks.

Posted on Apr 06, 2011

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SOURCE: I have a 2003 Yamaha

Allan this is a shop job for the connecting rod. You should be able to do the rest yourself if your mechanic abillities are good. If you got the engine hot enough to seize it you might have more problems instore for you. Are you sure it is a con rod and not piston in cylinder seized? If it is a con rod bearing see what a shop would charge, then see what is available on ebay for parts. I have seen them (crank and connecting rod) on ebay between $50.00 and $180.00.

Posted on Apr 19, 2011

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1 Answer

How do I replace Woodruff key in engine

Take the cover off the housing that covers the flywheel. The crank shaft comes up the middle of the flywheel and has a slot in the end. The slot has the woodruff key in it. The key fits in the slot on the flywheel. When you hit something with the blades the crankshaft stops and the flywheel keeps turning. This shears off the woodruff key or makes it move out of position and then the timing becomes out of spec. The motor wont start. You need to pull the flywheel off and replace the woodruff key. They key looks like a half moon piece of metal.

Jan 01, 2016 | Garden

1 Answer

Why do the Yamaha MT 110V 2 stroke - engine backfire and take no load and how do I repair it

timing is fixed by way of a woodruff key on the crank that the flywheel is bolted to. only way the timing can be altered is if the woodruff key has sheared and the flywheel has spun on he crank. You would need to remove to flywheel to check if this has happened

Mar 05, 2015 | Garden

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99 trooper 3.5 v6 , believe balancer pulley sheared the key.pulley is wobbling and motor knocking like rod this a zero tolerance engine and are they known for this problem.sounds like motor is out...

IT is a zero tolerance engine which means that if you break a timing belt there will be valve damage. Check the harmonic balancer and if there is a rubber insert between the pulley and the crank shaft hub then replace the harmonic balancer as this rubber has failed and the pulley will fall off. If the key has sheared as you suspect there would be no engine noise as the engine would not be running. Fix the balancer first then check for the noise as it may be just the balancer

Sep 08, 2013 | 1999 Isuzu Trooper

2 Answers

Does the crankshaft have a woodruff key for the harmonic balancer?

hi this depends on what harmonic balancer you are inquiring about, normal balancers do have a woodruff key,but the pulley type harmonic balancer only bolts to a cam hub on what ever it is connected to, such as water pump, etc etc... hope this helps

Sep 13, 2010 | 2001 Oldsmobile Aurora

1 Answer

How to get the key out of the crank shaft to install new harmonic balancer and new key?

it is just pressed in, use a falt blade screwdriver and tap it out from the end, also a good set of Gise Grips ( actual brand, they are the best) and remove it, that is what i use, calmp the vise grips as tight as u can and then tap on the bottom to loosen the woodruff key from the crank snout.

Sep 10, 2010 | 1989 Buick Park Avenue

2 Answers

5 hrspwr front tine tiller shears crank shaft key when fires..upon starting

What can cause this is a very worn crank shaft keyway, a loose flywheel nut or a worn out flywheel keyway. These are the only causes for a flywheel key to shear. If the crank shaft keyway is excessively worn there is no amount of flywheel nut tightening that will stop the flywheel key from shearing. The only fix at that point is replacement of the crank shaft. The same thing goes for the flywheel keyway... It is worn out the only remedy is flywheel replacement.

The only other thing that causes flywheel keys to fail is a sudden stoppage of the engine. Most of time this only happens to lawn mowers then the operator hits something like a mini tree stump or a large rock.

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I have seen both the crankshaft and the flywheel keyways worn to the point that both had to be replaced. In the event that both have failed, the replacement cost with labor if you have it done is a repair shop can be 60 to 70 % of the cost of a new engine.

May 01, 2010 | Garden

2 Answers

How do you change the crank shaft pulley?

If you have the 3.5l engine, and you don't remove the right side engine cradle bolts, you will not have enough room and will strip out the bolt when you go to put it back in. There is only one belt. There is not a woodruff key on that engine, and the pulley can go back on any which way.

Check out the pix at

and following.

Apr 03, 2010 | 2000 Oldsmobile Intrigue

1 Answer

Car will not accelerate as you shift through the gears (delayed a

i had that problem on a 93 escort and it was because the woodruff key that holds the harmonic balancer in place was broken, the poopy acceleration was because the crank sensor gets its "signal" from cogs on the harmonic balancer, which did not turn at the same speed as the crank shaft because of the drag on the crank pully (crank pully and harmonic balancer are same part)

Jun 26, 2009 | 1991 Honda Civic

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