Hi all,
I have a 2000 GSR that had the engine rebuilt some time ago and one of the things that happened is the crank bolt came loose. I took it back to the shop for them to fix it and all they did was tighten it back up through the wheel well. (This was one of numerous things these clowns did) About 6 mo. later I was driving home from work and I heard a loud clank. The crank bolt snapped off! Before I go and get all the extra parts to fix this, I wanted to see if everyone had some advice about whether or not the crankshaft was still usable. I'm including some pics of the end of the crank shaft. The main concern is the keyed slot.

THANKS!

 

I would see if you can't cut an extra key slot on the opposite of both your crank pulley and crankshaft end so the crank pulley will hold for sure. Try and use some quik steel to repair the existing key slot and use it in combination with your new key slot that you can make with a dremmel in both your crank pulley and your crankshaft end. This way you can keep the mechanical timing perfect. Its easier than you think, and could be done in less than an hour. If you don't feel confident cutting out the slot I can tell you from first hand experience that it is fairly simple. Just mark and cut. Your might need quite a few dremmel bits but it should work. I used a small file too to get the slot nice and straight. If this doesn't work than you need a new crankshaft.

 

Find a competent tig welder to build the damaged area back up and file away till the key fits in nice and snug. For getting the crank bolt back out hopefully it will just back out with an ez out and you wont have to drill it. Which is plausible considering there is no load on it and it wasnt cross threaded in.

 

damn there are no threads where the crank bolt goes ... how is that supposed to thread back in? I think that's what he's talking about, yes?

 

Like everyone else says.. Find a good tig welder. It still looks reusable.

 

The threads start where the bolt snapped. They do not start at very beginning of the crank, about 1/4 inch in.

As for the key hole, like everyone says, tig weld and then file away all axcess welds. Its a pain in the ***, but it is doable. Good luck.

 

Yeah dude that freaking sucks big time.

 

You should first determine what caused the bolt to snap like that.

 

Thanks for all the replies! Yes it does suck, but hopefully it's still usable as most have said. I think what originally caused it was the loose crank bolt from those idiots putting things back together and it damaging the crank pulley. The damaged crank pulley then probably put constant pressure back and forth on that bolt till it snapped. I'll post some pics of the inside of the pulley when I get a sec. I'll also start looking for a tig welder if everyone agrees that is the best way to go...

 

Here's a couple pics of the crank pulley. You can see the wear inside...