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This forum has been a great help to me over the years, but I’ve finally created an account in order to pick some of the big Jinny brains here.
The woodruff key for the crankshaft pulley on my Jinny (M13 engine) has been damaged. From what I can see the keyway appears to be undamaged. From what I have seen in the workshop manual and read, everything (oil pan, timing chain cover, and cylinder head cover, etc) need to be removed to gain access to the woodruff key. Is this the case or is there a magical way of removing it without doing all of that?
If I do have to remove all of the above, does anyone have any tips or tricks to help me do this as smoothly as possible?
The timing chain must come off to gain access. And so all the covers for that at the front of the engine. I would remove the radiator too for easier access.
But how can you tell it is broken without having gained said access?
Answer is you can't. If the securing bolt works loose then the pulley can move side to side and this can indent the key surfaces and also damage the key slot in the pulley ( cheap to repair ) and/or the c/shaft ( easier to get a s/hand engine ). I am assuming that the basic engine design is the same as that fitted to a Gen.4 as my workshop manual indicates that you can remove the pulley and then you will see the key and then maybe you will be able to remove it with a pair of needle nosed vice grips. There are a lot of maybe this and maybe that but I would like to know more about how Jimson has come to the conclusion that the key is damaged.!
My experience from yesterday, with the woodruff Key, is that they fall down when you pull the wheel off, and make a strange noise when they hit something they land on and then you search and search until you give up, and come back the next day with a flash light and then you find it on top of the spring.
The slot in the pulley is machined right through so it is visible when in position. You turn the engine over so the slot is at the top and then you slide the pulley off leaving the key in the slot. Then you grip it with he needle nose vice grips and lift the key out.
Still doesn't answer the question though!
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