July 21, 201610 yr Hi all, Need a bit of help to remove Woodruff key (bike running backwards when it actually runs!) on my 1994 Gas Gas Jt250. It appears to be stuck tight as, despite tapping with a drift, all I've managed to do is deform the end of the key but not move it - see photo. Any suggestions would be appreciated. attachment=18783:20160717_163825.jpg]
July 21, 201610 yr Bit of localised heat, let it get hot and cold twice, then a few light taps to free it. Hopefully!
July 21, 201610 yr Take the stator off. it will give you heaps more room to get at the key - and less chance of damaging the stator as well.
July 22, 201610 yr Arnoux is correct. Lube it, then hit the back portion of the key and the front will pop right out!
July 22, 201610 yr Author Thanks for the replies I'll give them all ago, although I was trying to avoid removing the stator as I don't have the gear to check/set the timing. Assuming the timing's not out, I guess if i mark the plate before removing, there's a good chance of putting it back in the same place. The other reason is that after 20 odd years of use, there was no end of crud in the casing and flywheel, which has corroded the casing alloy and cap head bolts, so I'm concerned I might have trouble removing them. Still in for a penny...
July 25, 201610 yr Author The key is out! Removed stator which, as suggested, allowed me to hit rear portion, which then brought up front section. Kept repeating to get it moving then was able to remove it completely. Thanks for help. i'll be back on if new key doesn't stop bike running backwards!
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