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Discussion Starter · #1 ·
Hi everyone. I am at it again. I can't find a pulley, at least not yet. Is it ok to take the one with the smaller internal diameter and machine it to fit the larger crankshaft?
I will definitely have to recut the keyway.
There are some splines in the pulley, what are they for?
 

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Assuming the Outer (Belt) diameter are the same, I suppose you could.
Not many of us have Lathe & Broaching capabilities, but you sound familiar or you wouldn't be considering it.

Regarding the splines.. There shouldn't be any, with a keyway feature.
Also, make sure the pulley bore is not tapered, I can't recall without a pulley in my hand.

Once the machine work is all done, you will want a way to balance it (ever notice the spot-face(s) on the pulley in OEM-form, randomly placed? These are from balancing).
And obviously, use sharp/New tooling.
Stress-concentrator's are NOT our friend.

How much larger, is the bore?
 

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Discussion Starter · #7 ·
(y) Tapered shafts give a better grip than a parallel or straight shaft, but I recon that the portion of the shaft for the pulley to fit on is too short to be tapered. I Guess Honda may need to look into this.
 
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