[robbyoj007]

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?

 

[dfb399]

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?

 

[robbyoj007]

Thanks for your reply. I machined it with zero tolerance so that it will fit snug

 

[dfb399]

Thanks for your reply. I machined it with zero tolerance so that it will fit snug

Oh, I am way to technical for that
Without any variance, it would not/will not go on the crank.
A few tenth's? Now you're talking, and that is not Zero.

Was/is it tapered as well (just curious)?

 

[robbyoj007]

I did not touch the crankshaft. No tapering. Should it be? I saw no sign that it should.

 

[dfb399]

I did not touch the crankshaft. No tapering. Should it be? I saw no sign that it should.

Nope, just couldn't remember without it in front of me.

 

[robbyoj007]

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.