Repairing a broken worm gear seat on a hub - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

 
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post #1 of 3 Old 02-23-2010, 06:22 PM Thread Starter
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Join Date: Oct 2006
Location: London, Ohio
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Repairing a broken worm gear seat on a hub

Front hub to my KLR was reduced to ground metal shavings last summer while riding in Tellico, TN. Here was the result of the frozen worm gear.


Well, today I got my wheel back from HC where experimental surgery was preformed on the wheel. Can you tell the difference?

The one without a retainer ring is the repaired hub. Here's a better look with the retaining ring in place.


As soon as I get a chance I will put this wheel on the KLR and give it a try to confirm it works correctly.
I can only assume Holycaveman will soon start offering this repair service to others who's hubs have been destroyed from frozen worm gears. I know there are at least three people locally here in Ohio who've experienced this issue.

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post #2 of 3 Old 02-23-2010, 07:01 PM
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Join Date: Sep 2006
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Cool.. whats the repair?.. a weld-up and machining...

- Joe

HighSpeed Hiker- DV o5'
Quote:
Originally Posted by larryboy
come awn... it's not far...it'll be fun..

sorry I can't....... I'm fishing today
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post #3 of 3 Old 02-23-2010, 11:13 PM Thread Starter
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Eggs-actly. But considering the price of a new hub or buying another wheel on e-bay I think HC will be able to get it done for much less. I was lucky to have a second wheel availble that was able to be used as a template for the repair work. The two hubs match up perfectly and I see no reason that with welded metal it would not be stronger and less likely to fracture should the worm gear ever seize again. I really think this will be a great benefit to those with broken hubs who would like to use the stock speedo and odometer again. If you want to ask HC about the repair yourself shoot him a pm on Cavemanriders.com.

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