Slotting camshaft sprockets....

[tkent02]

Any DIY ideas on how to slot the camshaft sprockets? After taking about five minutes per hole with a very expensive bit to enlarge the 550 sprockets from 6mm to 7mm to fit the 650 camshafts, it would take forever to slot them with hand tools. Rat tail file or something isn't going to cut it I don't believe. They used some seriously hard steel.
Google hasn't produced any results yet, either for how to do it yourself or where to buy a slotted sprocket for a 650 with the smaller size sprocket needed for the 550 engine....

What have you engine guys done? Or is it a "pay the professionals" type thing?

[rapidray]

Use a carbide cutter in a die grinder. This is assuming you have an air compressor.
Ray.

[tkent02]

Yep, no problem there. Carbide will get through it OK?

[Super]

I used a hand file to do mine, just like Suzuki Don. Wasn't too bad. I was actually surprised. I just took my time and it worked out fine. Patience is the key.

[Fjbj40]

I just just did my 1100 cam gears with a file. Sprayed them with lay out die and used a divider to mark the arc lines to follow. Took about 30 minutes per gear. Slotted them approximately 1 hole size on each side of the original hole.

Make sure you debur the holes after to remove stress risers.

A good quality file is recommended, a cheep of Harbor Freight file ain't gonna cut it!