Hi, the spines are way past it and I've purchased a new spindle but seeking a bit of advice on the best place to cut of the old one off or a recommendation to an engineering company Birmingham area that knows the procedure. Cheers Dave.
your old spline is good enough.
the problem is with the gear lever not clamping properly. just drill a hole into the end of the split where it can clamp up properly with the bolt.
the owners club should commission correctly made gear levers really.
Thanks Eddie, I've already got an engineering chap to cut drill and self the new shaft on but take your point about additional fixing, maybe I'll do both,belt and bracers so to speak. Thanks for your input, Dave.
There is a better solution to the repair shafts easily found.
https://pesltd.uk/?product=68-3294R (https://pesltd.uk/?product=68-3294R)
Mark
if the repair section is hardened fair enough. if not i would still modify the gear lever to clamp properly. having found out the hard way of this achilles heel.
I did read somewhere that the version of the repair section shown above has splines that are too long and so effectively become a rasp that wears away at the hole in the ally cover. Hope that's not the case!
Mark of PES has done a couple of these shaft repairs for me.
When used with a new gear lever they are a snug fit on the spline and the lever barely needs to crush if at all to have a tight fit.
I can weld and have access to a lathe, however I asked Mark to do mine as I felt he would achieve a tighter tolerance of concentricity than I could.
Thanks all, the route I've taken after talking it over with the machinist is to cut the existing shaft adjacent to the spines and then drill it to a reasonable depth so with cutting , turning down and inserting the new shaft it will be straight then weld and turn down to fit. The new spines although longer will still be outside the casing and if that does make the lever to far out I can always cut it back a bit.The next question is have I got the spacer ,oil seal and drive wheel in the correct positions,I think it correct but thought I'd check before fitting it all. Thanks for all your help I'd be really stuck without this forum. Dave.
Hi Dave. For what it's worth, the sprocket faces the other way around. You would put shims behind it to set the alignment with the clutch basket.
Thanks Allan, I'll need to get some shims.