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Pinion spline shaft to U-joint interface

F

ffraz

Just got it firing!
Joined
Oct 28, 2008
Messages
4
Hello drive train experts...

While I had the rear drive off my sporti to replace blown seal(s) I decided to have it re-geared with a 7/33 gearset. Now I'm attempting to reinstall the rear drive and I am unable to fit the u-joint on the pinion spline shaft. The new pinion splines appear outwardly identical to the original when held side by side. The old shaft slides right into the u-joint with a hint of play, but the new one refuses to enter. I have used my entire (limited) bag of tricks including heat, lubrication, moderate impact persuasion and I can only wrestle it in about 1/8".

I think something is amiss as the original came apart quite easily. It doesn't seem right to continue this way; it would make it a real bear to remove in the future and I also fear potential to damage to the u-joint and/or pinion gears if I continue to resort to brute force.

So... anyone have any insights, advice etc... I was under the impression that the only variation in Guzzi spline shafts was spline count. Am I wrong? Thanks in advance to the infinite well of knowledge.

Ciao - Ford
 
Ford,

Take the rear drive and your u-joint to where you had it re-geared. It sounds like a manufacturing error on the pinion. Sometimes they can be out of tolerance. A pinion that fits the u-joint is required. Since the splines are heat treated, you don't want to re-machine the splines to fit your u-joint.
 
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