gearbox output shaft

[taylor1960]

Hi all just want to ask has any one ever repaird the key way on a clutch shaft the tred and taper is ok but key mashed, i was thinking of geting welded and re cut do you think its a job or no

[morris]

Theoretically it can be done by a professional machinist, but it may cost you as much as a new one. He'd have to weld it, reface the taper and recut the keyway.
I would let the key out. If the taper's a good fit and the nut well tight you don't need it.

[edboy]

as the mainshaft is probably scrap due to the keyway damage you could try to bodge with some mig and weld the woodruft key in situ and avoid a strip down. depends on your skills really.

[Rocket Racer]

The key ways do commonly chip and its not usually problematic if the taper is fine -its the taper that does the work not the key way.
Might pay to post a pic so we can see how bad it is,
a second hand shaft would probably be more cost effective than repair if its that bad.
I'd still fit a key, just so the shaft sits in its usual place on the taper.

[taylor1960]

Thanks all will post a pic

[taylor1960]

Here is a pic i have the shaft out of box so no problem welding just wondering wit it afect the temper

[chaterlea25]

HI,
Eucchhhh
Thats nearly as bad as I have seen 
Welding will inevitably bend the end of the shaft 
Looking at that Its likely that the clutch adaptors taper will be damaged as well

I have replaced shafts thet were less damaged  than that!!!
So either bite the bullet and buy a new one from Autocycle engineering or find a good second hand one and clutch adaptor

My 2 cents worth
John

[taylor1960]

Hi its a bad one ok second hand ones arnt that common @ flee bay  will keep lookn i have no clutch eather so on look out for one aswell 

[Rocket Racer]

I've got plenty of good second hand ones if that helps pm me.

[coater87]

 I wonder if you could not visit the local machine shop and have them cut an identical keyway slot on the other side of the shaft. The only problem you might have with this is contact surface.

 As mentioned its a male taper that does the actual holding. By recutting the keyway you are losing some taper contact surface, but then again you have a new key to back it up also. I doubt the neck-snapping horsepower, huge tire contact surface, and general bad way we treat the restored machines is going to twist the output shaft off.

 Lee

[morris]

Agree with chaterlea John here. That's a really nasty one.
Wouldn't mind to much about losing the temper though. It's of more concern that the heat of the welding may bend the shaft and you'll end up with a wobbling clutch... or worse.
Don't think it's worthwhile trying to repair.

[taylor1960]

Thanks all i think i will go for 2nd hand one  now i need a clutch 4spring or 6spring which do U all think is best   

[chaterlea25]

Hi,
Best for 99% of owners and easiest to set up is the 4 spring

HTH
John

[Rocket Racer]

Ah onto clutches 
If you don't have an an existing half decent 6 or 4 spring clutch then I would seriously consider fitting anything else.
Both 6 and 4 spring can be reliable, however neither are that great. The 6 spring bearing arrangement is notably inferior to the 4 spring, but I dont rate the 4 spring either (its better but). In both instances cobbling together repro parts and good 2nd hand can result in a lot of headaches  .
I ran a 6 spring for 30 years on my 500 single and it was adequate . I have run 4 springs and they can be OK too. But neither compare to some of the after market clutches with proper bearing arrangements. 
So it does depend what you're starting with; if you have a complete clutch (6 or 4) persevere and it'll save some money and can work. If you have nothing or incomplete/shagged clutch, please seriously consider the expense of starting from scratch.
A decent clutch makes a big difference; you can actually change gear and pull up at lights without stress.
Suzuki GS550 clutch conversions worth considering, 2nd hand they are cheap as from a wreckers. My road a10 has a converted Suzie clutch and my race bike a BNR 

[taylor1960]

Never thought of going japanese  were do U get a conversion kit from i think i can pick up a gs clutch from a mate    my project came in boxes wit alot mising  no clutch or mag going wit wazel ignition system