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Northern and Central Asia Topics specific to Russia, Azerbaijan, Armenia, Georgia, Kazakhstan, Uzbekistan, Tajikistan, Kyrgyzstan, Turkmenistan, Mongolia, China, Japan and Korea
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  #1  
Old 7 Mar 2014
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Are the splines okay ???? Post a picture up if possible.

Don't bolt a sprocket onto the end of the shaft. That will never work.. It will just be torn off.

What is the bike and how is it meant to be held on ??

As it's already welded, then no doubt the splines are heat deformed and fused with the sprocket so grinding is likely to make a bigger mess and do more damage.

If the shaft is damaged too much then all you can really do is keep breaking off and welding on sprockets until you can get a new shaft. Just make sure you buy STEEL sprockets. And when welding. Allow plenty of cooling or you will damage the oil seal and that will just ruin your day even more..




If the splines are deformed, and if possible, then I suggest you move the sprocket over on the output shaft a little and then you can space out the read sprocket to match. Using shims, washers etc. Just make sure you use longer bolts.

If the splines are okay, fix a new sprocket and you can weld on the END of the shaft to stop the sprocket falling off.


To replace the shaft, you're talking a bottom end rebuild. Expensive and not to be done on a hostel floor...

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Old 10 Mar 2014
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Thanks Ted, your reply is very helpful.

I was hoping that splines are ok, but now I'm not sure at all. I don't have much experience with welding so not sure how penetrating the weld can be, but I really hope that it's not bonded too deeply. What do you think?

I'm attaching a picture, maybe it can give you some idea. Be warned, it looks ugly.




By the way, the new sprocket I got is JT Sprocket, High Carbon Steel. I assume it's good for the purpose.
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Old 10 Mar 2014
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oh my god... What a mess...

That is WELDED... Permanently... You're not grinding that sprocket off without taking the end of the shaft with it. He's turned the shaft molten from the very end. That's not just tacked on...

What's it like from the other side ????

I think you're best off cutting off the sprocket and the end of the shaft with it from the other side then welding on a new sprocket just to get you somewhere where you can have a new shaft installed.

Quite simply.... You need a new shaft.. It's F**ked.

Ted


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Originally Posted by jacekklimko View Post
Thanks Ted, your reply is very helpful.

I was hoping that splines are ok, but now I'm not sure at all. I don't have much experience with welding so not sure how penetrating the weld can be, but I really hope that it's not bonded too deeply. What do you think?

I'm attaching a picture, maybe it can give you some idea. Be warned, it looks ugly.




By the way, the new sprocket I got is JT Sprocket, High Carbon Steel. I assume it's good for the purpose.
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Old 11 Mar 2014
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I appreciate your advice. Now I have a better idea where I stand.

Hhmm, what do you mean the other side? I don't think I can say what it's like from the other side, can I?

So in conclusion, you don't even think that cutting this sprocket off and welding on a new one could be a semi-permanent solution (let's say, another 15-20k).

May be a problem with installing a new shaft in this part of the world and I don't plan on going west for another year or two. Probably the next place I can have it done is Japan, but first I need to put some more miles on the bike.

As a last resort I can just leave the damned sprocket as it is and keep changing chains every 10k before they die (that's the mileage I done on the current chain).

So to weld or not to weld, that is a question?
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Old 11 Mar 2014
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You can't leave that front sprocket as it is. It's dead. I'm surprised it isn't already throwing the chain and slipping.

You HAVE to change it as a matter of urgency.

If you put good chains on bad sprockets, it will just destroy the chain very quickly.

You need a new shaft.. It's that simple... An expensive PITA, but that's the truth of the matter.


If you can't change the shaft, then you will have be very careful and re-weld a new sprocket on the front. Put the chain on and make sure it is in line before it is welded on. That is what you will have to keep doing. But it's not something I would recommend.

I can't think of anything else you could do.
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Old 3 Jun 2014
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Just a quick update. I managed to get the work done in Tbilisi, actually thanks to Cliff who directed me to the right person. Thanks Cliff.

Also worth sharing contact details for Dato who worked on my bike. He's a 4x4 mechanic (fabrication / welding) and he is very good at what he's doing.

His phone number is 899 94 48 17. He doesn't speak English, but I believe his Russian is very good.

He did an excellent job on my sprocket & saved me a lot of trouble.
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