Tenere 1VJ front sprocket
 

Can anyone confirm that this is normal looking axle. I have removed fron sprocket, and I am confused why teeth on axle are narrow in the middle. Because of this front sprocket have allot of free play.

Output shaft
 

Unfortunatly thats pretty knackered,not that uncommon on early xt.
Options are strip motor and replace shaft......the savage option of welding the sprocket on?....or slightly less savage,get 2 sprockets preferably unworn,turn or grind one them down to reduce its diameter so chain clears it whilst running around other sprocket,bolt pair off them together and weld,then fit to spline,check retaining plate locates in groove ok,if not reduce thickness slightly of whole assembly..hope that makes sort of sense.
My 34l has a slightly worn spline,nothing like as bad as that so I done this as a way of increasing the life of shaft as long as possible..
There maybe some other alternatives if you sat and scratched your head a bit or found one of these engineering type old boys that are just bloody clever..
Good luck

Nah.....thats proper munted.....

I have no idea.... But from the looks of it, the cuts/grooves are too uniform...too regular... they actually look like they were made that way.

In any case, wait for a proper answer for some of the guys who know what's what with your situation!


Vando :)

In 7 days I'm going on 8000km trip, so I don't have time or money for this :( When the time comes I'm thinking of replacing engine with 3TB one.

This came to my mind also. There are few mm of "healthy" shaft in the back, second sprocket could fit there. Thanks.

8000 KMS on that shaft..... in that case get a new sprocket & weld it on, fit your 3TB engine when you get back..... I don't think there's 8000 k's left in that shaft.....

Got friend who says that he can weld and than sand welded parts to recreate teeth + he will weld two sprockets like someone above suggested. I think that will be enough.

suggestion?
 

hi i would replace the seal after you have had the welding and grinding to form new teeth done ,the heat wont do the old seal any good being so close ,just a suggestion steve

New seal already purchased :) I'm just hoping I got right dimension (SD 25-40-6)

I agree,that won,t last long and if you no time weld it on....good luck

25/40-6 sounds right, thats the one used on my '03 600e model :)

Good luck with the trip.

After few hours of welding, grinding and blood pissing problem is, so to say, solved.
First recreate teeth on shaft by welding and grinding them
https://lh6.googleusercontent.com/-Y...0/IMG_8179.JPG
https://lh6.googleusercontent.com/-j...0/IMG_8184.JPG

Then cut old sprocket so it will fit behind regular sprocket
https://lh3.googleusercontent.com/-m...0/IMG_8183.JPG
https://lh6.googleusercontent.com/-1...0/IMG_8194.JPG

Hope this will hold until I have time for proper fix.

looks a good job
 

hi that looks like a top class bodge ,well done ,that should last till you get back have a great trip steve

Just to update on situation - after 2000km on this "dual" from sprocket system I had to weld two sprockets together. Previously I had them only connected with two screws, but they are unscrewing every 300-500km. After welding two sprockets together everything worked OK for next 8000km.