How to a weld the pulley on the shaft?

[KFallsRider]

JoeX XV1700 Owners and Supplementary service manuals

[JoeX]

JoeX XV1700 Owners and Supplementary service manuals

The manual is for the model-year 2012-2013 my bike is from 2005 ... arn*t there too man differences?

[KFallsRider]

That’s all I could find for ya..someone here should have a digital copy

[JoeX]

I would be happy if someone has a digital copy for me

[JoeX]

Today I got the 36mm socket for my ratchet and opened the nut of my front pulley. Please watch the short video I made moving the pulley in all directions:

https://www.youtube.com/watch?v=j-SDJmdbpEk

I hope it helps you to help me (and I hope I don't need a new pulley )

[KFallsRider]

I think you need a new pulley

[Tcontrol]

Not gonna lie….
You need a new pully…. !!!!

[roadiemort]

Yup, new pulley, should be no visible play.

[Brad_G]

Can't really see the shaft to see if it's badly worn. But the teeth in the pulley almost come to a point it's worn so bad. I had the nut come loose last year and took some pics while apart. You can see in this pic how there is a nice flat area between the teeth. So I'd say at a minimum that pulley should be replaced. Need a better pic of the shaft to see it's wear.

[MidnightRide]

Today I got the 36mm socket for my ratchet and opened the nut of my front pulley. Please watch the short video I made moving the pulley in all directions:

https://www.youtube.com/watch?v=j-SDJmdbpEk

I hope it helps you to help me (and I hope I don't need a new pulley )

Pulley's definitely toast, start looking for a new one. Drive shaft splines don't look too happy either. If it were me, I'd order the new pulley, slide it over the shaft, and see what the fit looks like before going further.

[Tcontrol]

1600 cc torque spec

[JoeX]

Can't really see the shaft to see if it's badly worn. But the teeth in the pulley almost come to a point it's worn so bad. I had the nut come loose last year and took some pics while apart. You can see in this pic how there is a nice flat area between the teeth. So I'd say at a minimum that pulley should be replaced. Need a better pic of the shaft to see it's wear.

Here is the picture you were asking for:


Hope the shaft is not too bad. Is it possible and easy for a hobbyist mechanic to change the shaft?

My bike is 51.000 miles old ... is it normal wear, that the pulley is toast?

Used pulley or new one?

[roadiemort]

FFS wipe it clean and take another picture so we can see the damage clearly, the end of the shaft does look bad but need to see cleaned off.

[KFallsRider]

Yes another pic..it’s too shiny and hard to see what’s damage and what’s a reflection..it does look beat to hell

[MidnightRide]

It looks like the pulley pulled out and rode on the outer shaft and did damage there, but can't really tell. Might be able to be filed and torque that nut on really well to keep the new pulley back on what's left of the undamaged teeth.

Clean it off and report back!

[Brad_G]

Here is the picture you were asking for:


Hope the shaft is not too bad. Is it possible and easy for a hobbyist mechanic to change the shaft?

My bike is 51.000 miles old ... is it normal wear, that the pulley is toast?

Used pulley or new one?

Well that's been banging away on the shaft. To do the job right I'd say yes, the shaft needs replaced as well. A member here did that job not too long ago and I don't think it was terribly involved.

But to answer your question, no that's not normal wear. Many with well over double your mileage without any issue.

Another forum I'm on, there was someone with a 950 or 1300 that had a similar issue. I think they found some kind of paste like a JB Weld or Loctite brand that was designed to fill in those gaps and cure. I don't know how many miles he's got on since his repair to see if he's happy with it. So maybe someone else might have some knowledge of an alternate fix besides new parts.

[MikeyC]

That is what the epoxy was for. Previous owner filled with epoxy and the epoxy had come out. I have heard of that being done with JB weld but the proper way would be to replace shaft and pulley.

[Brad_G]

MikeyC, I agree new parts is the proper way. I've seen some pretty amazing stuff done however with modern tech/chemicals so given the right combination it might work in some circumstances.

[KFallsRider]

Used eBay $100 USD

[MidnightRide]

I'm wondering if you might want to consider going to a different pulley size since you'll be switching it out anyway. Lots of guys switch them out. As Mort suggested, take a toothbrush or wire brush and some solvent to the shaft splines to clean it off for a better representation of damage. Might be OK or something you can clean up with a file a bit.

[KFallsRider]

Here’s a how-to Video on replacing the drive gear

https://www.youtube.com/watch?v=fkH4myUf3Lg

[JoeX]

I'm wondering if you might want to consider going to a different pulley size since you'll be switching it out anyway. Lots of guys switch them out. As Mort suggested, take a toothbrush or wire brush and some solvent to the shaft splines to clean it off for a better representation of damage. Might be OK or something you can clean up with a file a bit.

I cleaned everithing now and made a

* new video: https://www.youtube.com/watch?v=xMTEqPBlXNY

* and some pictures (but please watch the video too):

[roadiemort]

Show us the pulley off the shaft also please mein Herr.

[JoeX]

Sorry, the pulley was only in my first video. Here are two pictures of it.

[KFallsRider]

Here’s what a New Pulley Hub looks like..NICE SQUARE shoulders

[MidnightRide]

I dunno, that shaft looks pretty messed up to me, but I'm not familiar with what a new one should look like. Just doesn't make sense the way it's worn. Lug Nut should have a better idea of what we're looking at since he pulls this stuff apart regularly.

[Shores]

If you bought the bike used, the spline damage may have been caused by a previous issue other than just the loose nut that you're seeing right now.

[JoeX]

Which hint do you want to give me? What does it mean for repairing?

[roadiemort]

Proper way would be to replace the shaft, pulley and fasteners. If your not prepared to do that at this time I would weld the pulley to the shaft as both are junk anyway, not ideal but will get you back on the road until you want to tear it apart to fix properly.

[roadiemort]

Sorry Shores wrong your lol.

[MidnightRide]

Not a bad idea, and long-lasting for sure, if the metals match and can be welded and the pulley gets a good tight fit before welding. Just grind the weld off when it's time to pull it back apart. Along that theory, coat the splines with epoxy before putting the pulley on, or would that make it impossible to remove later?

[JoeX]

Sounds tempding since the parts are expensiv .... but is a liitle bit welding at the end of the shaft enough for the torque of a xv1700?

[JoeX]

Did someone here my questions in the last video:
https://www.youtube.com/watch?v=xMTEqPBlXNY

especially where I asked what material is in the shaft, a ring or what else ... in some holes there is material in others not. I did not see this in other videos. Maybe someone before me "repaired" the shaft/pulley-problem with a "trick" ... put some material between them. I was driving 15.000 Miles with no problems .... maybe I can do the same "trick"??? Any idea?

[roadiemort]

If you weld it prepare the pulley by beveling a 45 degree chamfer for a root pass this way you put the nut back on and weld it also, this will last forever or until you need to remove it, anything else is a waste of time and effort IMHO.

[KFallsRider]

Those gaps / holes around the shaft all looks like the epoxy that was on the nut.
The previous owner didn’t want to fix it either. His “ Trick “ got ya this far

[Shores]

It looks to me like there is some epoxy on the back side of the shaft. I'm sure you could just put a sharp tool in there and Chip it out. It's likely softer than the shaft itself. It also looks to me like the pulley may have come totally off at some point and that's what damaged the outside edges of the splines. I agree with roadiemort, just welded it on and deal with it later if you don't have the time or resources to change the shaft.