1000 Sp UJ Fitting Problem

[Luxexterior]

I'm currently replacing the UJ on my 1000Sp. All as gone well, old carrier bearing etc removed & new bearing & circlip fitted.  I have purchased a UJ kit from Stein-Dinse that includes the UJ, carrier bearing, circlip, gaiter & clips. All good except that the UJ will not fit either the bikes output shaft or its drive shalt, the splines on the new UJ will not slide into the splines on the shafts, the gaps between the splines on the new UJ appear to be too small. I have greased the splines on the new UJ & on both shafts but shafts but no joy they will not fit.

The old UJ slides snuggly but easily on to both shafts. Not sure whats wrong here except that the new UJ is possibly faulty. Have I missed something here is there a technique to fit the UJ to the shafts that I don't know or do I need some kind of special tool? I'm glad that I tried fitting the UJ to the output & drive shaft before installing it into the bearing in the swinging arm that would really have p*##@d me off. Any help or advice would be much appreciated. Thanks in advance.

[twhitaker]

Do both components have the same number of teeth? Earlier models have finer (2mm) splines while the later models have coarser (4mm) splines.

[rodekyll]

There are three types of joints (pre-injection BB).  One was for drum rear brake, has 10 splines, and is smaller than the others.  One is for disk brake 5-speeds and has 10 splines.  The other is for the Convert, is one piece with the drive shaft, and has 20 splines.  Those should be the only variations.

Aside from those, there might be an OD difference where they go through the carrier bearing, but that's not your problem.

[Luxexterior]

Yes they are the same. Both UJ's look pretty much identical but the new one won't fit onto either the drive or output shafts. I've tried it both ways in case that was the issue but the result was the same. 

[Luxexterior]

There are three types of joints (pre-injection BB).  One was for drum rear brake, has 10 splines, and is smaller than the others.  One is for disk brake 5-speeds and has 10 splines.  The other is for the Convert, is one piece with the drive shaft, and has 20 splines.  Those should be the only variations.

Aside from those, there might be an OD difference where they go through the carrier bearing, but that's not your problem.

You are absolutely right. Mine is the disc brake 5 speed version, the replacement looks the same but won't fit. My guess is that the splines have not been machined correctly. Looks like I'll be returning it to Germany & spending anoth couple of weeks off the road.

[rodekyll]

I'd be more suspicious of the splines on your shafts being buggered, but I can't see them from here . . . .

[twhitaker]

Maybe a burr was raised in the machining process if the end was faced after the splines had been broached.

[Curtis Harper]

I have seen some of the current production units not fit the splines correctly, even on a new shaft. We had that problem a few years ago and had to return a dozen of them. They are pretty much all made in the same place. You may be correct one the manufacture problem.

[Luxexterior]

I have seen some of the current production units not fit the splines correctly, even on a new shaft. We had that problem a few years ago and had to return a dozen of them. They are pretty much all made in the same place. You may be correct one the manufacture problem.

Thanks for that Curtis. My drive shaft looks to be perfect but I've tried it with another spare one to be certain, neither fitted. The output shaft also looks A1 but again the UJ won't fit. We are not talking about the fit being poor or difficult to slide on to the shafts they don't just don't fit period. I'm glad to hear that this is not an isolated case, this gives me more confidence to argue my case with SD.

[Kiwi_Roy]

In the meantime consider getting your old one refurbished by John Chiocoine
I just sent you his address on a PM

He did a great job on my Eldorado
 

[Curtis Harper]

Or you could order a new one from me.

[Luxexterior]

In the meantime consider getting your old one refurbished by John Chiocoine
I just sent you his address on a PM

He did a great job on my Eldorado

Thanks Roy.

[Luxexterior]

Or you could order a new one from me.

Thanks Curtis. I think mine is fine but if I need one I'll order one from you.

[Perazzimx14]

There are three types of joints (pre-injection BB).  One was for drum rear brake, has 10 splines, and is smaller than the others.  One is for disk brake 5-speeds and has 10 splines.  The other is for the Convert, is one piece with the drive shaft, and has 20 splines.  Those should be the only variations.

Aside from those, there might be an OD difference where they go through the carrier bearing, but that's not your problem.

But in typical Guzzi fashion there are blurred lines between models. Some early disc BB's like my T3 use the earlier drum brake universal.

[rodekyll]

.  . .and there's the 20-spline sidecar driveshaft for the 5-speeds, and the dog-bone joint for the last Tonti's, too.  Any of the tiny fashion blurs can cause confusion.

While I'm thinking about it -- does anyone know why the 'vert has a 20-spline shaft while almost everything else is 10-spline?