Repairing broken clutch hub

[Punx Clever]

So, like many before me, I went down on the right hand side and sheared off 5 of the 6 posts on the clutch on my s2r1k.

While I was waiting for parts to come in, I decided to try and repair the hub that I had.  Here at school I have access to a complete machine shop, so tooling isn't an issue.  And the machine shop comes stocked with two grumpy old machinists who give advice to / yell at college students so they can get their projects done.  Details of the repair are as follows:

1. Separate the hub from the cush drive.  A hammer and socket works well for this, in fact it's straight from the picture in the service manual!

2. Media blast the part to clean it up before work.  The rubber pads int eh cush drive, plus the clutch dust, make for a messy piece.

3. Measure the remaining post.  My measurements were 10mm diameter, 27mm tall, with a hole tapped for a 5mm screw.

4. Spot-face the broken off nubs of post using an end mill.  Do the same with the remaining post.

5. Drill out existing holes to accommodate a 5mm screw going through the hub.  Countersink the other side and use appropriate screws

6. Cut new posts.  I started with .5" stainless rod then turned, cut, drilled and tapped.  The lathe was my best friend.

7. Try to assemble.

8. Realize that a screw with enough threads inside the post to hold it on will interfere with the screws that hold the springs in.

9. Drink a beer (or a case of beer, adjust to personal tolerances) to lament your failed attempt at fixing a part.

All in all, it was a lot of good experience in the machine shop, and almost had me back on the road with a temporary fix.

Sorry there aren't any pictures, but oh well!

[Speeddog]

Umm...well, thanks for takin' the bullet. 

How much interference between the screws?
Cause, you could use shorter screws to hold the springs, just may be too much of a bytch to get 'em started...

[Punx Clever]

1/8th inch.

Could use shorter screws on the back side.  Could use shorter screws on the front.  Shorter on the front would be a pregnant dog.  Shorter on the back and I'd be scared of em being ripped out.

Also, making the posts out of aluminum. then TIG welding them once you have them set in place with the bottom screws.  Should work to get em straight up and down and give you the depth of thread for the spring screws

[He Man]

This is why you get a clutch cover or a clutch plate that protects the post!

btw. goodluck! lol

[Norm]

Or you could weld them.

[Punx Clever]

meh, I'm over it really.  I'll just wait for the parts.