Mayday! 250SL down!

[michael_perrett]

Darrell, have you tried the file test on the bad countershaft yet?

Mike Perrett

[Darrell]

Darrell, have you tried the file test on the bad countershaft yet?

Mike Perrett

Hi Mike, sorry for the delay but I just tried that file test.

Yes I can get filings from the sheared edges of the counter shaft splines. I made a small bevel with a few passes of the file.

What do you conclude from this?

Thanks,
Darrell

[Darrell]

It's me again. According to your specific instructions, I could also quite easily file a small notch into a spline.

Now I wonder if the shafts were hardened in batches, or individually by hand. If it's the former then I suspect there could be more soft countershafts out there. However, I seem to be the first on this forum to have one fail.

[michael_perrett]

I tested mine. Had a hard time to get a mark on it. I will use the Honda XL 250 16 tooth sprocket and check the splines after a couple hundred miles. I also applied spline grease during installation.

Mike Perrett