Originally Posted by AntonLargiader
All of the old parts I have here show about 16mm of engagement, with 4mm unused spline in the hub. The R1100 5-speed has 18mm engagement.
FWIW the input shaft for the Hexhead has the identical profile with a 4mm longer clutch spline... but the rear end is too long with flutes that keep you from machining it to fit. So close...
It is good to see that even you are still chewing on this problem in your spare time. Just out of curiosity how often do you see worn splines nowadays.
I think that last 4 mm stay "unworn" on a destroyed part but the splines end about 2mm before the end of the shaft. Once the hub goes those extra 2mm get destroyed by the stepped down portion of the spline profile. I would appreciate feedback.