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Discussion Starter #1 (Edited)
My rear sprocket holder was very wobbly, and chewed away part of the hub.
In my case, the top hat washer (flanged washer) had eaten itself into the aluminium cush drive, which caused the play and eventually lead to the cush drive touching the hub.
Why the top hat spacer has eaten the cush drive I don't really know.. but nevertheless I found an almost new cush drive and sprocket holder and installed them on my brutalia.
But what I also noticed is that the top hat spacer has a big groove in it, on both sides. And the bushings that run inside the needle bearings also have grooves where they meet.
So as a result, the whole stack is just about 1 or 2mm (approx guess) too short, and this causes the top hat spacer to rub against the hub.

The bearings all look and feel very good still. I cleaned them out and repacked with lithium grease.
I cannot see or feel any axial movement or play. The shaft has the brown rings where the bearings run, as you see often on these shafts, but not worn and the diameter is still the same.

So what I like to try is to replace the spacer/bushing stack, because if the stack is just 1 or 2mm longer my problems seem over.
But for the live of me I cannot find any replacement parts, only full hubs or even hubs + swingarm (ebay).
So I searched the web for industrial bushings that have the same size, but to no avail.

Alternative is that someone machines a top hat spacer that's 1 or 2 mm taller, instead of replacing the whole stack.

Anyone here that knows a place where I can buy a new set? Or maybe someone has a set for sale? Or who can machine a taller top hat spacer?
Any help is greatly appreciated!

Video showing the play on the sprocket carrier:
Video showing the difference between old and new cush drive:
 

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My rear sprocket holder was very wobbly, and chewed away part of the hub.
In my case, the top hat washer (flanged washer) had eaten itself into the aluminium cush drive, which caused the play and eventually lead to the cush drive touching the hub.
Why the top hat spacer has eaten the cush drive I don't really know.. but nevertheless I found an almost new cush drive and sprocket holder and installed them on my brutalia.
But what I also noticed is that the top hat spacer has a big groove in it, on both sides. And the bushings that run inside the needle bearings also have grooves where they meet.
So as a result, the whole stack is just about 1 or 2mm (approx guess) too short, and this causes the top hat spacer to rub against the hub.

The bearings all look and feel very good still. I cleaned them out and repacked with lithium grease.
I cannot see or feel any axial movement or play. The shaft has the brown rings where the bearings run, as you see often on these shafts, but not worn and the diameter is still the same.

So what I like to try is to replace the spacer/bushing stack, because if the stack is just 1 or 2mm longer my problems seem over.
But for the live of me I cannot find any replacement parts, only full hubs or even hubs + swingarm (ebay).
So I searched the web for industrial bushings that have the same size, but to no avail.

Alternative is that someone machines a top hat spacer that's 1 or 2 mm taller, instead of replacing the whole stack.

Anyone here that knows a place where I can buy a new set? Or maybe someone has a set for sale? Or who can machine a taller top hat spacer?
Any help is greatly appreciated!

Video showing the play on the sprocket carrier: https://www.youtube.com/watch?v=fsnf17PF9eM
Video showing the difference between old and new cush drive: https://www.youtube.com/watch?v=H6fSRcTUdPM
You could buy one of my hubs and all your worries will be over.
Also you could buy the upgraded sprocket carrier which is the same as the pre2010 models run which is trouble free.
I know it is costly,but it means total reliability.
 

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I've gone through and broken down all the required information you may need on the other post you have made, Jeroen.

Please feel free to take a look at the provided information and if you do require any further technical assistance, please do let me know and I will be happy to help.
 

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Discussion Starter #4
Thanks Mitch, Jack, for the replies.

I've read the threads on the forum about the mitch hub, very nice piece of engineering! The motocorse hub looks like a very solid piece of kit too.
Still, it comes with a price. Especially mitch's hub, has to be shipped from the other side of the planet... Australia > Europe.

I think you would agree that it makes sense to first try to fix the bike by replacing a few bushings, instead of spending 600 euro's (700 USD).
If the bushings fix fails, I can always still buy a custom hub.

So if anyone has a bushing stack for sale, or know where to buy them, please let me know :)
 

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I believe (maybe I'm wrong) that Joe stocks Mitchy's hubs in The UK (or is it Ireland now)... gotojoe.

As for the bushings, you might try an email to CAG. He still has a lot of stuff, even though he is no longer formally in the parts business. [email protected]
 

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Discussion Starter #7
Try 'Star Twin Trading' (in Belgium I think). They used to be a forum sposor. They're pretty good for parts.

Cheers

Deano
Thank's for the tip! There's a star trading here in The Netherlands, I have sent them an e-mail asking for the availablility of the parts. Let's hope they have something!

I believe (maybe I'm wrong) that Joe stocks Mitchy's hubs in The UK (or is it Ireland now)... gotojoe.

As for the bushings, you might try an email to CAG. He still has a lot of stuff, even though he is no longer formally in the parts business. [email protected]
Hmm I found the ebay ad from Mitch himself on ebay, and it states it'll come from Australia... but I'll ask him when I really want to buy a new hub.
I emailed CAG too, let's see what's comes up :) Thanks for providing the email address!
 

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I did this and haven’t look back. The new version is complete crap. It will fail again and you could be on the bike at that point.

Search the forum for my post concerning this. It’s got a lot of good info.

My rear sprocket holder was very wobbly, and chewed away part of the hub.
In my case, the top hat washer (flanged washer) had eaten itself into the aluminium cush drive, which caused the play and eventually lead to the cush drive touching the hub.
Why the top hat spacer has eaten the cush drive I don't really know.. but nevertheless I found an almost new cush drive and sprocket holder and installed them on my brutalia.
But what I also noticed is that the top hat spacer has a big groove in it, on both sides. And the bushings that run inside the needle bearings also have grooves where they meet.
So as a result, the whole stack is just about 1 or 2mm (approx guess) too short, and this causes the top hat spacer to rub against the hub.

The bearings all look and feel very good still. I cleaned them out and repacked with lithium grease.
I cannot see or feel any axial movement or play. The shaft has the brown rings where the bearings run, as you see often on these shafts, but not worn and the diameter is still the same.

So what I like to try is to replace the spacer/bushing stack, because if the stack is just 1 or 2mm longer my problems seem over.
But for the live of me I cannot find any replacement parts, only full hubs or even hubs + swingarm (ebay).
So I searched the web for industrial bushings that have the same size, but to no avail.

Alternative is that someone machines a top hat spacer that's 1 or 2 mm taller, instead of replacing the whole stack.

Anyone here that knows a place where I can buy a new set? Or maybe someone has a set for sale? Or who can machine a taller top hat spacer?
Any help is greatly appreciated!

Video showing the play on the sprocket carrier: https://www.youtube.com/watch?v=fsnf17PF9eM
Video showing the difference between old and new cush drive: https://www.youtube.com/watch?v=H6fSRcTUdPM
You could buy one of my hubs and all your worries will be over.
Also you could buy the upgraded sprocket carrier which is the same as the pre2010 models run which is trouble free.
I know it is costly,but it means total reliability.
 

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Thank's for the tip! There's a star trading here in The Netherlands, I have sent them an e-mail asking for the availablility of the parts. Let's hope they have something!



Hmm I found the ebay ad from Mitch himself on ebay, and it states it'll come from Australia... but I'll ask him when I really want to buy a new hub.
I emailed CAG too, let's see what's comes up :) Thanks for providing the email address!

Yes,Joe (gotojoe) lives in Ireland and has stock,which makes shipping much cheaper for you.
The ebay price is inflated to cover their high commissions.
If you decide to buy a new hub buy it from Joe.
 

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Same as Atom, I went for the Mitchy hub as I didn't want any more hassles. I had the upgraded hub after the original shit itself at 5000k. Now that's useless cos the spacers wear. Thought of buying new spacers but beside availability I'd have been in the same place a few years down the track if I keep my current mileage up. I'll machine my own spacers when I get time (if I can find original dimensions) and pass it on to someone in need. Crap design.

Cheers

Deano
 

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Discussion Starter #13
Update:
Star Twin in The Netherlands, which is one of the MV Agusta specialists, replied that they have no MV parts in stock at all.
I e-mailed forum user CAG, but unfortunately he has no parts.

So in the mean time a friend will machine a new top hat bushing for me at work. The bushing will be taller in height, so I can machine it to lenght myself and finetune the lenght of the whole stack and thus the distance between the cush drive and the hub. Of course while still making sure the rear sprocket aligns with the front sprocket.

if all that doesn't lead to a good result, then next step is buying the mitchy or moto corse hub.
 

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Jeron, how much money and time is this costing you to do? With the comments from people who have done the same thing and ended up back at square one it doesn’t seem to make a whole lot of sense to not buy the upgraded hub in the first place. Or maybe I don’t fully grasp the situation...
 

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Discussion Starter #15 (Edited)
I spent 50 bucks on a new cush drive, which I needed anyway even if I would buy a new hub.
The machining of the top hat bushing costs me nothing, not even material costs.

My approach to this problem is to explore and try a relatively easy fix first, before pulling out the wallet and spend approx 500 euro's (600 USD).
For me that's a lot of money.
Please respect this.
 

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Same as Atom, I went for the Mitchy hub as I didn't want any more hassles. I had the upgraded hub after the original shit itself at 5000k. Now that's useless cos the spacers wear. Thought of buying new spacers but beside availability I'd have been in the same place a few years down the track if I keep my current mileage up. I'll machine my own spacers when I get time (if I can find original dimensions) and pass it on to someone in need. Crap design.

Cheers

Deano
It seams I have the same problem like some of you, and my bike is just out of guarantee. It is 2016 TV model and I already changed rubber dampers twice... Bike has 17.400km now.
My dealer has no answer from the factory but he suggested we get someone to manufacture a new spacer (I guess a wider spacer) and that should eliminate the play and bushing wear. I could also upgrade to a new (old) design (gen. 1), but this will be around 500-600EUR investment minimum... When you say "Crap design" you refer to OEM or the Mitchy hub?

Did anyone manufacture new spacer for OEM design before moving to aftermarket hub?
 

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I spent 50 bucks on a new cush drive, which I needed anyway even if I would buy a new hub.
The machining of the top hat bushing costs me nothing, not even material costs.

My approach to this problem is to explore and try a relatively easy fix first, before pulling out the wallet and spend approx 500 euro's (600 USD).
For me that's a lot of money.
Please respect this.
I plan to go the same route. Do you have any tips? I don't know if your bushing is the same as on 2016 TV but maybe you could give me info on diamter of your new ring?
 

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Discussion Starter #20 (Edited)
It seams I have the same problem like some of you, and my bike is just out of guarantee. It is 2016 TV model and I already changed rubber dampers twice... Bike has 17.400km now.
My dealer has no answer from the factory but he suggested we get someone to manufacture a new spacer (I guess a wider spacer) and that should eliminate the play and bushing wear. I could also upgrade to a new (old) design (gen. 1), but this will be around 500-600EUR investment minimum... When you say "Crap design" you refer to OEM or the Mitchy hub?

Did anyone manufacture new spacer for OEM design before moving to aftermarket hub?
Yes, I did. I installed it last weekend.
I asked the machinist to make the spacer (stainless steel) a bit taller in length than the original one, and during installation it I turned it down on the lathe until it was a perfect fit. After every iteration on the lathe I installed the whole assembly and torqued it down with the correct amount of torque. I kept making the spacer shorter until the holes of the shaft and the end nut for the final locking spring lined up again.
When that was done, I still had some play on the sprocket, between the sprocket carrier with the rubber cushions and the end plate that goes into the rubber cushions. It was only a little play, but too much for my liking.
It was the play that you can also see in the second video where I show the old and new sprocket carrier and end plate that I bought from ebay, for approx 50 bucks.
To fix this play, I machined a ridge in the back side of the spacer. So the inner part of the spacer close to the shaft is shorter than the most outer side. This I repeated until the play was minimal, but I wanted to keep a little play so the axial force of the end nut is still on the bushing stack and not on the outer radial part (flange) of the spacer. This also took a couple of iterations.

The wheel spins very freely and smoothly now, and I can feel or see no axial or radial play on the wheel when I pull or jank it hard.
Since the installation I've driven about 200km, and it still is rock solid. 200km is not much so let's see how this holds up. Fall is coming, which means a lot of rain and wind in my country so it will probably take some time before I can report back with serious milage.
If anyone is interested I can create a cad drawing on how the spacer looks like, with the ridge and all.
 
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