What has happened here please

[KERABO]

I removed this hub from a same make but different version PowaCycle bike but the flats on the Spindle don’t align.

I had the hub apart to lube the gears but I am sure the shaft is just one part So can’t see how I could change anything.

any ideas what is wrong? The bike it came from had dropouts the same.

Thanks

 

[Nealh]

In the first pic the hub axle needs rotating 90 degrees to align in the drop out, either turn the hub 90 degrees to align the flats of the axle in the drop outs or use a tight fitting spanner and manually rotate just the axle only to align.

 

[KERABO]

In the first pic the hub axle needs rotating 90 degrees to align in the drop out, either turn the hub 90 degrees to align the flats of the axle in the drop outs or use a tight fitting spanner and manually rotate just the axle only to align.

Thanks for the reply.
thats the problem the flat on the thread is 45deg out on the other side.
I can’t work out why.
I could open the hole or file the threads but I am puzzled why it’s like this.

Thanks

 

[matthewslack]

What's the history of this? Have the motor and bike have not always been together? Or has something changed?

The flats should always be machined in the same orientation both ends, so:

1. It was a serious manufacturing error, or
2. The axle has twisted in use, or
3. The axle has snapped, or
4. The motor was intended for a bizarre set of frame dropouts.

I don't believe 4 and I struggle to believe 1. Only way to know is to dismantle and have a look.

 

[sjpt]

What's the history of this? Have the motor and bike have not always been together? Or has something changed?

The flats should always be machined in the same orientation both ends, so:

1. It was a serious manufacturing error, or
2. The axle has twisted in use, or
3. The axle has snapped, or
4. The motor was intended for a bizarre set of frame dropouts.

I don't believe 4 and I struggle to believe 1. Only way to know is to dismantle and have a look.

I find 2 extremely unlikely as well. I don't believe it could twist that much without snapping.

 

[saneagle]

What's happened is that one of the axle nuts wasn't done up tight enough, so when the motor applied maximum torque it allowed the axle to turn in the drop-out at one end, during which it will have destroyed in thedropout in the processs. Something has moved inside the motor. Either the axle has twisted or something has slipped. You should be able to fix it by clamping one end of the axle in a vice and using a big shifting spanner (monkey wrench) on the other end to twist it back into position, or use two monkey wrenches. You should be able to feel whether it's slipping or twisting. If you want to be sure, you'd have to open the motor and look inside to see what's moved and how.

 

[KERABO]

The drive hub came out of the picture with the bare frame. PowaCycle and is now in the PowaCycle Lynx. Both have the dropouts equal.
I had the hub apart to lube the gears but the shaft seems to be one piece.
do you think it could twist the axle under power?
I put a spanner on the flat to see if it will move internally but it won’t budge.

 

[matthewslack]

I would expect the axle to be a single piece of metal, so twist under load begins to look like what has happened.

I would be concerned that so much twist may be close to failure, and failure whilst riding might have undesirable consequences.

My curious side would want to strip it down to bare axle to understand.

 

[Cadence]

If you turn the axle does it run true? If not then it has twisted, although It's hard to imagine how that would happen. It looks solid at each end - how does the cable enter the hub? I think the axle could possibly be 2-piece with a screwed joint somewhere inside. I would put two nuts on each side and lock them together. Then use open ended spanners on the inside nuts, or grip the nuts on one side in a vice if you have one. I would expect it to need turning anti-clockwise and it might need some force.
Edit- on looking closer I see a slot for the cable on one side, but I still can't imagine how the axle would twist to that degree.

 

[thelarkbox]

If the two sides were in sync and are now out of sync, and in the interim OP opened up the motor..

I would suggest perhaps the axle may be in 2 parts and reopening and realigning may be possible?

i am no cycle or motor expert tho..

 

[KERABO]

If you turn the axle does it run true? If not then it has twisted, although It's hard to imagine how that would happen. It looks solid at each end - how does the cable enter the hub? I think the axle could possibly be 2-piece with a screwed joint somewhere inside. I would put two nuts on each side and lock them together. Then use open ended spanners on the inside nuts, or grip the nuts on one side in a vice if you have one. I would expect it to need turning anti-clockwise and it might need some force.
Edit- on looking closer I see a slot for the cable on one side, but I still can't imagine how the axle would twist to that degree.

It seems solid and straight
I didn’t check but it must have came out of the old bike like it.
I will try to find another or file the dropout.
thanks for your help

 

[KERABO]

If the two sides were in sync and are now out of sync, and in the interim OP opened up the motor..

I would suggest perhaps the axle may be in 2 parts and reopening and realigning may be possible?

i am no cycle or motor expert tho..

Thanks for the input. I will find another drive

 

[chris_n]

Looks to me like the angle it is out is the equivalent of rotating the casing by one bolt hole on the first picture.

 

[saneagle]

It seems solid and straight
I didn’t check but it must have came out of the old bike like it.
I will try to find another or file the dropout.
thanks for your help

Do not file the drop-out to fit that motor. You need to re-align the axle.

 

[KERABO]

Looks to me like the angle it is out is the equivalent of rotating the casing by one bolt hole on the first picture.

I know what you mean.
I will first see if it spins when my controller kit arrives and if so will take the cover off again and double check.
thanks for your help

 

[KERABO]

Do not file the drop-out to fit that motor. You need to re-align the axle.

Ok yes your right .
thank you

 

[Sturmey]

5. The motor has a two piece axle and something has come loose/?.