ok so i got the engine back together installed in the machine,, rebuilt the front hubs, repaired some shoddy wiring, ordered the clutch rebuild kit and rear carrier bearings and seals, topped up fluids ect. I removed the rear axle shaft and layed it on the table, and the one side is bent about 3/8" out of center line. From anyone's experience, can i just lay this in a press and straighten it out or is this thing going to explode and take may arm off? I have presses at work to straighten pipe, on roller bearings and dial indicators. so its no big deal there. i just don't want to break this shaft. heating it is out of the question as it would become malleable and just bend again. I digress I never noticed the bent axle before, because the carrier bearings were so bad. I'd feel bad going back to the guy and telling him he needs a new shaft for $$$$? I'm almost done this, seem like one thing after another. Oh well that's how she goes. Next time someone brings me something in this state, I will over price the quote and leave some wiggle room so it doesn't snowball, At least it will be like new when it leaves.
Been busy on other stuff to take up the down time on this. Got an 89 cr250r completely rebuilt looks like it just came out of the crate, minus the laque of an engine. Which is in pieces in front of me just have to put the top end together, and throw it in. Looks brand new though.

 

Dont worry there is going to be a new plug. Just dont want crap falling into the cylinder.

 

Don't mess with trying to straighten a rear axle as you'll just further weaken the metal. Quote the guy a new drive shaft replacement.I had machines like this come in on a daily basis. Quote them on what they originally brought them in for and call if you find additional damage. You're not responsible for a bent axle,the owner is ..We even had a sign in the shop for this very reason on finding additional or hidden damage that we had the right to revise the estimate. MOST shops do the same thing..

 

Yah, that's what i figured. He knew it was bent, after I talked to him. I'll just through it back in and get him on his way. Its not a huge deal to replace anyway, other that the cost. He's not doing any high speed with it just going through the bush for hunting purposes. Thanks opt, you are a huge help here.