Problem with Second shaft or countershaft

[sfc]

I replaced my variator and it was very slow so I openned it up again and tried to get the primary sheave off the shaft and it wouldn't come off. I finally got it off but it looks like the shaft's teeth are damaged and the primary sheave has broken teeth. There was dust sized metal shavings also.

Does anyone know why that might have happened?

Thanks

[SqUiRmInAtOr/ Phred 501]

Major suction man!! Hard to say without a looky. You may have forgotten the washer between the nut and the spacer and mashed down the splines (legthwise groves) causing them to catch the edge keeping you from pulling it off.The fact that teeth are broken makes it sound as if you may not of hat the splines in the grooves of the sheave we you cranked her down. Thus, busticating the teeth off. Hopefully you didn't mess up the shaft splines too bad and they can be cleaned up. Sheave's are cheap compared replacing that shaft. Was the nut tight? Or all the way off when ya took it apart? Sorry about your misfortune

[sfc]

I'm paying a guy to file the shaft. Shouldn't be more than 140 to get it taken care of...

Can you tell me the order of parts to make sure I have everything, starting from the Variator?

So as I understand it..

1) Variator
2) Spacer the Variator sits on
3) Belt
4)Primary Sheave
5)One-way Clutch
6)Washer
7)Nut

Can someone check the service manual to make sure I got everything?

Thanks

[Dandy Dan]

I wrecked my crankshaft by not getting everything tight. Good think Honda covered it under warrentee. Anyways, your order of things looks good. Just make sure you get the nut on all the way which can be hard to tell cuz the belt pushing out makes things appears tight before they are. I suggest observing how much threads are sticking out of the nut before you start and then making sure you have the same amount after.

If you shorten anything you'll need to make another washer than is big enough to slide over the splines. If there is some minor damage to the crankshaft try and scrape out the splines with a flat screwdriver or something.

I'm not sure what you mean when you say you're paying a guy to file the shaft for 140$. The only thing I can thin of that you might wanna file is the spacer but there's no way that should be 140$. You said your variator was very slow after you played with it. Are you sure you didn't put something in backwards? Like the plate next to the roller weights?