apapanic

Hey,
I'm in charge of my team's stock of equipment and it seems that at some point, someone didn't do a very good job putting the cassette on the freehub. More specifically, they got all the cogs on in line except the little ring, which they failed to align properly. They foolishly went ahead with putting the lockring on causing the slots on the cog to sheer away part of one of the splines. I'll provide a picture when I get the chance.

This was discovered when someone was trying to remove the cassette (don't know if she did it or not when she installed the cassette) had trouble. What should we do?
A) File off the burs like one would do when getting the standard indentations from cassettes just so the cassettes are installed and removed easily, OR,
B) get a new freehub body because this damage is more than just the indentations (really need to get the picture posted...).

Thanks for the help guys! Cheers!

HillRider

If all but one of the splines are undamaged and only the smallest cog position of that spline is damaged, you should be able to continue to use it. Try installing the cassette properly and take the bike for a ride, putting as much pressure as you can on the small cog. If it's solid, you're ok.

onespeedbiker

Al the splines really do is stop the cog from spinning on the freehub. As long as the cog sits straight on the freehub and you can still tighten the lockring it shouldn't make any difference.

apapanic

Here's a photo of the spline. I would agree with you guys. One small part of one spline is damaged. Shouldn't be a problem.