Some parts are to be heated or cooled to fit when tight tolerances are required. Does the shaft almost start? I would say use the old shaft until you are sure it will fit w/o breaking the gear. Was reaming the old gear mentioned? How are the tines fitting on the new shaft? Please post a âÂÂclose Picâ of the shaft starting into the gear. Your supplier or Honda 800 Tech should have some good input. Good Luck!

Jacko,

I sometimes solve that problem by placing one part in the freezer to reduce its size and the other on top of the wood stove to increase its size. Just a few days ago I did that to install "press fit" ball bearings on my son's drill press spindle.

It works every time but you have to be quick, getting it done before the temperatures equalize.

Ray Waldbaum

Thanks for cold/heat tricks, makes sense so I'll give that a try. I will also take a picture if it doesn't get any further.