eh...im done, ive got no dog in this fight. I just got irritated at seemingly irrational responses from the OP.

OP.....i hope they get you some new servos and correct the issue if there is one. It sucks having good (expensive) equipment and not being able to use it.

They look perfect! I have measured them with a vernier and they measure the same as the 801's that accept the alloy horns fine.

I started racing approx 14 years ago I hope that i know how to align a horn now.

Sanwa products are fantastic when u sell on the scale they do every now and then these things happen.

I purchased another 801 a week prior to starting this thread it accepts the horn fine so I don't know when the batch was from-too.

I could take a pic of me attempting to put the horn on and I would get someone say the splines not aligned!

All I can say is if u brought a Sanwa servo this year just see if a descent quality 23 tooth alloy horn goes on. If it doesn't go on with light pressure it could be faulty!
I man handled attempting to get it on and I still couldn't! My new one it just falls on no pressure same as my old 801!

Have you had a response from Sanwa yet?

The first response before I had sent them off was they were not aware of any faults, that was when I posted this info on forums. I then spoke to one of our national A finalist's and he had the same fault but he uses mainly plastic savers so it wasn't a real issue but has sent it back with mine (I am led to believe)

They have been sent back to the uk distributor where I believe it's been sent to sanwa/Lrp Germany for investigation. As soon as I have the response I will forward the outcome. But it is always force in numbers ;-)