Broken Secondary Gear - 2nd time in 2 years

[Guest]

October 2015 - Noticed a clunking while on a ride 15 minutes from home. Got home and started looking into things and found this:



Replaced it with a good used unit. 5000 miles without an issue.

Yesterday, was pulling into my street and noticed a similar clunking. This time its worse...




Obviously something is wrong... maybe its my riding style? I never bang the gears without the clutch. I never downshift abruptly.

Question I have... would the gear from an 81 850G work on my 83 1100G?

[JTGS850GL]

My guess is that you didn't set the backlash properly. The lash needs to be set so the gears mesh properly. Too much and they bottom out against each other. Too little and you end up breaking off the tips of the gears. You may also have some debris in there getting caught between the gears.

[Steve]

The 850 gears are a bit smaller than the 1100 gears, and they have a different ratio. You will note that your broken gear in the picture has 17 teeth. The gear that it drives has 16 teeth. On the 850, those numbers are reversed.

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[tom203]

Years ago, I got a parts lot mostly 650 shafty stuff, but a few 850 items thrown in like this 16 tooth gear housing image.jpgassembly

[JTGS850GL]

Also, note that Suzuki doesn't sell the gears individually. They're sold as a complete set for a reason. Wear and damage on one gear will affect the other as well. Kind of like replacing the chain and not the gears on a non-shafty.

[gordinho80]

Damnit... What if I replace the gear that bolts to the driveshaft with the 850's as well?

[gordinho80]

I seem to have found the underlying issue... and it looks like my bike will be out of commission for the foreseeable future.





Gear that leads to the driveshaft itself is broken at the nut. Only way to get the assembly out looks to involve removing the motor... or at least loosening it a bit. The assembly hits the frame where the swingarm bolts on.

UGH!!!!!!!!

[Steve]

I know the 850 gears can be removed with the engine in place, not sure about the 1100.

Might be able to just loosen the motor mounts and tip it forward a bit to get the little bit of room that you need.

.

[gordinho80]

Steve,

Do you see any issues with swapping the 850 gears into the 1100? I'm working on acquiring a nearly complete 850G.

[Steve]

It would change your drive ratio a bit, going from a 17/16 to a 16/17, but you would also have to change the driveshaft itself, as the yoke has a slightly smaller pattern than the 1100's.

That being said, I don't know for sure if the secondary gear housings are the same size, so would need to check that first.

.

[gordinho80]

This sucks! I just sold the Honda a month ago and now with the riding season getting into full swing, this happens! ARGH!

[JTGS850GL]

This sucks! I just sold the Honda a month ago and now with the riding season getting into full swing, this happens! ARGH!

It's one reason I NEVER have less then 2 bikes road ready.

[AMK]

Secondary drive busted stud is the very reason I bought my second 1100. Wrench one, ride one and visey versey.
I don't know how closely related the G is to the GL in that area but my gears came out without removing the engine. I didn't have to loosen it either.

[gordinho80]

I managed to get the driveshaft side gear assembly out without pulling the motor. Removed the rear and mid engine mount bolts and loosened the front bolt. Gained enough leeway to get the broken assembly out. The gear I bought off eBay two years ago included that assembly so I bolted that guy in.

EDIT:

I just picked up a replacement gear on eBay for $50. Seller listed it as new condition. Looks great in pictures. Will have it hear in a few days.

[Charlie G]

I managed to get the driveshaft side gear assembly out without pulling the motor. Removed the rear and mid engine mount bolts and loosened the front bolt. Gained enough leeway to get the broken assembly out. The gear I bought off eBay two years ago included that assembly so I bolted that guy in.

EDIT:

I just picked up a replacement gear on eBay for $50. Seller listed it as new condition. Looks great in pictures. Will have it hear in a few days.

Following along. Are you going to changing the pair of gears or just the broken one?

cg