GS1100GK: noise & vibration in 4th / 5th gear - gear box? transmission? drive train?

[tano1980]

Ha! I have lots of other bike (and home) projects! I collect bikes and am always working on a variety of them. I did a complete rebuild of a V65 Magna with only 8000 miles on it.. super strong bike! My son and I also did a rebuild of a FZ600.. just waiting to flush the tank now that it is running so it can be on the road.

The GK is bigger than I normally ride so it didn't get a high enough priority. I mostly needed it out of the way now so got it to the shop. I'll pull the part and see how it goes. I do like the bike... good power and mpg... so we'll see if it makes it back into the riding rotation.

Thanks!

[Redman]

I had the threaded shaft break off the back of the secondary driven gear. Although all I noticed was occasional vi ration on decell.
am trying to post pic to verify if that is what you are describing g, but am having difficulty with that.
if you want, go to my imgur pictures, RedMan52, look for album name 2017_PiecesParts.

i think we are talking about the same thing. And you are not going to like it.
yes, if use donar parts there is all that measuring and shimming.
there is another option, can discuss later.

and with GK, I found there is a complication in removing the drive gear assembly in that the GK has some extra braceing on the frame that interfere with pulling the gear set from back of engine. Reguires unbolting engine from frame to jack up and shift over engine. Can some what see that in my pictures.

would like to help more but do not have full access to my pics now.

note: the secondary drive gear is the one on transmission shaft. The driven gear is the one that has the flange for the shaft drive . Took me a while to understand that.

[Redman]

look like this?

also, see the swing arm pivot? see the big brace thing there sticking out? that on GK is what is in the way of pulling the gear housing-assembly out of the back of the engine



that bolt laying there still hasthe threaded shaft in it that should be on the end of the gear


here can see the broken shaft. Gear is still in the housing.

[Redman]

here is my little sketch-notes that helped me learn what is what


another way to say it:
the Drive Gear is what can come out the side of the engine.
the Drive Gear is what can come out the back of the engine.

[londonboards]

I guess this is what's happened then:

http://members.dslextreme.com/users/...pair_zooks.pdf

[Redman]

Tano,

I will most likley be unavailable, and not have resourses to respond much further over the next couple week,
but did want to get this to you

http://members.dslextreme.com/users/storagecliff/images/bevel_gear_shaft_repair_zooks.pdf

It takes a good machinest.

you say you took it to a shop, and they found the broken thing.
to find that they would have needed to remove the swing arm. Which would be about 1/4th of the work needed (especially on the GK) to complete this project (not including the machining).

[tano1980]

Thanks, all! Yes, the "Bevel Gear Shaft Repair" is what we are going to try first. If that doesn't work then we'll use a donor part. My concern with the donor part is that it may break the same way that the original did.. and exactly what the posted pictures shown. The shop has a metal lathe so they are going to see if they can drill and tap existing unit as the "Repair" link indicates. Hopefully it will do the trick!

In the meantime I'm doing an engine swap in an FZR1000 to keep my mind off the GK. :-)

I'll let you know how the repair goes!

[Gorminrider]

I had this same and the zook's repair is working fine. You will more'n likely find this a good opportunity to change the swing-arm bearings too.