HELP, GS1000G shaftie grinding!

[vodkalex]

Hi All.
Just out today for a ride with the lady, then disaster.
Strange jolting of the bike and a grinding/clunking coming from the area by the gear lever, the casing with the gear diagram on. Bike still engages gears, and turns over fine, but has difficulty movin.
Any help would be great!

[Dogma]

I've never experienced those symptoms, but I'm thinking something concerning the universal joint gave up. If you loosen the boot of the u-joint (next to the left swing arm pivot) you should be able to see the u-joint and start to make a determination if the problem is there. Have a helper turn the rear wheel to see if the movement is normal.

That's where I'd start, anyway.

[49er]

I've never experienced those symptoms, but I'm thinking something concerning the universal joint gave up. If you loosen the boot of the u-joint (next to the left swing arm pivot) you should be able to see the u-joint and start to make a determination if the problem is there. Have a helper turn the rear wheel to see if the movement is normal.

That's where I'd start, anyway.

If the universal joint checks out ok, the fault could be with the secondary drive gears at the back of the engine, or the teeth worn away on the diff drive splines. The sound location would suggest the universal or secondary gear failure.

How's the oil level in the secondary gear case?

[SqDancerLynn1]

I think they are pointing you in the right direction. The secondary gear set- output flange bolt sometimes breaks. IT CAN be fixed- see Basecliff's site

[Nessism]

Yes, secondary output flange often breaks. The rear splines often strip too (you need to pull the rear wheel to check. The rest of the drivetain is bullet proff so I'd start by checking these two things out.

[vodkalex]

Hi guys,
Thanks for the response.
Checked the shaft, all fine, the rear wheel, also fine, the noise is behind the bolt that goes onto the engine part of the drive. I removed the shaft, and wheel, but there is a bolt on the drive that is pressed in. How the hell do i remove that to get into the gear?mmm

[twr1776]

Did you pull the spline completely out of the rear wheel to inspect it? If you are not familiar with the spline hubs it will be hard to tell from the outside view if it is bad or not.

http://www.thegsresources.com/_forum/showthread.php?t=149097

[vodkalex]

Yeah i pulled it out and all seems good. There seems to be a jarring and grinding in he secondary drive area in the engine, any ideas how to get in there to look?

[49er]

Yeah i pulled it out and all seems good. There seems to be a jarring and grinding in he secondary drive area in the engine, any ideas how to get in there to look?

Loosen off the 2 crankcase bolts either side of the mount flange. This relieves some tension in the area where the gear assy fits up. Now undo the 4 flange bolts and gently prise the gear assy out of it's position. You may need a rubber mallet to shock it loose, or carefully pry it forward from the case with a couple of screw drivers, at 180 deg apart.
Did you checked the oil level in the secondary gear case?

[vodkalex]

ah great, yeah, it was low, I had a leak from the gasket.

[vodkalex]

Found the problem

Hi guys, got back from holiday, and finally got round to pulling the secondary drive gears apart, and found the problem. One of the 2 bearings on the shaft that faces out of the engine behind the rubber cover had completely disintegrated itself, leaving bits of it all inside the housing. Everything else was A OK. So just gotta clear out the mess and get a couple of new bearings. Any ideas about how to do this? ie: where on earth I can get some bearings? I am UK based.

[49er]

Hi guys, got back from holiday, and finally got round to pulling the secondary drive gears apart, and found the problem. One of the 2 bearings on the shaft that faces out of the engine behind the rubber cover had completely disintegrated itself, leaving bits of it all inside the housing. Everything else was A OK. So just gotta clear out the mess and get a couple of new bearings. Any ideas about how to do this? ie: where on earth I can get some bearings? I am UK based.

Sounds like the output shaft where the drive flange is mounted. You can get replacement bearings relatively cheaply for these engines. Suzuki or through places like http://www.alpha-sports.com/suzuki_p...GS1100G/54.htm

If you look closely, you'll find the actual bearing dimensions are quoted. This enables you to purchase them directly elsewhere at a cheaper price, unless they are a special size.

[vodkalex]

Any ideas how i remove the gear assembly? I have taken the outer housing off and the nut, but cant get any further.

[Buffalo Bill]

Bike's so reliable, you forget to check stuff…

ah great, yeah, it was low, I had a leak from the gasket.

Bummer! But thanks for the posting, I'll check mine own tomorrow.
Bill

[SqDancerLynn1]

Put the driveshaft flange back on and get a block of wood. Give it a good whack to drive the assembly out the back of the case. Once you get it to move you can pry with a screwdriver (a claw hammer works too) - that first 1/16" is a Bit#h. Don't loose the shims. If you have the swingarm off you could try a slide hammer