Diagnosis of secondary drive

[Gorminrider]

I found ...."the Zooks Syndrome" .bevel_gear_shaft_repair_zooks.pdf - Microsoft Word Online
Snapped bevel gear boltzooksSyndrome.jpgThat bolt end is supposed to be attached

(picture copied from MrZooks pdf available on BassCliff's)

' going to be a nuisance fixing it. I certainly can't do it with my hand held drill and rusty tap-and-die kit!

[Gorminrider]

The point was to check it out and not ignore the noise. It shows what COULD happen.

yes, sorry, but I couldn't see anywhere in it mentioning the noise

I heard a clunk, clunk, screech, clunk and the rear wheel locked up

.

That is not much of a clue and didn't seem helpful when AMK and I were still trying to orient ourselves around the engine to find where the whine was coming from....

[AMK]

yes, sorry, but I couldn't see anywhere in it mentioning the noise .

That is not much of a clue and didn't seem helpful when AMK and I were still trying to orient ourselves around the engine to find where the whine was coming from....

I'm thinking any noise from that area commands an inspection. How many miles were we away from the "clank, clank, screech"?
We very well may have dodged a bullet.

I'm glad we had this discussion.
I thank you, gorminrider, and everyone for your input!

[AMK]

I found ...."the Zooks Syndrome" .bevel_gear_shaft_repair_zooks.pdf - Microsoft Word Online
Snapped bevel gear bolt[ATTACH=CONFIG]46058[/ATTACH]That bolt end is supposed to be attached

(picture copied from MrZooks pdf available on BassCliff's)

' going to be a nuisance fixing it. I certainly can't do it with my hand held drill and rusty tap-and-die kit!

I did see that on BassCliff's site but it was before I was sure enough to tear into it.

If you don't have a machinist nearby and inexpensive enough I will extract that bolt for you for shipping if you need it.
It looks like I'll have one to do also.

[Gorminrider]

Indeed, I confess I didn't know what I was even looking at on various posts until I found the trigger from that archived post! Funny. ...You can lead a horse to orange juice or root beer or water but you can't make it drink if it doesn't recognize it as "drinkable".

http://www.thegsresources.com/_forum/showthread.php?199533-Can-t-separate-secondary-drive-from-shaft&p=1734304#post1734304

Anyways, you got me going again on it, so thanks for that-sigh.

and Thanks for the offer! but I'm (still) hopeful I'll be able to find a fix...and anyways yours may not fit a 650G...mildly Interesting: I have found a compatibility list of the part at MrCycles that includes (only)the GS 450GA...

[AMK]

Anyway, you got me going again on it, so thanks for that-sigh....

Sorry about that . I hate being down in prime riding season too.

I'm going to tear into the rear end tonight.

Good luck to you, and thanks again.

[Gorminrider]

All fixed here,(most time since waiting for the oil seal) but I'm still wondering how the end got torn off in the first place ie: what is the cause of "Zook's Syndrome"? I am guessing the secondary gears must pull the whole shaft forward really hard , so I will not be popping anymore wheelies on this shaft-driven bike!

[AMK]

All fixed here,(most time since waiting for the oil seal) but I'm still wondering how the end got torn off in the first place ie: what is the cause of "Zook's Syndrome"? I am guessing the secondary gears must pull the whole shaft forward really hard , so I will not be popping anymore wheelies on this shaft-driven bike!

That's gotta be a relief. And peace of mind.
Mine is still waiting. I've been spending time on the other one getting the charging system in shape and trustworthy.
I also went through the archives and found some valuable threads on this problem. I did read one opinion that makes sense as to how this happens.
Can't find it now but it said the nut must work loose and the hammering back and forth breaks the stub off.

So, what did you end up doing, Zook's repair? How did the hand drill and rusty tap and die set work

[Gorminrider]

So, what did you end up doing, Zook's repair?

Yes. But I took it to a machinist. I will die without ever having drilled a hole exactly in the centre of anything

...Not exactly "peace of mind" but it's nice to not hear the whine. I also did the swing-arm bushings as they were galled. And a b*gger to get the races out!
I am certainly developing a watchlist for this bike...It is a little more emphatic then my GSX400s' !
..."Hammering backn'forth" as in forward and backward - perhaps -' not sure why it would be "hammering" and my bolt had not loosened out very much if at all before snapping... and seeing as my pinion gear was also moved out of the rear bearing (like yours?) I'm certainly leaning to Pull more than push.

[AMK]

Got some time to tear into it.

Got it apart and just as suspected...20161017_184550.jpg
One Zook's repair coming up.

[Gorminrider]

you too,eh? I thought you had it fixed? or did it shear off after reassembly? any clue what caused it?

[AMK]

you too,eh? I thought you had it fixed? or did it shear off after reassembly? any clue what caused it?

I hadn't fixed it yet. I bought the '82 to ride while I had the '83 down but it needed brought back up to par first.
I've got it running and driving like a champ now so that affords me time for the '83.

You were right about having the same problem. I am still at a loss for cause. My only guess would be the wrong material and heat treat for that stub design.

[Gorminrider]

Good point.It does seem an awful difficult piece to make when... it would seem that drilling a hole for a bolt would have been easier than all that machining (?) just to leave a stub to thread a nut too...I guess they figured the threaded stub would be so much more secure to lock a nut onto versus a simpler bolt threaded in with locktite but apparently "nut coming loose" was not the only issue they should have prepared for...I expect it's something WE will have to watch...the bolt coming loose, I mean ...otherwise, it's difficult to imagine just what tears it off, since the bike will run/whine along with the the nut off it anyways