how do you take out the splines from the tire

[bwringer]

This is great info, I'd be high and dry sometime soon if you all hadn't brought this up. As luck would have it, I have an 82 850G with 32K miles, but have used Honda Moly 60 on the splines since I got it at 17K miles. However if these early 80's splines are toast by 50K miles, I'm going to need to replace it pretty soon. When I look on the parts fiche under Rear Wheel, there's something called a Joint, Hub Driven part 64680-45113 for about $100. Is that it, or is it under the Propeller Shaft section of the fiche?

Yup, that's the critter right there.

[Giblet]

In 376 000KM I have never had, or heard of this malady on the GS before reading this thread, guess mine must have the black or silver uprated spline ring in the rear wheel, but I will certainly be checking when the wheel comes off.

Believe me, it is quite unerving when the hub adapter fails and you find yourself on (by my estimate) 800 lbs of motorcycle rolling backwards down a short but very steep slope. My incident triggerd a torrent of discussion about the topic. I replaced the 82 spline with an 80 spline and now have it sitting in my tool box just in case. My 81 1KG still has its original spline.

[Flyboy]

That's an impressive number of kms that you and your 1000G have clocked. How many engine rebuilds?

None, and still giving me 15Km/L on gas and using minimal oil, had the head and barrels off a long time ago to fix the typical GS base gasket leaking oil, but no parts ever replaced in the motor, that is why we love them, I could never part with her, we have been together too long.

Are you telling us that your rear splines have survived 376,000 kms without a drop of Honda Moly on them.

Yup, wasn't even aware of the spline issue until now, and I would not bring anything with the "H" badge on it anywhere near my bike, not even the RR

I presume that you have done your own maintenance from new. How often have you lubed the splines? What type of grease have you used?
Your '81 should have the black splines from new.

I bought the bike with 15 000Km's on, I was working as I motorcycle courier on a little GPZ 305 and it wasn't up to the job so I wanted something that would be reliable and cheap to maintain, so a chain drive was out, I rode approximately 800Km a day for 10 years.
I did my trade as a motor mech, and am clued up technically, so yes I did all my own maintenance, from when I owned it, being my bread and butter, I also looked after it, and made sure I did a lot of preventative maintenance.
I just used a common local moly type graphite grease, every time the wheel came off for a tire change, wich was about every 24 000Km, never pulled the wheel especialy to lube up the inside.

But sadly, the years of work are showing quite badly and a "frame up" rebuild is needed.
It will proberly cost me more than the bike will ever be worth, and I will over capitalise seriously, but she is my baby and we have come a long way together in the last 27 years, also don't know too many people who have owned one bike for that long, I just cannot see myself parting ways with her.
Watch this space for the rebuild thread.

[flyingace]

Since I have an '83 with almost 50K miles, this thread convinced me to remove the wheel/hub and take a look. Glad I did. The hub splines where at least 80% worn with only narrow ridges remaining. Fortunately, I have a spare '79 engine and chassis from which I took the hub and replaced it. I don't know how many miles the spare bike had, but the splines were like new. I have to agree that the design of these splines is under-engineered. They seem small for the power and weight of these bikes.

The purpose of this post is to re-empasize the point that you CAN"T diagnose worn splines without removing the hub from the wheel. A small fraction of an inch at the very front of the splines was not worn at all. This is the part visible when you remove the wheel, and it's easy to conclude they look like new. Don't assume.

[bwringer]

But sadly, the years of work are showing quite badly and a "frame up" rebuild is needed.
It will proberly cost me more than the bike will ever be worth, and I will over capitalise seriously, but she is my baby and we have come a long way together in the last 27 years, also don't know too many people who have owned one bike for that long, I just cannot see myself parting ways with her.
Watch this space for the rebuild thread.

If any of us worried about what our bikes were "worth" vs. what we've spent on them, we wouldn't own these wonderful old bikes and thrash them at every opportunity.

We look forward to the rebuild and lots and lots of photos. But please, make sure you post plenty of photos of your baby first with her well-earned patina of miles and years.

Are you doing a mechanical rebuild or are you planning a full cosmetic rebuild as well, with new paint, polishing, etc.?

[Flyboy]

Hi bwringer
I hear you, I am planning to tear her down, every last nut and bolt and rebuild from the ground up, internals as well as cosmetics, the plan is to bring her back to factory original, only better than factory new condition, of course this will probably be a long term project, as the finances dictate, I am not planning on salvaging anything that can not be brought back to mint condition, seeing as that I do not use her for working anymore, she can enjoy her well earned retirement, cruising around when the weather is good, purely to be riden when I feel like going for a ride.
Given the service I have had so far, she should out last me after the rebuild, I promise that I will post plenty pics. especially before and after.
But be warned, this is going to be a long term project, spares for these things aint cheap on this side of the pond, just got a quote for a new stator cover from the local Suz dealer here, 1600 bucks.

[flyingace]

Hi bwringer
I hear you, I am planning to tear her down, every last nut and bolt and rebuild from the ground up, internals as well as cosmetics, the plan is to bring her back to factory original, only better than factory new condition, of course this will probably be a long term project, as the finances dictate, I am not planning on salvaging anything that can not be brought back to mint condition, seeing as that I do not use her for working anymore, she can enjoy her well earned retirement, cruising around when the weather is good, purely to be riden when I feel like going for a ride.
Given the service I have had so far, she should out last me after the rebuild, I promise that I will post plenty pics. especially before and after.
But be warned, this is going to be a long term project, spares for these things aint cheap on this side of the pond, just got a quote for a new stator cover from the local Suz dealer here, 1600 bucks.

Flyboy - $1600.00 US dollars for a stator cover? I have a '79 stator cover I would be happy to sell for a mere $800.00 But seriously, don't kill yourself with those kinds of prices. Try Ebay or the for sale section of this site. I know a place in Seattle that I know will have one for about $40. These pieces can be buffed/polished until they look like new.

[Flyboy]

Hi flyingace
No jeeeez 1600 USD would be extortion, 1600 ZAR, that would be about 160 USD, I do keep my eye on ebay, but they are far and few between, and unless I can pick it up real cheap on ebay the shipping to this side of the world would kill the deal anyway, hopefully I am going to be over there for a week late July for the EAA Airventure at Oshkosh, I will bring a shopping list.
Looking for the original orange decal set, can't find anyone who has them, tried reproduction decals and a few others, not sure if you guys got it in the orange and black livery, have not seen any on the forums.