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XL600VJ Transalp Countershaft Wear / Worn Output
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TOPIC: XL600VJ Transalp Countershaft Wear / Worn Output

Re: Project XL600VJ Transalp 9 years, 1 month ago #1543

DanH wrote:


And my reply to that is, 'this whole project could be worthless without a serviceable output shaft'

You are quite right though, tiredness got the better of me last night and I wanted to give a bit of cometary to the pics so figure I would give the next instalment and include the photos tonight.

See www.adventuretrailrider.com/forum/40-pro...ect-xl600vj-transalp

Hope to pick this (above) up again soon thought in the meantime I've been out in the garage checking the splines on the output shaft that the front sprocket sits on. Having read reports that they are liable to wear, it's been on my mind almost since the day I got it, but I always figured that it would be ok given the relatively low mileage.

I should have checked this first in hindsight to give me some idea of what I was up against but only now I've started putting in some real time and effort did I decide that this should be a priority.

Well it was on my mind since the minute I woke up so it was to be the first job, well almost first job, i nearly tripped over the battery that was sitting in a ice cream tub charging in the conservatory so figured I would connect this first and see if she would crank over..

(Bit about battery moved to the main project thread)

Chuffed to bits with the fact that the battery was ok and while she was on the centre stand it was time to face the music and inspect the splines.

Off with the cover, slackened the rear wheel, removed the retaining plate then nervously slid the sprocket off the shaft...

Oh dear, not looking to good but need a second opinion so I will post the pictures here then on XRV then make a call from there though my first thought is that the splines have worn rather than started to sheer. So if I can cut 6 short lengths of piano wire that may well be hard enough to take up the slack yet soft enough to take future wear rather than what is left of the splines.

Any other thoughts very much welcome though if this doesn't hold, it looks like it could be time to split the engine and replace the shaft.













Last Edit: 9 years ago by East Coast.

Re: Project XL600VJ Transalp 9 years, 1 month ago #1552

DanH wrote:


Well it sounds to me like you will have plenty of oportunity to take pictures now

www.xrv.org.uk/forums/transalp/80413-ta6...lines-condition.html


It's engine strip down, split and rebuild time

Is your bench still free??

P.S. will follow up XRV thread tomorrow but i'm inclined to agree with all replies, especially Chad - then its ****ed

Re: Project XL600VJ Transalp 9 years, 1 month ago #1554

  • DanH
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I'm sure I can find room somewhere
Take the Byway not the Highway
The following user(s) said Thank You: East Coast

Re: Project XL600VJ Transalp 9 years, 1 month ago #1579

East Coast wrote:
DanH wrote:


Well it sounds to me like you will have plenty of oportunity to take pictures now

www.xrv.org.uk/forums/transalp/80413-ta6...lines-condition.html


It's engine strip down, split and rebuild time

Is your bench still free??

P.S. will follow up XRV thread tomorrow but i'm inclined to agree with all replies, especially Chad - then its ****ed


My two bobs worth...
The general consensus seems to be that it's half worn, so perhaps another 20 odd K left before failure?
Remember that these are best guesses based on pix, if possible is it practical to get hold of a new counter sprocket and offer it against the shaft; that way you're not guessing about how worn it is.
2 things, as above you can tell the wear, and you'll need one if you rebuild anyway.
THE END OF THE ROAD IS THE START OF THE FUN
The following user(s) said Thank You: East Coast

Re: Project XL600VJ Transalp 9 years, 1 month ago #1593

  • Boris
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If you want to put off rebuilding for a while then weld a new sprocket on. Don't get too much heat into the shaft as you will do in the gearbox seal. It's not as if the shaft is salvageable
The following user(s) said Thank You: East Coast

Re: Project XL600VJ Transalp 9 years, 1 month ago #1646

  • GB
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Boris wrote:
If you want to put off rebuilding for a while then weld a new sprocket on. Don't get too much heat into the shaft as you will do in the gearbox seal. It's not as if the shaft is salvageable


I was gona say the same thing, new sprocket welded on using a Mig to keep the heat localised.
Rather be loud than lazy......
The following user(s) said Thank You: East Coast

XL600VJ Transalp Countershaft Wear / Worn Output 9 years ago #2680

I've moved the relevant posts to here for clarity then will refer to this from the 'Project Thread'..

Re: Project XL600VJ Transalp 9 years ago #2683

Boris wrote:
If you want to put off rebuilding for a while then weld a new sprocket on. Don't get too much heat into the shaft as you will do in the gearbox seal. It's not as if the shaft is salvageable


GB wrote:
Boris wrote:
If you want to put off rebuilding for a while then weld a new sprocket on. Don't get too much heat into the shaft as you will do in the gearbox seal. It's not as if the shaft is salvageable


I was gonna say the same thing, new sprocket welded on using a Mig to keep the heat localised.


Thanks guys, I was heading toward this as a temporary fix though not having a mate locally who can weld to submarine standard could end up meaning that I've got to take the bike somewhere, leave it there, collect it, fork out an hour or so labour and have the risk of the seal been damaged and at the end of the day have at the back of my ming that the welds could give out on me. For the most part though, I have discounted this option from the point of view of not knowing someone who is up to the job.


Trevor Pastrami wrote:
East Coast wrote:
DanH wrote:


Well it sounds to me like you will have plenty of opportunity to take pictures now

www.xrv.org.uk/forums/transalp/80413-ta6...lines-condition.html


It's engine strip down, split and rebuild time

Is your bench still free??

P.S. will follow up XRV thread tomorrow but I'm inclined to agree with all replies, especially Chad - then its ****ed


My two bobs worth...
The general consensus seems to be that it's half worn, so perhaps another 20 odd K left before failure?
Remember that these are best guesses based on pix, if possible is it practical to get hold of a new counter sprocket and offer it against the shaft; that way you're not guessing about how worn it is.
2 things, as above you can tell the wear, and you'll need one if you rebuild anyway.


Cheers TP. I am in fact leaning more towards the 20 odd K being left in it.

My take on it is that the splines have worn.

To my mind surfaces only wear when there is friction between them.

In order for there to be friction, there needs to be movement.

As I understand it, some front sprockets have movement as standard. This design would require the shaft to be regularly greased to prevent wear.

Front sprockets and shaft mating where there is no movement like a tapered shaft with a bolt (not seen this in real life but using as an example) where a puller is needed to remove would have no movement and therefore no need to grease and no wear.

I'm just thinking that if I can minimise the movement then I can minimise the wear and hopefully get several thousand miles out of her before engine strip down time. I've also seen a post that makes a similar claim using thread locker to prevent movement and stem potential shaft wear.

I've heard of welding wire used to good effect to pack the gap.

So it's back to plan A for me and piano wire.

I'm desperate to get this bike on the road and see how I get on with her before I invest lots of time in an engine rebuild or custom paint job as I'd planned, so I think this is the way forward for now.

Oh and I also have a mate (Phonoplug) who's between bikes and keen to join us on the Safari so that's given me an extra bit of encouragement to get moving on it if not only so he can borrow it for the weekend and join in the fun
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