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PostPosted: January 4th, 2015, 3:31 am 
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Joined: October 18th, 2014, 11:45 am
Posts: 34
Location: Essex...England
I can confirm if anyone wants to know, ? that it is very,very, difficult, but possible to drill and tap an XL600v Transalp gearbox output shaft to M6 x 1mm standard metric thread. I have done so ! to depth of 19.5mm. with the shaft still fitted. Special tools are required though, and ordinary drills will not even scratch it.....and if your not into engineering in quite a big way do not attempt it....Andy


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PostPosted: January 5th, 2015, 10:02 am 
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Joined: July 6th, 2011, 9:15 am
Posts: 86
Location: Gardnerville NV
Thanks for posting. Some folks might find themselves in this very same situation. Good option.


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PostPosted: January 15th, 2015, 7:56 pm 
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Joined: May 27th, 2013, 6:09 pm
Posts: 60
Wow. It's case hardened, isn't it? And why did you need this?


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PostPosted: January 16th, 2015, 8:07 am 
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Joined: October 18th, 2014, 11:45 am
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Location: Essex...England
Hi...JWB...I don't like the method Honda and a few other manufacturers ie Kawasaki, Suzuki some small Yamaha's use to hold on the front sprocket on SOME of their bikes, and decided to change it completely. The splined washer idea wears out the washer teeth, allows more movement on the shaft, increasing wear. I only put this posting on as someone said it cannot be done...not easy...but can be ! ! ...look at vrx site / transalp / knock knock knocking posting....ME...some pictures and write up on there to see why...and yes...I DO KNOW THE SPROCKET IS SUPPOSED TO FLOAT SIDEWAYS....mine now will not, it's not being thrown about, and the chain alignment is spot on perfect, it not a race bike.....Nice question though..WHY ?...BETTER ANSWERED WITH PICTURES....cheers for the interest...HAVE A LOOK......Andy


Last edited by andy stannard on March 28th, 2015, 11:11 am, edited 1 time in total.

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PostPosted: February 17th, 2015, 2:54 pm 
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Joined: October 18th, 2014, 11:45 am
Posts: 34
Location: Essex...England
Attachment:
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Hi All...Transalp superwide front drive sprocket fixing modification all back together, finished off and drives lovelly..if any body wonders what I am on about..see xrv.org.uk or adventuretrailrider sites...I don't know how to put pics on here but am trying....


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PostPosted: February 17th, 2015, 7:48 pm 
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Joined: July 8th, 2011, 7:02 am
Posts: 945
Location: Mackay, Queensland, Australia
Hi Andy, I bought my '03 650 new in '04 and have done over 140,000km on it. I've had no trouble with the front sprockets and the securing washer in that time, but then I've been the only owner and already knew about road bike mechanics setting the chains of these types of bikes toooo tight. I think that's what I was told is the main cause of the this problem.

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Born to be MILD
2003 Honda XL650V Transalp; 1977 Kawasaki Z750B twin;
2006 Hyosung GT250R; 2001 Yamaha FZS1000.


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PostPosted: February 18th, 2015, 3:02 pm 
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Joined: October 18th, 2014, 11:45 am
Posts: 34
Location: Essex...England
Hi Jackflash.....at last some interest, and all the way from OZ. Yep chain slack too tight seems to be what causes shaft wear...only had my machine a year and I set slack to much more " plus 10mm " more than the recommended maximum in the manual...so not caused by me ! BUT i have fixed it nicely, and posted it up so others can have a go at it if required after finding any wear like I found on mine...hopefully it will last a very long while...and outlast my biking time.....


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PostPosted: February 19th, 2015, 4:03 pm 
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Joined: February 4th, 2006, 6:26 pm
Posts: 1245
Location: Champaign, IL USA
Your the man! Love your safety wiring! But, if you didn't catch a sharp end and bleed when you did the wiring it won't take...

_________________
Garry Bird, YMRacing, Owner/Mgr.
AHRMA, CCS #72
'89 TA, 06 Ducati Sport 1000 Bella Boomer the race bike, '76 XS650 Farrah the race bike, '76 RD400 Evil Spawn the race bike, '97 Buell T-Bolt S2, '97 Dyna-Conv, '06 KLR 650 off road hooligan, and a '79 GS1000E (sold 25 March 2017 after 30 years of ownership), but ride the TA the most miles!


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PostPosted: March 28th, 2015, 11:08 am 
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Joined: October 18th, 2014, 11:45 am
Posts: 34
Location: Essex...England
Bikes now done 400 mile since my shaft fix and putting it back on the road 7 weeks ago...Took it mega easy for first 100 mile and gradually increased the right wrist use, to check it all out...Had it accelerating flat out yesterday on a few slip roads to join some really quick " evil, nasty; bike hate'ing bastards in cars....and it has all held together...didn't like giving it that treatment, but the other choice was hospital food and some broken bones and a smashed bike. The 49 tooth rear end really came in handy ! and this thing is definitely faster off the mark. It's actally doing more mpg around town and on my short 5 mile run to work, but has lost a couple at a nice comfy 70mph......still averaging 56 mpg though...LOVELY.


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PostPosted: May 18th, 2015, 8:47 am 
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Joined: October 18th, 2014, 11:45 am
Posts: 34
Location: Essex...England
Done 1000 mile now ! so my " extra wide drive spline " front sprocket modification is doing A+ OK. I am surprised though: at how little interest " my fix " has had. My spline had only minimal wear, so did not require large shims, and had a chance for a new life....but I have seen some major problems with images on google...perhaps all them bikes have either been run into the ground and eventually scrapped, or the sprocket welded on to prolong the problem down the road a bit, or maybe the shafts have been replaced ? with a lot more effort put into a proper fix it job....but see...www.xrv.org.uk/forums/transalp/knock-knock-knocking... for the rest of my pictures of what I done .. because it has done the job !....might bore the crap out of you though...unless of coarse you find a similar problem with your bike ?


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PostPosted: May 19th, 2015, 8:35 am 
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Joined: July 14th, 2014, 4:55 pm
Posts: 303
Location: California USA
Andy,

I think what you have done is very impressive. I think most of us here at Transalp.org know what causes shaft wear and how to prevent it (or at least slow it down). I change my sprockets and chains frequently because I ride mostly off road so besides changing for wear I also change for different ratios. I use a 13t-16t on the front depending on what kind of riding I'm going to be doing.

But most of us don't have access to carbon drills and jigs. For myself in the time it took you to do all of of your modifications, I could have pulled the motor and replaced the shaft and refreshed the rest of the engine. But I'm a Honda mechanic and not an Engineer and that is what I do best.

I would like to see a brand new shaft drilled to fit a 10mm bolt and use that (and spacers of coarse) to hold the sprocket in place like on the CRF450. Do you think it would be possible to drill the shaft to 10mm?

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Ride Now, Work Later!

89 Transalp XL600V X3, 01 Goldwing GL1800, 99 Varadero XL1000V
05 CRF450X Plated, 01 XR650L, 84 Passport C70


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PostPosted: May 19th, 2015, 12:45 pm 
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Joined: October 18th, 2014, 11:45 am
Posts: 34
Location: Essex...England
Hi Skyliner....No chance for an M10 thread, not even enough shaft diameter to risk an M8. That's why I went for the M6. There would be no metal left to maintain the strength of the shaft and it would just rip it apart. The solid part of the shaft under the splines on a Transalp is only 21mm and it's softer inside. Luckily I wont be doing lots of cog swopping for varying uses etc and have settled for medium final gearing, a bit more revvy with the extra two teeth at the back. Which i prefer ! I have never had a bike engine in bits and would probably screw it all up...the engines fine at only 30 K, shame previous owners or mechanics set the chain slack to tight, and luckily the bearing and seal are good. I done loads of car engines though, and a generator; but gearbox's scare me after two failed attempts at changing synchromesh gears in old ford and triumph gearbox's back in the 70's....The fix I did was not too many man hours, as I just played " grovelling on a cold floor " in the garage in the cold winter, doing a lot of fiddling and taking my time staying out of the family's way. Hopefully it will come apart easily enough when I want to fit my spare front sprocket when it wears out in about 7 years time, and all the shim bonding will stay intact...Who knows ? ? I might be instructing the grandkids how to do it for me ? or for themselves if I give up on biking, as i'm nearly an OAP. If I ever came to sell the bike I reckon I would have a very bad time convincing a prospective purchaser that it was a good one under that cover...and what would your buddies in your workshop do if such a modification came in for a new chain and sprockets ? Think my name would stink a teeny weeny bit....Thanks for the post....Stay safe....Andy


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PostPosted: October 9th, 2015, 12:06 pm 
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Joined: October 18th, 2014, 11:45 am
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Location: Essex...England
Shaft fix is well tested out now, 8 months and 2200 mile later. Have ridden hard and harder...NO WHEELIE CRAP THOUGH...just normal biking stuff; but these machines are not quick and when riding with machines with double or triple the power you have to give it a little bit extra to keep up....and it's all still perfect so i'm chuffed to bits....


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PostPosted: October 9th, 2015, 4:39 pm 
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Joined: February 4th, 2006, 6:26 pm
Posts: 1245
Location: Champaign, IL USA
andy stannard wrote:
Shaft fix is well tested out now, 8 months and 2200 mile later. Have ridden hard and harder...NO WHEELIE CRAP THOUGH...just normal biking stuff; but these machines are not quick and when riding with machines with double or triple the power you have to give it a little bit extra to keep up....and it's all still perfect so i'm chuffed to bits....

As well you should be! :clap: :clap:

_________________
Garry Bird, YMRacing, Owner/Mgr.
AHRMA, CCS #72
'89 TA, 06 Ducati Sport 1000 Bella Boomer the race bike, '76 XS650 Farrah the race bike, '76 RD400 Evil Spawn the race bike, '97 Buell T-Bolt S2, '97 Dyna-Conv, '06 KLR 650 off road hooligan, and a '79 GS1000E (sold 25 March 2017 after 30 years of ownership), but ride the TA the most miles!


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PostPosted: July 1st, 2016, 4:04 pm 
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Joined: October 18th, 2014, 11:45 am
Posts: 34
Location: Essex...England
Hi all...over 3000 mile now...front sprocket fix is still all good...and i shouldn't say this...but with the 49 tooth rear end and standard 15 front...that front wheel " can lift " while trying hard to keep up with the mates much bigger beasts...even with my 17 stone on the thing and ! practically on the tank...it shocked me ! ! too !...but i was giving it some....buddies do have R1, ZZR1100, CB1000r...so i'm a bit under powered at times with my massive 50 bhp....


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PostPosted: July 2nd, 2016, 5:04 am 
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Joined: July 8th, 2011, 7:02 am
Posts: 945
Location: Mackay, Queensland, Australia
Glad to hear it's holding up to the test of time and distance Andy.

_________________
Born to be MILD
2003 Honda XL650V Transalp; 1977 Kawasaki Z750B twin;
2006 Hyosung GT250R; 2001 Yamaha FZS1000.


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PostPosted: May 13th, 2017, 12:13 pm 
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Joined: October 18th, 2014, 11:45 am
Posts: 34
Location: Essex...England
Hi all....Still here and Transalp'ing, and reading the posts on here... Same XL600v, and all is still excellent with my spline repair jobby...done over 5,000 mile since the fix and the bike is wearing a damn site better than me...am using it a bit more than i normally would at the moment as one of the cars ! a " V6 Passat 2.8 " needs a water pump and cambelt change that i have been pushing my luck with for about the last 2,000 mile...No garage room as full of useful stuff ; so waited for the good weather...NOT A NICE JOB..But i managed a V6 quad cam Vauxhall cambelt a couple of year ago...Need some good luck and sunshine very soon.....


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