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PostPosted: January 4th, 2015, 3:31 am 
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Joined: October 18th, 2014, 11:45 am
Posts: 45
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
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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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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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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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Location: Essex...England
Attachment:
P1040772 - Copy.JPG
P1040772 - Copy.JPG [ 536.57 KiB | Viewed 1879 times ]
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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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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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
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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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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...

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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 RIP 8 June 2017, the bike my son was riding), '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
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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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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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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
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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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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 RIP 8 June 2017, the bike my son was riding), '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: 45
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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Location: Mackay, Queensland, Australia
Glad to hear it's holding up to the test of time and distance Andy.

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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: May 13th, 2017, 12:13 pm 
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Joined: October 18th, 2014, 11:45 am
Posts: 45
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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PostPosted: June 9th, 2017, 2:41 pm 
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Location: Essex...England
Nothing to do with biking i'm afraid ! ! ....Had the good weather and the good luck...My Passat is all fixed...hopefully for another 6 years
...Now i can do some bikey jobs that need doing too.....


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PostPosted: June 9th, 2017, 5:40 pm 
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Joined: June 12th, 2016, 2:38 am
Posts: 116
Location: Tauranga, NZ
Is it one of those VR engines? That´s a weird design, but seems to do the job ok as long as you keep up with the service schedule...

About the TA, what kind of rpm´s do you get with the sprocket combo at, say 80km/h, 100km/h?



Cheers!

neppi

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I'm from Finland, live in NZ and ride Transalp XL600VR 1995


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PostPosted: June 10th, 2017, 12:50 am 
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Posts: 45
Location: Essex...England
Hi...Same VW design as the VR, but only 204 bhp, VW's ridiculous idea !...that if you simply need a thermostat changed ? that the whole lot has to come off at the front end that's driving the cams, and all the front bumper bodywork too...to pull the slam panel forward to get in there ! Once you get passed the seized up fixings and bolts etc it's easy enough...BUT NEVER BUY A " VW " CAR WITH A 2.8 V6....Bikewise..I will get back to you soon with exact RPM figures after a ride...also got a 130/80 rear tyre instead of the 120/90 which has a lesser rolling circumference as well...I much prefer it over standard...but i'm on the heavier side at 17.1/2 stone...if you pillion it would help loads...and the rear sprocket is a standard early Africa Twin 49 tooth, i wanted larger but had no luck finding anything else.


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PostPosted: June 11th, 2017, 1:30 pm 
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Joined: October 18th, 2014, 11:45 am
Posts: 45
Location: Essex...England
Hi Neppi...at 80 km/hr it's 3900 rpm....100 km/hr is 4900 in top gear with a half worn 130/80/17 metzeler tourance tyre on the back...you get about 20.3 km/hr per 1000rpm in 5th...and about 17.6 km/hr in 4th per 1000 rpm. In 4th at 100 - 120 km/hr your right on the max torque rpm..with the horse power kicking in too..so at our max limit over here in England at 70 mph it gives a healthy tug...Dont ask what top end mph is as i never have and never will know..all i can say is it is more responsive throughout and can now just about plod along at 48 km/hr ( 30 mph ) in 4th gear...and gives about 5 mph per 1000 rpm ( 8 km/hr ) in 1st gear....Hope this is of some help....still get very good mpg....


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PostPosted: June 11th, 2017, 2:57 pm 
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Location: California USA
FWIW, I had my TA out in the dirt a week or so ago and when I do that I put on my wheels with the knobby tires. The back wheel uses a 510-18 tire. I also change the counter shaft sprocket to a 14 tooth. That all said and done, at 4500 RPM I'm doing about 58 MPH (93km). At one point I came to a long straightaway and opened it up. Got it up to 95 MPH (153km) and it didn't matter if I was in 4th or 5th, 95 was as fast as it was going to go. I was also at 5500 feet (1676m) elevation so it might be faster down here at Sea Level.

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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: June 11th, 2017, 8:38 pm 
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Location: Tauranga, NZ
I'm running 16/47 and that's perfect for the highway, but quite annoying offroad. I'm getting a new chain with my swingarm swap and I'm thinking of going back to stock...

Has anyone ever added a few links to the chain? I've still got the piece I cut off the chain when I changed it, not too many thousands ago. If I'd get a couple of rivet links I'd get the job done with a few bucks! Ü

N

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I'm from Finland, live in NZ and ride Transalp XL600VR 1995


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PostPosted: June 11th, 2017, 8:39 pm 
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Location: Tauranga, NZ
Oh, and Thanks for the specs guys!

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I'm from Finland, live in NZ and ride Transalp XL600VR 1995


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PostPosted: June 16th, 2017, 4:56 am 
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Why add a few links when you can easily remove one or two teeth from the front sprocket without the need to shorten the chain. I have run two different front sprockets in the past. 16 to 47 for my 80km round trip work commute, then 14 to 47 for diirt roading and heavy long trips.
It worked well and 2 off the front equals an extra 6 on the rear, and the chain will adjust for those 2 until the last 1000km, when it will start to stretch like the elastic in an old pair of jocks and you'll know it's time to order a new set.

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


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PostPosted: June 16th, 2017, 2:23 pm 
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Location: Essex...England
Jackflash...When i did my repair jobby i did not find anything smaller than a 15 front and nothing bigger than a 49 rear...unless i dropped down to a 520 chain...more teeth..less wear...i wanted to go 16/53..so it lasts as long as possible...would still go bigger on the rear if i could and no choice now on the front...do they do a better selection in Oz ? but would want steel and 525....cheers...Andy


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PostPosted: June 17th, 2017, 8:55 am 
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I know for sure that 14, 15 and 16 tooth front sprockets are available because I have them all. I thought at one time a 53 tooth rear was available, but I'm not seeing it now. SuperSprox.com will make you a custom rear sprocket.

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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: June 17th, 2017, 11:14 pm 
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Location: Mackay, Queensland, Australia
andy stannard wrote:
Jackflash...When i did my repair jobby i did not find anything smaller than a 15 front and nothing bigger than a 49 rear...unless i dropped down to a 520 chain...more teeth..less wear...i wanted to go 16/53..so it lasts as long as possible...would still go bigger on the rear if i could and no choice now on the front...do they do a better selection in Oz ? but would want steel and 525....cheers...Andy

I haven't tried getting a 14 since going back to the standard 525 chain. I ran 520 for years, and since going back to the 525 I know that front and rear suspension need overhauling, so I won't be doing bothering with the lower gearing until that is sorted. That said I thought the 525 had a 14 tooth available here in Oz from whichever sprocket suppliers my preferred bike shop uses.

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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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