Drivetrain breakdown

[AussiXS11G]

I have a spare swingarm - and diff too I think
I need a fuel tank.....
0404540617
Bryan

[Eveready1100]

Hey Grant, any chance of getting some photos of the flogged out bits?

[coe1948]

    I have got a bit of XS1100 stuff,i would have what you need send me a list of what you need to replace i am in Dandenong Vic

   Regards Dale

[melbxs]

The other place you might get one is for, Fungorous, he has broken several xs's.


Email-     salvaged_cycles@yahoo.com.au
Carl Britton    Phone- 0408 590 580

In Tassie, so postage should be OK too. Top bloke, very reliable.

[melbxs]

Plenty on EBay in the states.

http://shop.ebay.com/i.html?_from=R40&_trksid=p5197.m570.l1313&_nkw=xs1100+shaft&_sacat=See-All-Categories

Just make sure that they are happy to ship to Aus at a decent price before you buy.

Also, you could try Andreas on the XS11 USA site. He always has bikes to break. His prices are good and he is very fair on postage.

http://www.xs11.com/forum/member.php?u=42

I got my TCI from him and he was a pleasure to deal with.

[Aussiexs11]

first thing I say thanks to all who offered thought, but I have the answer , discovered today when the swingarm/ drive was opened and removed.
The drive shaft (approx 10inches long) and the cup holder piece (dont know the names) are shagged, the splines srtipped totally.
How? They had been lubed but they failed.
mechanic says "never seen this before" but it happened.
So my next question - ANYONE GOT ANY BITS?? Please call me if you can help and let me know what you would want$$ wise. My mobile 0427 406003. Need them ASAP.
When I get the part numbers or better descriptions I will advise but mechanic says anyone who has had this area dissasembled will know what Im referring to.
So thanks for all the comment, but now Im on the hunt....

[steptoe]

things I,d be looking at 
      #1 on the centre stand, in gear, grab the rear wheel, roll back and forward and see if you can make it clunk,, sitting beside it you may be able to locate the noise

      #2  it,s obviously drive but which bit, starting from main clutch nut thru to diff,  I'd start at the diff,, the middle box drive splines are enormous and aren't going to "strip", not with out some god-awful treatment, and the bearings arent going to cause slipping, they'll lock up, the flange bolts won't grip and slip,

       #3  jonesy might be onto something, if those smaller splines haven't seen lube in a while

but the diff is full of large area finer splines, and being on the end of the power train it's last to get the big power,, but first to get smashed by back lash on de-cell,,and the wheel trying to change angles under heavy cornering,, where also a very worn bearing will have more influence to what stays in place and what moves around,

       #4  seperate the drive shaft at the flange,, that will help, turn the middle box and listen,, redo the bolts up then put a rake handle or some thing more solid thru the rear wheel and turn the shaft, the prob should show itself
just my 5 cents worth
                               

[melbxs]

Copy of that manual here:

http://www.ringler.us/xs1100/ShaftDriveManual.pdf

[Jonesy]

If it does turn out to be the middle gear and you want to rebuild it
PeteJW posted an excellent link in the last couple of posts in this topic below
http://xs1100.com.au/forum/index.php?topic=1030.0

[Fred]

Mate,

if the worst comes along and it is the middle gear case then take it to someone who knows the rebuild process. An older yamaha dealer with an even older mechanic would be good (bellylaugh).

It needs some special tools and the correct measurements for shimming back up. I had mine rebuilt a few years ago and when it came back out of the Yamaha shop it sounded like it had a turbo installed, it whistled and whined that badly. I asked the mech to what tolerances he had reshimmed the splines and of course he said "WHAT SHIMS?"

If you need to go down that road get yourself the 'Yamaha Shaft Drive Service Manual', part number '1J7-28197-19' and take it with you to show the mech.
It's not a cheap fix at about $700 and if that's an issue you might consider a second hand one. Personally though, when it comes to essential moving parts I tend not to buy someone elses troubles.
My manual is available for loan to any member who needs it.

[Jonesy]

I'll stand corrected if I'm wrong....But, the hardend gears in middle drive box generally wont just wear out and fail without some warning signs developing over an extended period of time, such as metal glitter in your used oil when you drop it for an oil change or exaggerated backlash rotating the back wheel back and forth during a routine check
On the other hand even though the drive shaft splines are hardened they are for some reason more prone to wear, and generally goes undetected as its one of those items that rarely get any attention.
A previous bike I owned had the spline worn down to resemble something more like the teeth on a circular saw and werent far off total failure when I had to go searching for a replacement.
And just my opinion but what you described is how the final total let go would unfold.

Whatever it turns out to be....its still a real dissapointment and a pain in the A

[Eveready1100]

I'll hazard a guess at the middle drive gearbox. That's what I'd imagine it would sound like as it failed.

[Jonesy]

1)worn out spline(s) on drive shaft?
2) worn out spline from final drive to back wheel?

what a s#$t way to spend your between job brreak ......and how K'n cold was it?

If I can help at all you've got my number.

[Aussiexs11]

Well,
heres an epic and hopefully not too expensive tale.
I was heading out for a 3 day unscheduled adventure prior to starting a new job, loaded the bike (minimally -1 change of clothes) and fuelled up and pointed west to the warm(or so I thought.)
Left Lithgow with thermals well fitted, headed to orange (even colder!) and as I came into Orange under decelleration head a very unusal "clunk, clunk" from the drivetrain.
Kept riding wondering what the??
Got into Orange into city trafic back through gears and under decel /slight accel the clunk got a little worse then stopped.
Im now wondering what has happened. So I stopped, checked rear wheel, looked for any major issues, saw none. mmmm so I kept moving wondering. Anyway all was good heading to Molong, then under accelleration very momentarily I felt something akin to when a chain slips on a push bike on worn cogs. Now major mmmm.
So I stopped in Molong and checked middle drive oil /final drive oil, read wheel movement etc, no smells, no discolouration , no movement in wheel.
I decided to head back to orange . No further adventure travelling yet.
It clunked and "slipped" once on way back.
Now my sister lives in Orange so I stopped at hers and did all checks again, then bravely (or stupidly) decided that I would head back to Lithgow to fully investigate.well, as Murphy dictates, 30klm outof Orange in the sleet and approaching dark, as I accellerated up a rise, the engine kept reving and the drive stopped but with an awful clunk /rotating sound. I pulled in clutch and noise stopped (a new clutch by the way) and the bike changed back through the gears to allow me to find neutral. Now the network kicks in and I call a mate in sydney whos father in law lives in orange comes to the rescue and about an hour (in the sleet) later picks me up and transports me and bike back to Orange.
Now the bike is back in Lithgow and I have to diagnose issue.
I think its a broken middle drive (and thankfully I have a spare), but its now I throw this open to all for some thought- what has happened. Im thinking everything from a primary gear, to middle drive to coupling of middle /shaft. I have it with a good friend and yamaha mechanic to open up, so I will find the issue but let me know what you guys think.I will keep you all advised. I may even need to call on someones stock of parts if its a really big issue.
So my adventure closed, but bloody hell, I think it now begins.