Has anyone rebuilt a final drive? Does it take special tools like the manual says? Can one make do?
I have two or three posts describing the clunk in my bike. Short story, it began with a clunk as I let out the clutch when shifting from 4th to 5th, then whenever shifting up from any gear. Now I can get the clank after slowing to enter a curve when I increase the throttle to exit the curve (even with no braking beyond engine brake). This progression has unfolded over about 4 to 5,000 miles (the bike has less than 30K on the clock)*. As I said in other posts, my mechanic heard the clunk with his stethoscope at the final drive and suggested it might be the splined drive shaft or U-joint. I pulled the pumpkin, checked everything visually, and re moly-ed the splines. U-j felt fine. No difference in noise after reassembling the bike.
Kevin - the mechanic - pulled the final drive and says there is excessive play between the pinion and drive gear but they show no excessive wear patterns. Splines look fine, U-J shows no excessive play. He does not have the special tools to rebuild the unit, and a dealership has quoted in the 5 to $600. So, I found a final drive on e-bay and will see if this gamble will pay off. I don't want extended down time on the bike now, but I might rebuild my final drive if possible in the next year or so.
*And yes, I know this part never goes bad this young - but then, the maladies I suffered on two Econolines "never happen to Fords" either.
I have two or three posts describing the clunk in my bike. Short story, it began with a clunk as I let out the clutch when shifting from 4th to 5th, then whenever shifting up from any gear. Now I can get the clank after slowing to enter a curve when I increase the throttle to exit the curve (even with no braking beyond engine brake). This progression has unfolded over about 4 to 5,000 miles (the bike has less than 30K on the clock)*. As I said in other posts, my mechanic heard the clunk with his stethoscope at the final drive and suggested it might be the splined drive shaft or U-joint. I pulled the pumpkin, checked everything visually, and re moly-ed the splines. U-j felt fine. No difference in noise after reassembling the bike.
Kevin - the mechanic - pulled the final drive and says there is excessive play between the pinion and drive gear but they show no excessive wear patterns. Splines look fine, U-J shows no excessive play. He does not have the special tools to rebuild the unit, and a dealership has quoted in the 5 to $600. So, I found a final drive on e-bay and will see if this gamble will pay off. I don't want extended down time on the bike now, but I might rebuild my final drive if possible in the next year or so.
*And yes, I know this part never goes bad this young - but then, the maladies I suffered on two Econolines "never happen to Fords" either.