Primary Drive / Final Drive / Drive Shaft connection to Primary Drive...

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Aug 23, 2022
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Hi Guys,

Okay, you're gonna think I'm nuts... That's okay. No need to reply with, "You're nuts, forget it!!"

I am looking into the possibility of changing gearing on the st1300 so that ALL gears are taller. I've posted my logic for this before. Quite simply, this is a Honda motorcycle made in Japan by people with an insular type of thinking (I married a Japanese, I lived in Japan, I speak/read/write fluent Japanese, I understand their culture better than a whole lot of books on the subject). Honda makes their motorcycles with ridiculously short gearing, which is great for their main roads which go up to 80kph (this is a fast road) except for the toll highway system, which are not often travelled by motorcycles. For other international roads where 100-140kph is a desirable cruising speed, the gearing is way too short. Agree with this or disagree with this, it doesn't matter. Many (most?) cars are designed to run on the highway at 110kph near 3000rpm for ideal fuel economy and for not over-stressing the engines. Our motorcycle basically has a car engine! It should have been designed with gearing such that 100kph yields nearer to 3000rpm.

At any rate, presently I'm in discussions with a specialty machine shop that does work with automotive gearing. The EASIEST to access for changing gear ratio is the final drive. I bought a used final drive to work with for this purpose. But, the gear design/manufacture for a worm gear and ring gear (I think that's what they're called) is more challenging than simpler "cog" style gears.

I was looking in my Honda repair manual, but I cannot see how the front end of the shaft connects with the engine-unit's primary drive.

Questions: Does the front end of the shaft hook onto the output of the engine primary drive with a 1-to-1 ratio (ie: it just locks in and is co-axial with the final drive output shaft)...?

Or, does the front end of the shaft hook to the engine output shaft via a gear system...?

It seems as if I were to attempt to have custom made "cog style" gears for the primary drive, the engine/transmission cover would have to come off for access, meaning the custom alteration would prove more troublesome than changing the final drive gears only.

Again, I don't need nay-sayers telling me I'm nuts. I'm just looking for information.

And FYI... I altered my 2003 Shadow Slasher 750 (yes, a Shadow "Slasher") with first a different chain gearing, then I purchased a custom-gear ratio belt drive kit for the motorcycle. The change in gearing made ALL THE DIFFERENCE in the world. Changed the bike from high revs in 5th gear at 100kph (about 4500rpm if memory serves correctly) to comfortable revs (about 3250rpm) at the same speed. I had to sell the bike when I left Japan so I don't exactly remember the revs. But this vastly improved in-town driving (didn't need to change from 1st gear to 2nd before 10kph), and vastly improved highway driving as well.

The st1300 has the exact same "short gear" syndrome!! In town, for ideal rpm's I wanna change from 1st right in the middle of a turn from a stop-light or stop sign. And I'm busy changing gears - into 4th and 5th gear at 50 and 60kph. Absolutely ridiculous!!

This is my biggest complaint about this bike. It is a GREAT bike! No bike is perfect. But this one is close to it! (If it could shed 100 lbs that would be nice, too!)
 
I'm intrigued, although it sounds like a GW with a DCT may solve the same issue for you. Can I assume you don't have a service manual? Here are a few shots of the final drive. Seems changing the two gears we all Molly when removing the wheel would work and these two gears would be the easiest.

IMG_4885.jpegIMG_4886.jpegIMG_4887.jpegIMG_4888.jpeg
 
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I hope asking a question doesn’t label me a naysayer. What makes you think the ST series was designed for the Japanese home market? There is evidence that the ST was designed for the European market with its high speed roadway system. The seed for the ST was sown by Honda of Germany who wanted a bike to compete with BMW.

The desire to lower the final drive ratio is shared by some Goldwing enthusiasts which is where I first heard of Henry’s Final Drive.

 
I'll just sit back, sip a cold one (I wish) and watch this pan out.
As have some here, I've often wished for a taller 6th gear for interstates, but not to the point I'd be willing to undertake such a daunting task.
So I'll watch from a safe distance, because I find this interesting.
 
Me too, I sure do miss that 6th gear and the lower rpm at freeway speed, around 70 to 80 the mileage could be better. But if I was serious about that concern I should have bought a smaller bike
 
I understand what your trying to do. You can split the trans case and change the input gear and counter shaft gear that should get taller ratio across the board. Changing the ring and pinion in the final drive would be easier but where would you get the gears? Pinion depth is important setting it up wrong would cause premature failure and noise. There is no easy way. Just get a taller tire instead of an very expensive experiment.
 
One thing that I have noticed since I began riding a KLR which needs higher revs, is that I now am running higher rpms on everything else. The ST doesn't seem to mind it much. The throttle response is crisper and engine braking is firmer. The top end is not lacking in speed. I think I got used to short shifting and keeping rpm down because this engine recovers at almost any gear at any speed
 
The drag coeffeicent is almost double on a normal motorcycle versus a car.

You might wish to have a bike that turns 2000 rpm at 70 mph but it won't work quite like you expect. To go 70 mph takes more horsepower on a bike than it does a car because bikes have so much more drag. Bikes are terrible in the drag aspect compared to a car. If you double the speed (of a car or bike or an airplane) drag goes up by 4 times. It takes 4 times more power to go 70 compared to 35. Or said in hp, 25 hp at 35 requires 100 hp at 70.

And it's been tried with the Honda Valkyrie. Valkyries have near the same rpm's at speed as an ST1300. A company called "Mario" made gears for Valks (2001?) with a lower final gear ratio (700? lower rpm at 75). It required splitting the engine into halves for gear replacement, lots of work. most who bought and installed the Mario gears took them back out. It was not better than what Honda designed. The bike didn't have the power to pull the higher gear ratios and did not have an improved mpg.

But go ahead and try.

I get near the same gas MPG at 80 as I do 70 mph. Around 44 mpg at 70 and 42 at 80. 387,000 miles of real time experience.
 
Nobody has directly answered your questions, but the answer is in the Service Manual. The output shaft from the motor drives the U-joint, and the drive shaft has a splined end that fits inside the aft end of the U-joint. This is direct drive, with no gearing. No idea what is inside the engine cases. Having pulled apart a final drive, I've seen how little extra room there is between the pinion and ring gear and the cast aluminum case. Changing the gear ratio will require diameter changes in these two gears and I'm not sure you have the room to make these mods.

As you noted, these are not simple bevel gears but spiral bevel gears. This is what wikipedia has to say:
"A spiral bevel gear is a bevel gear with helical teeth. The main application of this is in a vehicle differential, where the direction of drive from the drive shaft must be turned 90 degrees to drive the wheels. The helical design produces less vibration and noise than conventional straight-cut or spur-cut gear with straight teeth.

A spiral bevel gear set should always be replaced in pairs i.e. both the left hand and right hand gears should be replaced together since the gears are manufactured and lapped in pairs."


Changing gears in the transmission might be easier.
 
Nobody has directly answered your questions, but the answer is in the Service Manual. The output shaft from the motor drives the U-joint, and the drive shaft has a splined end that fits inside the aft end of the U-joint. This is direct drive, with no gearing. No idea what is inside the engine cases. Having pulled apart a final drive, I've seen how little extra room there is between the pinion and ring gear and the cast aluminum case. Changing the gear ratio will require diameter changes in these two gears and I'm not sure you have the room to make these mods.

As you noted, these are not simple bevel gears but spiral bevel gears. This is what wikipedia has to say:
"A spiral bevel gear is a bevel gear with helical teeth. The main application of this is in a vehicle differential, where the direction of drive from the drive shaft must be turned 90 degrees to drive the wheels. The helical design produces less vibration and noise than conventional straight-cut or spur-cut gear with straight teeth.

A spiral bevel gear set should always be replaced in pairs i.e. both the left hand and right hand gears should be replaced together since the gears are manufactured and lapped in pairs."


Changing gears in the transmission might be easier.
The drive shaft spline is connected the output shaft thats driven by the transmission counter shaft. Ring and pinion gears do not change size with different ratio's. Back in the muscle car era everyone would pull out the stock 3.23 diff gears and put in 4.11 and even 4.56 gears. gears are same diameter the teeth are a little closer together. Honda gear sets are about $300 so I can't imagine what it would cost to have a gear set custom made.
 
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The drive shaft spline is connected the output shaft thats driven by the transmission counter shaft. Ring and pinion gears do not change size with different ratio's. Back in the muscle car era everyone would pull out the stock 3.23 diff gears and put in 4.11 and even 4.56 gears. gears are same diameter the teeth are a little closer together. Honda gear sets are about $300 so I can't imagine what it would cost to have a gear set custom made.
This does not make sense to me, Al. Think of two gears (not bevel), the driver and driven (output) Changing the number of teeth does not change the output speed except maybe the amount of power transmitted. You have to change the relative diameters if you want the output (driven) gear to turn at a different speed for the same rpms as the driver.

The numbers you posted are the ratios of the two gears diameters (number of turns).
 
This does not make sense to me, Al. Think of two gears (not bevel), the driver and driven (output) Changing the number of teeth does not change the output speed except maybe the amount of power transmitted. You have to change the relative diameters if you want the output (driven) gear to turn at a different speed for the same rpms as the driver.

The numbers you posted are the ratios of the two gears diameters (number of turns).
you haven't worked with rear differentials. When I say a 4.11 gear that means it's a 4.11 to 1 gear set. This is a link for Ford 9 in gears, all the ring gears are 9 inches yet look at all the different ratios. Look how the gears are made. They all fit in the same carrier. https://www.summitracing.com/search...ars?N=differential-case-design-type:ford-9-in
 
This does not make sense to me, Al. Think of two gears (not bevel), the driver and driven (output) Changing the number of teeth does not change the output speed except maybe the amount of power transmitted. You have to change the relative diameters if you want the output (driven) gear to turn at a different speed for the same rpms as the driver.

The numbers you posted are the ratios of the two gears diameters (number of turns).
The pinion diameter does change but the OD of the ring does not.

373-vs-410-gears_a8ba5e32.jpg

From left to right - 2.73, 3.07, 4.10, 4.88. below.

pinion_compare.jpg
 
you haven't worked with rear differentials.
Correct, I have not. What I said was the only way you can change the ratio is by changing the relative diameters - that is what the ratio is.
Ring and pinion gears do not change size with different ratio's.
This is what you said that is wrong, in light of your later post showing different diameter pinion gears. So the ratio of diameters does change.

Bottom line, having stripped a final drive, there is not a lot of room inside the chamber for a larger pinion. I would guess that changing the ratio in a differential requires changing the shims on the ring gear to move it farther away or closer to the pinion. I don't know if there is sufficient room inside a Honda final drive to do that.
 
The problem will be in the clearences of the ring and pinion in the gearcase. IDK if there's enough room the box. Interesting to know how this turns out....
 
I went out for a 750 KM (465 mile) ride today. Part of that ride found me doing about 200 KM (125 miles) of major highway on the way out and on the way back that allowed me to ride at consistent speeds over long distance. During those two portions of the ride I was thinking about this thread, and therefore paid attention to my RPM, speed and fuel consumption so that I could gather some data out of curiosity. I am not advocating for or against going ahead with this project. I am only providing a few data points and thoughts that I thought might be of interest.

I have a 2009 ST1300 ABS which is all stock with no performance modifications, not even the air filter or spark plugs.
When running at and just slightly over 4,000 RPM in fifth gear my speed was between 115 Km/H (71 MP/H) and 117 Km/H (73 MP/H). This is actual speeds as measured by a GPS, not the speedometer. At this speed my fuel consumption meter was regularly reporting between 20 Km/L (56.5 MP Imperial gallon, 47 MP US gallon, 5.0 L/100 KM) and 21 Km/L (59.4 MP Imperial gallon, 49.5 MP US gallon, 4.8 L/100 KM).
I have logged the data for every single tank of gas that I have ever put in to this motorcycle since the day that it was new, so I know that the above numbers are consistent with past experience.

I also know from experience that at 3,000 or 3,200 RPM in fifth gear my fuel consumption is much less than what it is at 4,000 RPM, but my speed is much to slow as well and there is insufficient power and acceleration available when needed in an emergency without down-shifting. I also noticed, and have noticed many times in the past, that my fuel consumption is less at 4,000 RPM in fifth gear than it is at 3,750 RPM in fifth gear even though I am traveling at a slower speed at 3,750 RPM.

This proposal would result in a significantly higher speed in fifth gear at your desired and significantly lower 3,000 RPM than what is achieved stock. At the speeds that we can normally ride on our highways the engine would not remain in the power band in fifth gear. I have to wonder if this will leave the engine lugging all the time and actually result in even worse fuel economy, not to mention insufficient power and acceleration being available in an emergency maneuver. The result might be the need to ride in fourth gear a lot more of the time than with the stock configuration, which might be defeating the purpose of this.

My observation is that in the stock configuration at 4,000 RPM in fifth gear it is traveling plenty fast enough, the engine just sings along happy as a clam making barely any noise, it remains in the power band, it has plenty of power and acceleration available when needed without having to downshift, and it remains very fuel efficient for such a big heavy motorcycle.

I also recall that you have another thread where you are reporting abnormally high fuel consumption. I don't recall if you have solved that problem or not. Whether or not you go ahead with this endeavor, this can not be seen as a repair for a high fuel consumption problem. The cause of the high fuel consumption needs to be found and fixed. Going ahead with this prior to fixing that problem will only be treating the symptom and skewing the ability to compare data to solve the fuel consumption problem.

Nonetheless, I am curious to see what you come up with and if this turns out to be viable. If you proceed with this, keep us informed.
 
I went out for a 750 KM (465 mile) ride today. Part of that ride found me doing about 200 KM (125 miles) of major highway on the way out and on the way back that allowed me to ride at consistent speeds over long distance. During those two portions of the ride I was thinking about this thread, and therefore paid attention to my RPM, speed and fuel consumption so that I could gather some data out of curiosity. I am not advocating for or against going ahead with this project. I am only providing a few data points and thoughts that I thought might be of interest.

I have a 2009 ST1300 ABS which is all stock with no performance modifications, not even the air filter or spark plugs.
When running at and just slightly over 4,000 RPM in fifth gear my speed was between 115 Km/H (71 MP/H) and 117 Km/H (73 MP/H). This is actual speeds as measured by a GPS, not the speedometer. At this speed my fuel consumption meter was regularly reporting between 20 Km/L (56.5 MP Imperial gallon, 47 MP US gallon, 5.0 L/100 KM) and 21 Km/L (59.4 MP Imperial gallon, 49.5 MP US gallon, 4.8 L/100 KM).
I have logged the data for every single tank of gas that I have ever put in to this motorcycle since the day that it was new, so I know that the above numbers are consistent with past experience.

I also know from experience that at 3,000 or 3,200 RPM in fifth gear my fuel consumption is much less than what it is at 4,000 RPM, but my speed is much to slow as well and there is insufficient power and acceleration available when needed in an emergency without down-shifting. I also noticed, and have noticed many times in the past, that my fuel consumption is less at 4,000 RPM in fifth gear than it is at 3,750 RPM in fifth gear even though I am traveling at a slower speed at 3,750 RPM.

This proposal would result in a significantly higher speed in fifth gear at your desired and significantly lower 3,000 RPM than what is achieved stock. At the speeds that we can normally ride on our highways the engine would not remain in the power band in fifth gear. I have to wonder if this will leave the engine lugging all the time and actually result in even worse fuel economy, not to mention insufficient power and acceleration being available in an emergency maneuver. The result might be the need to ride in fourth gear a lot more of the time than with the stock configuration, which might be defeating the purpose of this.

My observation is that in the stock configuration at 4,000 RPM in fifth gear it is traveling plenty fast enough, the engine just sings along happy as a clam making barely any noise, it remains in the power band, it has plenty of power and acceleration available when needed without having to downshift, and it remains very fuel efficient for such a big heavy motorcycle.

I also recall that you have another thread where you are reporting abnormally high fuel consumption. I don't recall if you have solved that problem or not. Whether or not you go ahead with this endeavor, this can not be seen as a repair for a high fuel consumption problem. The cause of the high fuel consumption needs to be found and fixed. Going ahead with this prior to fixing that problem will only be treating the symptom and skewing the ability to compare data to solve the fuel consumption problem.

Nonetheless, I am curious to see what you come up with and if this turns out to be viable. If you proceed with this, keep us informed.
My bike has mirror and fairing wind deflector kits installed.
if I run at 110kph, I'll get 16.5 km/l on the fcd for level ground. The only way I can get up to and sometimes slightly above 20km/l is to ride at 80-90kph. Of course deceleration yields super high fuel economy but that doesn't count.
i can't imagine the wind deflector kits are robbing 25%fuel r economy at 110kph. The kits are certainly slightly more wind drag but I can't imagine so drastic.
 
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