Stripped Engine Shaft!

During a run-of-the-mill tech day earlier this year, it was time to do the chain and sprocket change.  Unfortunately it proved to be nothing like a run-of-the-mill days.   


We had terrible trouble trying to remove the front sprocket retaining nut.  At one point, my strapping fellow biking buddies Steve and Dino were standing on the breaker bar to try and turn the nut.  Eventually after much sweat and an almost toppled bike, the nut finally came off, and with it left behind a complete nightmare.  The nut and output shaft threads were completely
chewed to pieces!!!  


We reckon that the shop who replaced it last time, managed to cross thread the nut and forced it on with an air gun.  A call to my local Suzuki dealer confirmed in the 'likely' event that the thread is not salvageable, this would mean a complete engine re-build to replace the shaft that runs right through the gearbox.  This would cost over £1000 for labour alone, more like £1500 with parts.  So not being happy with that news, I set about a repair.  


Here's what happened..

With the nut finally off and a clean of the shaft clearly reveals the nightmare stripped shaft

You can see that there is good thread on the inner part of the shaft. Hmm.. 

Here is my rough drawing and measurements of what I have to play with.
I have caluated that if I can get a new nut on, there is
sufficient thread remaining to hold it

So the idea was to use a Hex Die and split in in two halfs

This is the M20 split die that I bought.  You can clearly see that my toolmaker has sliced it in half using the wire erroder.  The shims are to replace the width of the cut.
You can also see that I got him to machine a recess at one end.  This is so that it will fit over the splined shaft and make sure that all the cutting edges of the die start on the good threads.
The die has been reversed too, as we are cutting counter-clockwise.

This is the 38mm socket to turn the die.  My toolmaker machined some grub screws to ensure that the two half's of the die are pressed together when inside the socket.

It was impossible to show in a picture, but this is the socket with the die inside.  And I am just nipping up the grub screws.  It was infact extremely tricky to get the die & shims in the socket.
Its one of those things that seems simple when you go over it in your head - a different beast altogether in reality!

It was extremely nerve-racking when cutting the thread.  I would cut a bit, stop and dismantle the whole socket and check and make sure I wasn't damaging the good thread.
I did this so many times, and to be honest I was cacking it!  I knew that if I fooked this up, it was strip-down engine time.
I used lots of lube, and finally the die was through.  This is the finished thread.  Now it might not look that great, but I am very happy with the result.

The very badly damaged threads were never going to return, there just wasn't enough metal left to cut on to.  But it did ensure the good threads were cleaned up and that the thread would
start nicely and a nut would go on without cross-threading.  Here I had purchased an M20 std hex full nut to try out first before using the locking nut which comes with locking compund already.

And so the finished thing.  I have torqued the nut to 113Nm and put a marker as suggested by Greywolf/Preload. After a few rides and miles, I'll check it a few times.
But with the amount of good thread (ended up with about 1 thread protruding the nut), the lock nut, locking compund, good torque and a washer, I'd be surprised if this sucker moves!

Lighting up a V-Strom

This small project was to add some extra lighting to the bike, and specifically to make the appearance quite wide at night time for on coming vehicles to see me better.
I had seen the new Ducati Multistrada and its very impressive LED's on the hand-guards, and the intention was to try and mimic this effect using much cheaper materials.


So lets see how it turned out?..

Strip of waterproof 12V white LED's encased in silicone

Time to mark and drill some holes in the handguard

They seem to fit nice and snug

Slightly protruding on the front face is intentional

Some silicone to fix in place

So far so good

Testing with a 9V battery

And fitting on the bike and run from the 12V supply

Very effective at night!

Chevron Graphics

Made by Humvee Graphics for the BMW GS style aluminum boxes, these coloured and reflective chevrons look great on any luggage and do a decent job of letting other traffic know how wide you are when riding with a full set of luggage.

Red on the rear

Amber on the side

White on the front

Storage Tubes

The idea of these Tool Storage Tubes began as a group buy on the VSRI forum.  They are essentially a waterproof ABS plastic tube usually fixed to machinery/vehicles etc. and used to store tools, instruction and maintenance manuals.


They make an ideal extra bit of valuable storage for the touring motorcyclist, where space is always at a premium.  The problem of course is where and how to mount them.  I have seen many ideas from cable tied to engine crash bars to vertically mounted to the top-box.  There really isn't a right or wrong way, it is all down to your personal preference and your intended use.


Personally, I wanted to store anything dirty or that could leak, such as a litre of oil, chain lube or a dirty chain and padlock.  And I bought two thinking that I would keep one spare, but then considered the possibility of mounting both of them.


Anyway, this is very much a work in progress for me, and by no means finished.  And although not very 'ptretty' at the moment, they have given me the opportunity to test them out.

I have the SW Motech Quick Lock Pannier racks

The whole rack can be quickly removed when not required

The inside of the rack shows the aluminium plate/bracket that I made

This is shown from the front

I am not very happy with the way it looks at the moment

View from the rear

View looking though the bike

Looks okay from this angle

Shows the clearance to the wheel and plastics

With the Givi E21 cases on, it doesn't look too bad

The angle of the tubes was important to me, visually had to look right

You can see the angle matches the exhaust

So this is my idea so far.  I haven't painted it yet because it is not finished and I will continue to find a better solution to mounting them that visually looks good, and without having to have the side racks installed.