Middle drive shaft replacement

[r_squared432]

I am one of those "lucky" folks who had the nut snap off the middle shaft that is connected to the universal joint on the shaft drive. Nut and washer were still in the boot and make a few nice dents in the front of the middle gear housing. See picture. We got everything disassembled today.

 

Looking at some earlier posts of folks who have done this before, anyone have thoughts of installing a used shaft vs buying new? The taper bearing on the shaft looks good - bike has 90K on it - can I get by with using it or better to go new? The bearing at the other end of the shaft in the middle gear housing has a pretty nice dent in it - presumably whacked by the nut flying around in the boot so that has to be replaced. New bushings and seals etc for the rest and hopefully all will be well again ,,,soon.

[MiCarl]

I'm going to tell you about something we just did to a V-Star 1100 with the same issue. I cannot guarantee long term results.

 

On the 1100 V-Star the middle gear set cannot be removed without splitting the cases. I found descriptions on the web where people drilled a hole in the output shaft and replaced that broken nut with a bolt. Some of them were only using 8mm bolts!

 

A machinist friend made me a couple fixtures so I could drill and tap reasonably straight. I cut the threaded portion off and drilled and tapped for a 10mm bolt. Last I knew the repair only had a couple hundred miles on it, but was holding up.

 

In your case, the output gear can be removed without splitting the case. You could get it to a machine shop for the drilling and tapping, much easier than on the bike.

 

Might be worth a try......

[paysaw]

Not sure if you can do that.I have not seen the pics.I had to pull my middle gear out to fix the problem.I just bought another one and replaced it.There is no need to split the case.Loosen the pinch bolts and gently pry the middle gear out.Move it side to side but it will come out.Be sure to watch your shim placements too.If the nut and shaft are together snapped off ,you don't have much choice.