XR11/73

[garry55]

Hi Dave
firstly, and forgive my ignorance, but I need clarification of which gearbox shaft is which

I have various documentation which describes the shafts as:

primary & secondary or

mainshaft & layshaft or

input & output.

Input and output are pretty self-explanatory, mainshaft is, I guess, the clutch driving shaft and the same as the primary (and input)?
In which case, the sealed end of the GS's primary / main / input shaft is a real benefit for dry clutch application as it will stop oil from spewing out of the centre of the clutch.

[Suzukidave]

Yep .. make it easy , the input shaft

[Suzukidave]

Lots of nice dry clutch pictures to get idea's http://www.bing.com/images/search?q=tr7 ... &FORM=IGRE" onclick="window.open(this.href);return false;

[garry55]

thanks for that Dave

lots of work-in-progress at the moment, but nothing to show for it yet…………….

[tz375]

Dave, on the output shaft, did you machine the flange or the bearing to get that extra 1.5mm?

[Suzukidave]

I did the flange but SmokyAllan who did 2 sets , did 1 set where he machined back the bearing and this also worked . I didnt see any side load on the flange so didnt think it would be a problem but this does give you a choice to get the results you need .

[garry55]

wrt to the above - is it feasible to omit the half-ring and peg the bearing into the casing instead?
I had to have all the crank bearings for my V4 project spark-eroded to take the locating dowels so it's easily do-able.

[Suzukidave]

The GS bearing does come with the peg instead of the half ring and i just swapped out the GS to GT bearings , either way the shaft length has to be modified to get the bearings narrow enough . Allan used a carbide cutter with clean results but all i had was a hi speed grinder tip to work with so i made do with it .

[Suzukidave]

Something we noticed about the GS~ GT bearings was one used more balls in the bearing than the other .. we didnt really look into any advantage one over the other but Suzuki must have had some reason to make the change ?

[garry55]

my mistake - I assumed (incorrectly, it appears) that you were trying to align the half-clip grooves.
My GS750 transmission set is en-route from the USA, so I'll wait until I can fit it in the casings before commenting further !

[Suzukidave]

Yeah .. the GS output shaft is just 1.5mm wider at the bearings , to get it narrowed back up to line up with the retaining ring it needs to be narrowed .

[garry55]

collected the dry-clutch hub and pressure plate today - standard item on left,modified on right..............

[garry55]

had a play with the GS750 gearbox. Proof that size really does matter - the GS750 input shaft (on the right) is 6mm longer than the Kettle's, which is fine as I need an extra 8mm for the dry clutch unit to fit........



and it drops straight in to the cases...........



only fly in the ointment is that the GS bearings have these locating pins, as well as circlip grooves. So, do I remove them, notch the casings or find replacement bearings without the pins.......?



the GS output shaft in place................



problem here is that the clutch-side bearing circlip groove does not align with the casing circlip, preventing the shaft from sitting flat...............



a bit of machining required to overcome this. That aside, everything else lines up perfectly......

[Suzukidave]

The GT bearing fit right on the GS shafts , looking close you will see the output shaft bearing on the sprocket side is too wide .. 2 ways to fix this narrow the bearing or narrow the shaft . http://suzukidave.com/index.php?sfpg=R1 ... M2U1NzVjZg" onclick="window.open(this.href);return false;

[tz375]

Notch the cases for the pins. They are roll pins and can be pulled if you don't like that idea.

Correct, the input shaft is a drop in and the output shaft is too wide on the sprocket side - not the clutch side, so adjust as required. You can either slim teh shaft or bearing. I had teh bearing ground down and next time I'll try filling it with wax to keep the balls and cages clean.