Splitting the case

[turd_polisher]

i just got a 94 gs and the previous owner broke the final drive and welded a new sprocket to the shaft looks like a decent job but it interferes with the clutch operation. i want to put in a new final drive shaft but im not sure how hard it is to split the case. can i do it without taking the whole top end off? anyone ever tried this before? responses greatly apreciated.

[Big Rich]

While it should be possible to do it, everything would be much easier without the top end hanging on. Could rebuild the top end while you are at it (rings, valves, etc)

[the mole]

+1.

[turd_polisher]

thanks for the input. i would rebuild the entire engine but im kinda on a budget and the shaft alone is usually like $70, i bought the bike for $260 and it runs ok but the weld on the final drive interferes with the clutch operation so i kinda need to do something about it.

[Big Rich]

$70?!

I just gave one away from a gs450......

[The Buddha]

Well I have one I'd happily donate to you ...
2 things to remember though.
I have to pull it from the bike and check it for galling cos that bike spun a rod.
The second point is, how are the bearings and tolerances, can you put one with a different wear pattern in there and not have it seize the first time you put load on it ?

Cool.
Buddha.

[Gisser]

Cantcha carve out enough clearance with a hand grinder     Oh, you want to make it right.  You want to change the sprocket someday.

If you don't want a big job then just pull the engine, split the case, swap output shafts and leave well enough alone.  That's how a shop would do it.  There, that should ease your conscience while you leave the rest for another day. 

[Trwhouse]

Hi there,
I agree with Gisser.

I'd pull the engine, split the cases and replace the bad countershaft.
Simple as that.

I used to work in a bike shop and that's how we'd have done it.

Now, if you see any other damage or problems while you are in there, that's another story.

Best wishes,

Trwhouse

[turd_polisher]

thanks guys. i think im going to get ready to pull the engine soon. if anyone has any advice on things i mught run into because ive never worked on a gs before. And @budda parts would be greatly appreciated 

[socialDK]

I may be wrong on this but isn't the GS a horizontally split case?  If so pull the engine and flip it over then take off the bottom and you'll be looking at the input and output shafts.

[turd_polisher]

heres what it looks like........

[birdhandler]

yes the case splits horizontally after the side covers come off
I cannot see why you would need to remove the head and barrels to slip the case
I have never done this
here is some pics of the rostoration thread
http://gstwins.com/gsboard/index.php?topic=43550.0
Hope this helps
Cheers