Stuck in the joint

[saddlesore]

My drive shaft is stuck in the u-joint.  It is through almost a quarter of an inch past the inside lip.
I have a new shaft, seal, spring and u-joint ordered.  So my questions are... How can that happen in the first place?
How can I separate the two? 
If I heat the u-joint are there seals in the joint that could get damaged? 
Would a machine shop have a press that could possibly get the job done?
When this happened I heard gears grinding.  Is it possible that the pinion gear separated from the pinion cup to make that noise?  There was no damage to the splines as I was going very slow when it happened.
When I had the drive shaft separated from the engine out put I started the bike and was able to run it through the gears.
Any other theories?  I'm dying here waiting for parts!

[tank_post142]

pictures?

[saddlesore]

I wish I could but I started using Photo Shop Elements.  It totally hijacked everything. I have no control.

I have pictures but can't move them.  Just another problem I'm trying to work out.

There's not much to see anyway. All the splines look good and it's hard to see inside the u-joint to show how far the shaft is in.
When I serviced the rear end about 1000 miles ago I know I assembled in the proper order.
All I can do is wait for the new parts, put together  and hope for the best.

[Rio Wil]

On the drive shaft end that goes into the ujoint, there are about 1 inch of splines that are full diameter.  Then the remainder of the splines have been partially machined (ground) away.  Is it possible the shaft has entered the ujoint so far that only the machined down portion of the splines were in contact with the ujoint splines and have stripped from thye torque.....causing burrs on the splines and holding the shaft captive in the joint. The drive shaft should enter the ujoint only about 1 1/4 inches, sounds like yours has gone an additional 1 inch further than it should.....

I wonder if we have actually found the real purpose for the c-ring that holds the drive shaft in the pinion cup..

Do you know if your drive shaft had that c-ring on it and was it difficult in separating the shaft and pinion cup.

I might be wrong about this, but it seems I remember that a G/W shaft is longer than the Valkyrie shaft.....wonder if you have a too long shaft?

[saddlesore]

Yes, the c ring was there and in place.  It was very easy to pull the shaft out of the pinion cup.

I'll have to go back and see exactly how the ring holds the shaft in the cup. That sounds plausible.
I didn't see any signs of metal shavings.

I can't comment on the length of the shaft and I really don't care to compare my shaft with someone other guys shaft.   

[Rio Wil]

If the shaft was fully seated in the pinion cup and yet extends into the ujoint about a inch too far, then the drive shaft is about a inch too long......or.....was the spring and spring retainer still on the drive shaft at the ujoint end?

[The emperor has no clothes]

Yes, the c ring was there and in place.  It was very easy to pull the shaft out of the pinion cup.

I'll have to go back and see exactly how the ring holds the shaft in the cup. That sounds plausible.
I didn't see any signs of metal shavings.

I can't comment on the length of the shaft and I really don't care to compare my shaft with someone other guys shaft.   

I don`t blame you I hate it when guys wanna compare shafts!

[Warlock]

My drive shaft is stuck in the u-joint.  It is through almost a quarter of an inch past the inside lip.
I have a new shaft, seal, spring and u-joint ordered.  So my questions are... How can that happen in the first place?
How can I separate the two? 
If I heat the u-joint are there seals in the joint that could get damaged? 
Would a machine shop have a press that could possibly get the job done?
When this happened I heard gears grinding.  Is it possible that the pinion gear separated from the pinion cup to make that noise?  There was no damage to the splines as I was going very slow when it happened.
When I had the drive shaft separated from the engine out put I started the bike and was able to run it through the gears.
Any other theories?  I'm dying here waiting for parts!

Was wondering if the drive shaft had the spring on the end of it. This keeps it from going too deep into the u-joint. Anyway make sure the spring and retainer clip is on the end of the drive shaft before installing into the u-joint.
david

[saddlesore]

The spring was on and I thought I may have forgot a washer between the spring and the joint. That would have caused the spring to wedge between the shaft and joint. Not the case.
Not sure where I read this but when assembling the shaft should be tapped on the end to make sure to seat the pinion gear in the pinon cup.  I put the shaft into the u-joint  first..  That may have been my mistake.

[Warlock]

The spring was on and I thought I may have forgot a washer between the spring and the joint. That would have caused the spring to wedge between the shaft and joint. Not the case.
Not sure where I read this but when assembling the shaft should be tapped on the end to make sure to seat the pinion gear in the pinon cup.  I put the shaft into the u-joint  first..  That may have been my mistake.

The one I'm talking about you have to use snap ring pliers to remove. It fits on the end that
goes into the u-joint. Should have a bottom piece and then slide the spring on and the snap ring on top to hold the spring in place.  David

[Rio Wil]

The ujoint has two different lengths yokes....which yoke is the shaft in.....long one or short one?

Also, it is dang near impossible to properly seat the pinion cup/drive shaft seal if the shaft is fitted to the ujoint first.....if this seal is not seated, p/c lube will be lost quickly. This shaft rotates about 2000 rpm+ at highway speeds

It's not needed to tap the shaft into the p/c, it will just click into place with light/moderate hand pressure......sometimes it is a bear to get out

[saddlesore]

Hmmm....I think you guys solved my problem(s).  As near as I can tell I don't have a snap ring in there,at least I can't see one. 
The shaft is in the shorter portion of the yoke.  Sooooo, it looks like I screwed up on both ends of the shaft.
I ordered all the other parts so now I have to find a compatible washer and snap ring without sending in another order.  When tracking the order for the shaft etc., it shows they are still putting the order together in their warehouse yet.  10 days?

Thanks a lot! I think that's the first time I ever made a mistake.

[Jess Tolbirt]

Hmmm....I think you guys solved my problem(s).  As near as I can tell I don't have a snap ring in there,at least I can't see one. 
The shaft is in the shorter portion of the yoke.  Sooooo, it looks like I screwed up on both ends of the shaft.
I ordered all the other parts so now I have to find a compatible washer and snap ring without sending in another order.  When tracking the order for the shaft etc., it shows they are still putting the order together in their warehouse yet.  10 days?

Thanks a lot! I think that's the first time I ever made a mistake.

and it certainly wont be the last

[Grumpy]

Sounds like the shaft was not seated in the pinion cup, then when the bolts were tightened, it shoved the shaft too far into the u-joint spline. Proper installation calls for seating the shaft in the pinion cup and then inserting the whole assembly into the swing arm and u-joint.

[Rio Wil]

Just to be clear, the drive shaft does go into the short side of the ujoint and the long side to the output shaft.