Pinion Cup & Drive Shaft... Again!

[DDT (12)]

I've just returned from a road trip out west, by way of Mandeville, LA. The pinion cup and drive shaft went out again on ALI (third time in two years), and I had to haul her from Carlsbad, NM, back to Mandeville so Troutdude could have a look and perform repairs. What follows is an excerpt from a story I wrote about the trip... the whole story is really, really long, and I figured it would be too long to post in its entirety... Anyway... once I arrived at Dennis' house...

It didn't take long before the rear wheel was off, and the shaft and pinion cup were exposed... Rust! And, the splines were bone dry and worn down considerably. Dennis checked the boot very carefully to see if water may have gotten in through there... Nope, the boot was perfectly positioned, so no source of water through there.

Next, the universal joint was removed and inspected. Good shape, practically new... t-man403 had replaced that too the winter before. The problem was that water was getting to the pinion cup somehow, and until the source of that problem was found, any repair or replacement of worn parts would only be a temporary fix... Something besides mechanic error or oversight and simple neglect had to be going on here...

Dennis is very insightful and most knowledgeable about wrenchifyin' and such... He'd impressed me on several occasions before, and this time I was confident things were going to work out... He is also patient, confident, and unperturbed... stress and frustration are seemingly unknown to this cool customer. I was sure answers were soon to be found. I was right.

Closer inspection revealed that the inside surface of the swing arm had a great deal of rust, gunk, grease, and metal filings all up and down it and all inside the part between the two 'arms', as well.

He figured the problem must be in the swing arm... We removed that, then covered one end with plastic and filled the arm with water... Water flowed out of a hole on one side of the swing arm about half way down the side opposite the side that housed the drive shaft... Hmmm, that doesn't seem right!!!

We also learned that there were actually two holes, one on each 'arm' of the swing arm put there by the manufacturer. They are located at each end of the weld bead that runs from about halfway up the arm, around the inside of the 'horseshoe' to about halfway down the other side. From the ends of the weld bead and holes to the ends of the arms there is a channel on each arm.

One of those holes on ALI had been clogged up (the one on the drive shaft arm side), who knows how long ago, and that had prevented water from being able to exit or dry out through ventilation... The trapped water then migrated down to the pinion cup where it collected and did its nasty work in corroding everything and severely shortening the life of the splines of the shaft.

We'd eliminated all other sources of water intrusion - the universal boot, swing arm bearings and entry points, and where the swing arm attaches to the 'pumpkin'. At least, that's our theory... We'll see how this theory holds up when we inspect the cup and shaft at the next rear tire change...

Warlock had the special tool necessary to remove the left side swing arm bearing lock nut, and he volunteered to meet us at Punisher's house Friday and let us have it... Yes, Punisher had a spare swing arm, and he had offered it to us already! Can you believe this?! 'Our bike' is becoming even more so every day, it appears!!!

Dennis and I rode up to Hattiesburg, MS, Friday morning... No, I didn't ride as a passenger. Shelia kindly consented to allow this humble rider to straddle 'Saphera', her '98 Valk Tourer.  We had a nice visit, too, at the 'manor'.

We returned to Mandeville and began assembly of parts. We were still at it the following day when Allan & Jackie arrived, so Allan jumped right in and helped Dennis... I was doing a very good job of staying out of their way... something all good mechanics insist I do...

At dusk, the work was finished, and it was time for a test ride... and I got the honor. WOW! She felt mighty good, and no noises or other signs of a problem were detected. Dennis also gave her a ride... All was good, it seemed!

I'm back at my place now, and the ride back here was uneventful... except for being the wonderful ride that it was. I now have greater confidence in ALI's delicate derriere, and I'm very much looking forward to riding her again and again...

Dennis especially, but also Allen, David, Gordon and others who participated either in person or via phone have my undying gratitude... Thanks folks.

DDT

[..]

I'd suggest posting this info on the Tech board with a title tha would make it easdy for others to find in the future.

[R J]

Man are you hard on equipment or what.

I'd go inspect my holes, but I don't got no Swing Arm anymore.......

Bruce, glad ya found the problem and glad ya got it fixed AGAIN.

What is the TOTAL mileage on ALI now?

Mine isn't adding miles very hard.    Less than 2,000 miles this yea on MGM.

The Chevy caught hell however.     Just under 14,000 on it and I'm strapped to a ferkin O2 tank 24/7.

Every year it is getting harder for me to accumulate any miles.     I can't take it anymore.

I guess gettin old is the cause of this.

[Smokinjoe-VRCCDS#0005]

I may have the same problem I just lost my pinion cup the first one in 16 years of owning a Valkyrie. My drive-shaft tube was " damp " however no water but my cup was rusted. I take great pains in cleaning and re-lubing everything between 10,000 and 11,000 miles at the rear tire change and as stated this is my first time of finding rust in the  pinion cup. This was also the first time I noticed moisture / condensation in the tube 

[DDT (12)]

Britman,

Good idea... I did so under the title "Pinion Cup & Drive Shaft Failure"... thanks for the suggestion.

RJ,

It would appear I am indeed rather rough on equipment... Oh well, ALI has never complained, although she has proven to be vulnerable to wear and tear just like anything and anybody else... I'm optimistic Dennis has solved the conundrum this time, however, and we're looking forward to many, many more miles out yonder together! So far we have shared over 458,000 fantastic miles/smiles together... not including 1,000 miles 10 days ago when I drove a U-Haul truck with her strapped down in the back from New Mexico to Louisiana.

Sorry to hear of your ongoing health issues and declining road readiness... Is it possible that you, too, have a plugged-up hole some place?   lol   

Joe,

Check your swing arm for plugged holes... Dennis, Allan, and I are thinking this could be a more frequently heard about item as all of our Valks continue to age... Many of us, you and I included, have ridden ours on some pretty nasty roads over the years... anything is possible, I suppose. Still, we'll all have pinion cup/drive shaft problems to deal with sooner or later, so keeping the chatter up about what we find is a good idea... Thanks for sharing your discovery... sad as it is for you to find... believe me, I know!!!

DDT

[t-man403]

Here's the video "trout dude" sent for my viewing displeasure 

http://1drv.ms/1wpVhra

Actually very glad this was found and remedied! 

[Oss]

Bruce, if you could post a picture or draw a picture showin where on the swingarm
those holes are and whether they can be seen while everything is assembled
 that would be really helpful to those of us who would like to check their stuff

Would hate to see the equipment have a problem when out in middle of nowhere
You always need the equipment ready for action


Oops that pic was meant for John Schmidt's post about thumb size...

I ride in a lot of rain and other nasty weather

There is also a big rubber ring that goes around the final drive that BIGBF replaced on
my Valk in April, He said the dealer had buggered it up trying to remove the wheel at some point
that could also be a source of water

Glad you and Ali are enjoying life to the fullest and Merry Christmas my brother

[trout dude]

Here are some pictures to go with this post
Swing arm still on bike




After i cut it open








What came out of the swing arm all magnetize

[Hook#3287]

Trout Dude, are those pictures of a cut swing arm and what came out of it?

If so, I'd say we need to keep our swing arm holes clean, which just sounds really weird, but must be done. ???

[Hook#3287]

Okay, I didn't see your comments between the pics at first.

I can't believe that came out of your swing arm ???

[trout dude]

It didn't it came out of DDT'S swing arm
  Dennis

[R J]

It didn't it came out of DDT'S swing arm
  Dennis

Bruce is going to have to start using the BRIDGE instead of crossing the Creek at the low point.    It only saves him 2 blocks off of his route.

A block over and a Block back.   Jeez Louise.

[KY,Dave (AKA Misunderstood)]

  So can you show where the holes are that were infiltrated?

[eric in md]

well bruce , this is my side of the story.. first off i think its all your fault for washing ali everyday. i hear to say it not going to hurt her to have bugs and dirty on her a dirty girl is a fun time sometimes. you should try it.  next im going to blame terry for not looking into this swing arm as he held ali hostage for 6 long months ..  then we can fast forward this issue to the present time. did  dennis shove gordon in the swing arm for a inspection? wait bruce let me guess you stood back and watched all this going on ? didnt even care to help my lil buddy gordon  you know he could have been hurt damnit. its all fun and games till i show up and  straighten you boys out . bruce be easy on your girl we all love her .  ps really boys i love you all i mean it .. merry christmas lets have a safe and happy new year .. lets ride ...  ITS ON

[t-man403]

  next im going to blame terry for not looking into this swing arm as he held ali hostage for 6 long months 

I even cleaned the grime out of that spot while the wheels were being polished ...... guess I shoulda' left it on! 

[eric in md]

  next im going to blame terry for not looking into this swing arm as he held ali hostage for 6 long months 

I even cleaned the grime out of that spot while the wheels were being polished ...... guess I shoulda' left it on! 

  lol im just picking were all still learning ..

[trout dude]

T-man just tell Eric the truth next time we will block it off with some american cheese not cheddar.

[eric in md]

T-man just tell Eric the truth next time we will block it off with some american cheese not cheddar.

lol i love it

[t-man403]

T-man just tell Eric the truth next time we will block it off with some american cheese not cheddar.

Probably better than JB- Weld!!  

[KY,Dave (AKA Misunderstood)]

I have 2 pictures from my spare rear setup and you can see, not only the channel holes that mike highlighted in his pictures that are probably where the water is getting slung in, but also 2 holes below them that would act as drains. I see it as Joe says in the tech thread to inspect the inside for moisture and insure the holes aren't clogged and thus preventing drainage. Keep in mind these pictures are of the swingarm upside down, so the drain holes are on the bottom.
one side



And the other side