gear shaft end float

sparks · May 11th, 2007, 01:57 AM

Can any body tell me how much end float there should be on the output gear shaft 550 04.

Sparks.

dsducati · May 11th, 2007, 06:10 AM

I can't find it anywhere in my service manual. Ball bearings can't handle side loads yet the gears can't be floating around either. On other engines, you typicaly see around .2MM with a threaded countershaft sprocket nut pulling everything to one side.
dan

sparks · May 11th, 2007, 08:03 AM

Yes that was what I was thinking, on the Husaberg the output bearing is a roller and the sprocket is held in place with a circlip, no shimming to take up the end float.
Just was wondering what end float other people had on theres, I would probably say there is about 2mm on mine.

Sparks.

dsducati · May 11th, 2007, 08:23 AM

I've seen some looser with 1MM+ of end float, with the sprocket nut firming things up to the one side.
dan

JoeUSA · May 11th, 2007, 08:52 AM

Hi Steve,

I had an output shaft problem with my brand new 04 550, it had 0.33mm end play.

The final fix was to replace one of the 1mm stop discs on the shaft with a custom 1.25mm disc that Dale Lineaweaver made for me, leaving 0.08mm end play.

The bike had never been ridden except for some minor amount by Motoxotica in their parking lot to rejet the carburetor before I picked it up. I started it once to make sure it ran and was surprised at the amount of noise it made. I had previously planned to remove the balancer on any new Berg that I might buy that had the existing balancer design. I noticed while removing the engine from the bike that the drive sprocket wobbled and was very loose (axially) on the shaft. I measured this to be 0.33mm. While reassembling the engine I noted that the 1st gear idler was rubbing on the side of the 5th speed idler and that by pushing the output shaft to the left side of the engine the noise went away. So I decided something had to be done to correct the excessive end play. I also doubted that the 0-ring on the shaft would seal with that much end play, so I changed the stop disc from 1mm to 1.25mm.

The 4th picture is in the next post.

Regards,

Joe

JoeUSA · May 11th, 2007, 08:55 AM

4th picture.

Joe

dsducati · May 11th, 2007, 11:43 AM

Joe,
Mine has about .2MM end play, roughly twice what you ended up with. Not having any noise issues or oil leaking. Looks like .33 is a bit excessive and creates problems. Funny how this has to be hashed over online and is not in the manual. As stated earlier, other bikes are all over the place on end play, with the sprocket firming up everything to one side. Man, you need to know what you are doing and understand all the little caveots when working on these engines.
dan

sparks · May 11th, 2007, 11:58 AM

Joe, Dan, thanks for the input about the output,I think I might have an issue here my end float is deffenatly around 2mm, so I suspect a badly worn stop disc as you call it Joe or a circlip has come adrift.
There is no adverse noise coming from the gear box and all gears are smooth changing up and down and nuetral is very possitive.
I'll see how it goes through the summer and will give it a complete overhaul at the end of the year and will upgrade to one of Dales after market stop discs.

Sparks.

sparks · June 19th, 2007, 12:17 PM

Hi All,

This is the answer to the excessive end-float on the counter shaft, after pulling the motor apart today the reason for the end-float was who ever rebuilt the motor last put the stop disc at the wrong side of the cir clip next to the final output bearing, hence the big end float.

Joe and Dan just thought I would let you know the out come, apart from that the rest of the internals are in good shape just going to replace all bearings seals and cam chain.
At least you know where you stand when you know what has gone back into an engine rebuild.

Regards

Sparks.