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Old 25 Aug 2012
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Advice needed in Mongolia: Transalp output shaft/ sprocket/ retainer problem, Urgent

Hi guys
I'm nearing the end of my 7 week trip through Central Asia, Altai-Russia and Mongolia.


I have a problem, I think, and would be really grateful for suggestions/ comments/ possible solutions. It is also urgent as I fly home to England next weekend (today Sat 25th Aug, flight Sat 1st September). I was hoping to leave the bike in Mongolia to continue my trip into eastern Siberia next summer, 2013 (preferred choice). If necessary, however, I can freight the bike back to the UK from Mongolia, but would need to set things in motion very quickly.


The bike: 1988 pd06 XL600v Honda Transalp, unknown mileage (I'm the 12th owner!), but anywhere above 50/80 thousand miles/kms. On this trip the bike has done 8500km/5000miles, about 50/50 pavement/gravelMudSand. The front sprocket is OEM Honda 15 tooth, rear steel aftermarket and chain expensive DID 525 118 link vx. All 3 are still in good condition, I believe. Please see images below.


I reached my destination Ulaan Baatar, the capial of Mongolia a week ahead of schedule, so decided to take a ride south to visit the Gobi desert. Yesterday morning (8300km/5000miles into this trip), just before setting off I noticed the damage to the sprocket cover (see image: I removed the plastic centre circle, it was still 2/3 attached to the cover). This damage would have happened very recently as I definitely would have noticed a gradual issue.


Before leaving for the Gobi, I replaced the sprocket retainer (number 1) with a new spare (number 2). It last precisely 200km/120miles! See image.


I rode as carefully as I could back to Ulaan Baatar today. Before setting off I also loosened the chain a bit more too. Retainer number 3 is already half worn after this further 200km/120 miles!


The front sprocket does “wobble” a little on the shaft.


How/why did this happen? I believe the chain tension wasn't too tight. The output shaft is IMHO in good condition (much better than the one on my 1995 Africa Twin...).


What's the solution?


1. Weld the sprocket onto the shaft? (not a problem, the bike is cosmetically very nasty and only really worth gbp600/us$1000/euro700, if that). This can be done locally, if I can find a competent Mongolian welder who understands English or German.


2. Replace the output shaft? The would require a full engine rebuild, for which I don't have the expertise. Finding a competent English/German speaking mechanic in Mongolia will be a challenge! Also the parts would have to be sourced and imported. I can ship the bike back to England where I know a very reliable mechanic, but I can't justify the cost (it would be 1500euro shipping for a 700euro bike and that is before paying parts and labour.)


3. Just put on a new front sprocket? I don't have one with me, but could easily bring one with me when I would return to Mongolia in 2013 for my Siberia trip. I'd also bring a job lot of new retainers with me.


4. Or? Over to you!


FWIW, I am sending this email using the wifi at the Oasis Guesthouse. Rene and Sybille, the owners, are currently out of town, but back on Wednesday. I'm hoping to be pro-active from Monday (27th August) morning onwards.


Several images are below that will hopefully help solve my problem.



Retainers from left to right
1 lasted 8000km
2 lasted 200km!!
3 is half worn after 200km!!
4 is new (for comparison)





Chain tension





Chain tension





Chain pulled off rear sprocket, still v good condition, IMHO





Retainer number 3 on sprocket, before setting off this morning.





Output shaft looks Ok to me, I've seen a lot worse on my Af Twin that has about 1/3 missing off each tooth





See above comment





When I pulled over for a pee, a quick glance revealed this shocking image (of the sprocket/retainer/shaft, not my manliness!)





See above comment





Sprocket looks fine, but does wobble a little on the shaft





See above comment





Sprocket cover after removing the worn central section


Any input is very gratefully received! Thanks in advance! If we meet, payment in s. If not, good Karma all round!


Ride safely,


Chris
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