Super Tenere Gear Coupling Keeps Wearing Out. Fixed....

[Bigguy136]

Hi,
I posted this on ADVRider and assumed everyone here is also there but you know what they say about assume....
With that, I thought I would also post here. Sorry if I should only post on or the other forums.

I have about 65,000 miles on my 2014 Super Tenere. At 32,000 miles, I went thru my bike because I went to Inuvik, Canada with a fair amount of mud and wanted to be sure all was good.
I saw some oil in the area when I pulled the rear end off. I saw the seal cut thru the Coupling, Gear 23P-46123-00-00 so I bought a new one (seal looked good) and replaced. I put a lot of silicone grease when assembling.
Now at 65,000 miles (33,000 on coupler) I again took it apart and saw a cut mark on the coupler and the seal was still looking perfect. I decided it was time to machine it down and change the material the seal rides on. The seal surface was 50.0MM dia. I turned it down to 48MM, turned a sleeve made from 17-4SS and pressed it on with .0025" press fit. I left the OD a bit big, indicated on the center spline to be running to .002" TIR and turned the OD to 50.00MM. Will see how it looks after another 30,000 miles. I'm still taking everything apart but everything else looks perfect. Hopefully this fix will allow me to go another 100,000 without touching it.
I don't think my bike is unique. I never saw an oil leak until I removed the rear end. There wasn't any standing oil. It had some lightly oiled dirt. At first, I was just going to clean the dirt out but later decided to pull the coupler and saw the notch. I replaced it with a new coupler. Over the summer, I rode 26,000 miles going to Canada and Alaska. I was on the North/ South Canol, Dempster, Dalton and every other road I could find. With the beating the bike took, I want to take everything apart and inspect it. This time, I never saw any signs of oil so I was pulling the coupler to wash and re-grease around the seal area. I wasn't expecting to see the groove on my 2nd coupler.

Here is the part I'm taking about:

Here is the coupler with notch. Notch was .008" deep.


I turned it down to 48MM dia. Here it is before pressing the ring on.


With the ring pressed on.


And finished to 50MM with chamfer.

 

[Mak10]

Nice set of skills you have. Looks great.

 

[RCinNC]

Great....I've got 65,000 on my 2014, and now I gotta worry about something else wearing out....

 

[Don in Lodi]

Crankshaft dampeners on autos do the same thing. Some timing cover kits come with a sleeve for the dampener so the seal has a new surface to ride on.

 

[BWC]

Bigguy136, Very nice repair. Takes some serious skills to pull off. I had a local rider who I helped with his maintenance last summer. He called me to say, “ how much oil should be in the final drive” about 8 ounces I told him, so a couple of tablespoons ran out when I drained it is that OK ? Turns out he had an oil leak at the coupling gear seal for awhile and had lost most of the gear oil. I removed the final drive assembly and he took it to the local dealer for repair. Fortunately the only failure point was the seal- coupling gear, internal gears were fine. After looking at the old coupling gear I have wondered if something like a https://www.timken.com/products/timken-mechanical-power-transmission-products/seals/redi-sleeves/ would be a suitable fix for future reference. I’ve replaced oil seal #25 on my bike due to a minor leak that seemed to be more from contamination than wear at around 85,000 km but all other seals are doing fine.
This dosent seem to be a common occurrence on the Tenere but can happen especially if the rubber plug in the swing arm goes missing and allows dirt/water inside. Something to check on a regular basis.

 

[magic]

Nice workmanship. I wonder if an SKF Speeedi-sleeve would work for someone without access to a lathe and press.

 

[Bigguy136]

Thanks all!!
I would assume there are many seals that are seeping some oil but you typically won't know without pulling the rear end. If oil is leaking, the oil should drip back inside the rear end when parked being this seal is above the oil level and the housing is angled such to make the oil return to the rear end rather than drip on the ground.
Maybe I could've looked the other way, washed everything and re-assembled and all would be fine for 100,000 miles. I just don't like things that are not perfect. I guess another reason I own a Super Tenere and FJR1300.....

 

[Bigguy136]

Crankshaft dampeners on autos do the same thing. Some timing cover kits come with a sleeve for the dampener so the seal has a new surface to ride on.

I remember these. Maybe about .010" thick and installed with loc-tite. I thought of looking for one first but I figured they were specific kits for certain model car engines.

 

[Bigguy136]

Time for an update. I only put about 18,000 miles on this summer. Sucked that Canada borders were closed but Mexico and Central America borders were open....
I figured with FJR and Super Tenere needing the rear ends looked at, I would make a quick tool that pulls the driveshaft seal.
A quick wash and as you see below, my coupler has no wear and seal is perfect.
Feels good now that I just need to change rear end oil and ride.
Rear end has always been Yamaha oil and changed when tire is changed (10,000 to 15,000 miles)

 

[holligl]

Hi,
I posted this on ADVRider and assumed everyone here is also there but you know what they say about assume....
With that, I thought I would also post here. Sorry if I should only post on or the other forums.

I have about 65,000 miles on my 2014 Super Tenere. At 32,000 miles, I went thru my bike because I went to Inuvik, Canada with a fair amount of mud and wanted to be sure all was good.
I saw some oil in the area when I pulled the rear end off. I saw the seal cut thru the Coupling, Gear 23P-46123-00-00 so I bought a new one (seal looked good) and replaced. I put a lot of silicone grease when assembling.
Now at 65,000 miles (33,000 on coupler) I again took it apart and saw a cut mark on the coupler and the seal was still looking perfect. I decided it was time to machine it down and change the material the seal rides on. The seal surface was 50.0MM dia. I turned it down to 48MM, turned a sleeve made from 17-4SS and pressed it on with .0025" press fit. I left the OD a bit big, indicated on the center spline to be running to .002" TIR and turned the OD to 50.00MM. Will see how it looks after another 30,000 miles. I'm still taking everything apart but everything else looks perfect. Hopefully this fix will allow me to go another 100,000 without touching it.
I don't think my bike is unique. I never saw an oil leak until I removed the rear end. There wasn't any standing oil. It had some lightly oiled dirt. At first, I was just going to clean the dirt out but later decided to pull the coupler and saw the notch. I replaced it with a new coupler. Over the summer, I rode 26,000 miles going to Canada and Alaska. I was on the North/ South Canol, Dempster, Dalton and every other road I could find. With the beating the bike took, I want to take everything apart and inspect it. This time, I never saw any signs of oil so I was pulling the coupler to wash and re-grease around the seal area. I wasn't expecting to see the groove on my 2nd coupler.

Here is the part I'm taking about:View attachment 62246

Here is the coupler with notch. Notch was .008" deep.
View attachment 62247

I turned it down to 48MM dia. Here it is before pressing the ring on.
View attachment 62249

With the ring pressed on.
View attachment 62250

And finished to 50MM with chamfer.
View attachment 62251

Have you considered selling this upgrade? The OEM coupler is pretty pricey. I'd rather pay you for a rebuilt one...

Sent from my SM-N950U using Tapatalk

 

[Bigguy136]

Have you considered selling this upgrade? The OEM coupler is pretty pricey. I'd rather pay you for a rebuilt one...

Sent from my SM-N950U using Tapatalk

Thanks,
Not sure how mods feel? Years back when I had my bike shop and I offered services, I was quickly approached to advertise or have my profile banned (road race bike forum, not here). I can do these projects to help people out but I'm not doing these projects for profit. I also travel to Europe and ride my tenere there for the summer. If someone wanted this done over the winter and the mods are good with it, drop me a PM.