HELP - 03 EV wheel + final drive

[SemperVee]

   Pulled the wheels off to change tires of my new 03 EV Cali.  No problem.  Reinstalled rear wheel after lubing the spline and moving caliper back into swingarm spacer connection, slipped in axel and HAVE too much space from wheel to final drive I am thinking?  I have pulled wheel off twice and replaced and same thing.  Evenly about 1/4 inch all around.  Feels fine, no noise, axel tightened. brake works but I have not started it.   
*I did not take notice if wheel and final drive had ANY measurable space when fitted correctly.  *What am I missing here?  I'm thinking it should be flat against the final drive?

I have pulled off and replaced wheel a few times. Nothing changes.  Service manual makes no mention of rear wheel removal as it does the front.

See picture.  There is a 1/4 inch space from wheel to flat final drive housing?   What have I missed here or was it that way?  See pic

[John A]

There is a spacer that controls that distance. It is a snug slip fit in the bevel box. You can see it from the right side if the axel is not in. It is visible as a thin piece around the inside of the axel hole. It is stepped so it only goes in so far and with the wheel off it sticks out a couple inches and butts up against the wheel bearing. That gap is not uncommon so it may have been like that. Remember to tighten the axel before tightening the four nuts on the front of the bevel box.

[SemperVee]

There is a spacer that controls that distance. It is a snug slip fit in the bevel box. You can see it from the right side if the axel is not in. It is visible as a thin piece around the inside of the axel hole. It is stepped so it only goes in so far and with the wheel off it sticks out a couple inches and butts up against the wheel bearing. That gap is not uncommon so it may have been like that. Remember to tighten the axel before tightening the four nuts on the front of the bevel box.

Thanks for the in depth explanation John A.  I have only pulled the axel. Nothing on the "Bevel" box or any other bolts have been touched so I don't understand about "tightening the 4 nuts" on the front of the bevel box? I am going to pull the wheel again in the morning to take another look see to see if I can recognize what you speak of.
   Seems like it should be a simple thing just fitting the gear and spline together.   

[pehayes]

There was a similar issue with the 98EV that lead to a service bulletin.  The bike was designed around a specific tire.  Other brands of tires were too wide and would rub the inside edge of the swingarm.  In the center of the bevel box is a hollow spacer tube that the axle goes through.  Guzzi provided a slightly longer tube which would move the center of the wheel over and provide clearance between alternate tire and swingarm.  Said tube was a press fit and would easily tap out of the bevel box for replacement. Also required a shorter 'brake anchor pin' on the opposite side so the pin would not bind.  Use of the longer spacer tube would result in a wheel to box gap just have you have photographed.

Patrick Hayes
Fremont CA

[SemperVee]

Thanks PE Hayes..     I will sleep better knowing it might be nothing to worry about.  I will make myself more familiar with the interior of both the wheel and the bevel box. 

[John A]

The four nuts on the front of the bevel box I mentioned is if you take bevel box off to grease the driveshaft splines. The proper way to reinstall it is to tighten the axel nut before tightening those four nuts. I do it in stages. It’s in the maintenance manual, I just thought I’d mention that. I usually grease the splines every other tire change. It doesn’t have anything to do with your original question, just general knowledge.

[SemperVee]

 It was exactly as you said Hayes..   I put it all together again after lubing and taking apart again then reinstalling and all is fine!  I included some pics I took of the connection of wheel to bevel box and all looks fine, to me.  Wiped away the rust and relubed teeth with old tube of Honda Moly grease I had.   Came apart easily.  I measured with calipers and it is 2-3 mm from bevel box to wheel. Quite concerning if you think it is suppose to have no material space between!!  Thanks John A and you for the why it is..





 

[pehayes]

Hate to make your task more complex.  This 03EV is new to you.  How many miles on the machine?  Those wheel splines look just fine.
However, there is another set of smaller diameter splines where the drive shaft mates to the input of the bevel box. Those internal splines are harder to reach and hence more prone to being starved of grease.  Next time you replace a tire, make sure to remove the bevel box and grease those hidden splines.  There are a few little tricks like leaving the four mounting nuts a bit loose during axle install.  You might also consider disassembly of the wheel's cush drive and lubrication of its internal O-ring.

Patrick Hayes
Fremont CA

[John A]

When I service the driveshaft, I clean and degrease the splines. I spray them with moly dry film and cure that by heat, I then put Wurth sticky grease on them. I get the best service life doing it this way.

[SemperVee]

Hate to make your task more complex.  This 03EV is new to you.  How many miles on the machine?  Those wheel splines look just fine.
However, there is another set of smaller diameter splines where the drive shaft mates to the input of the bevel box. Those internal splines are harder to reach and hence more prone to being starved of grease.  Next time you replace a tire, make sure to remove the bevel box and grease those hidden splines.  There are a few little tricks like leaving the four mounting nuts a bit loose during axle install.  You might also consider disassembly of the wheel's cush drive and lubrication of its internal O-ring.

Patrick Hayes
Fremont CA

Patrick, The speedo reads 15K but he replaced the broken speedo some years earlier Original owner said to add another 10K  = Approx 25,000 miles in total.   I will heed your advice and go further and deeper in next time..Thanks for the heads up.  

[73 sport]

   If you don't grease the splines you missed, the next session might be to replace the worn out parts. They may be "Unobtainium".

[SemperVee]

   If you don't grease the splines you missed, the next session might be to replace the worn out parts. They may be "Unobtainium".

Noted.  I did have the idea of going back in there while it is new to me and still doing a front to back maintenance.