Hi,
I have an '85 K100RS and plan to do a clutch spline lube.
PROBLEM: Doing earlier welding repair work to the silencer (muffler ) I was unable to remove the exhaust headers from the engine although all fasteners removed easily, the pipes would not move even slightly as if they were a permanent attachment to the head.
QUESTION: Is it possible to remove the gearbox without disturbing the exhaust assembly, preferably keeping the silencer attached to the pipes?
thanks
Ian

WINGLESS wrote: I was unable to remove the exhaust headers from the engine although all fasteners removed easily, the pipes would not move even slightly as if they were a permanent attachment to the head.

What methods did you try to remove them?

WINGLESS wrote:Hi,
I have an '85 K100RS and plan to do a clutch spline lube.
PROBLEM: Doing earlier welding repair work to the silencer (muffler ) I was unable to remove the exhaust headers from the engine although all fasteners removed easily, the pipes would not move even slightly as if they were a permanent attachment to the head.
QUESTION: Is it possible to remove the gearbox without disturbing the exhaust assembly, preferably keeping the silencer attached to the pipes?
thanks
Ian

Simple answer - yes

Yes, you don't need to remove the exhaust to lube the clutch splines.

You don't have to remove the transmission completely either.  With a pair of 100mm long 8mm bolts installed to support it, you can simply slide the transmission back a bit to expose the splines so you can reach them with a long parts cleaning brush to apply the lube.

Replacing the GB bolts with supporting studs is the best idea but I use 3 to give it a bit more support. Also a good idea to remove the clutch push rod first, to avoid damaging the end of it when sliding the GB back (not possible with the K75).
Use minimal moly paste. I used an old toothbrush to clean and apply.
Leave the muffler on.

If you need to remove the headers, just a bit of perseverance and a little swearing is needed. Sounds like they've not been removed for sometime and now that you've loosened them I'd suggest removing completely and replacing the header gaskets. There's a chance they won't seal properly again.