Since Microsoft's new Copilot AI offered to help me out, I asked it to tell me how to repair the output shaft on my K100.
I thought I'd share the wisdom that Copilot gave me.

Repairing the Output Shaft on a BMW K100
A Step-by-Step Guide
The BMW K100, known for its durability and performance, sometimes requires maintenance, particularly on components like the output shaft. This guide provides a comprehensive step-by-step process to help you repair the output shaft on your BMW K100.
Tools and Materials Needed
·         Socket set
·         Torque wrench
·         Circlip pliers
·         Rubber mallet
·         Grease
·         Replacement output shaft parts (bearings, seals, etc.)
·         Service manual for BMW K100
·         Work gloves
·         Safety goggles
Step-by-Step Repair Instructions

1. Preparation

Begin by preparing your workspace and ensuring you have all necessary tools and parts. Make sure your motorcycle is on a stable surface, and use a motorcycle lift if available to make the process easier.

2. Remove the Rear Wheel

Use the socket set to remove the bolts securing the rear wheel to the swingarm. Carefully take off the rear wheel and set it aside.

3. Access the Output Shaft

Remove the final drive unit by loosening and taking out the mounting bolts. Be cautious as the final drive unit can be heavy. Once removed, you will have clear access to the output shaft and its surrounding components.

4. Disassemble the Output Shaft Assembly

Using the circlip pliers, remove the circlips holding the output shaft in place. Carefully take out the shaft, ensuring you note the order and orientation of any washers, bearings, and seals. It might be helpful to take pictures during disassembly to assist with reassembly.

5. Inspect and Replace Components

Once the output shaft is disassembled, inspect it and the related components for wear or damage. Replace any worn-out bearings, seals, or other parts with new ones. Clean the area thoroughly before reassembling to ensure no debris causes future issues.

6. Reassemble the Output Shaft

Reinsert the output shaft, making sure all components are in their correct positions. Use the rubber mallet to gently tap the shaft into place if necessary. Secure the shaft with the circlips you removed earlier.

7. Reattach the Final Drive Unit

Carefully reattach the final drive unit to the motorcycle, ensuring all bolts are tightened to the proper torque specifications as indicated in the service manual.

8. Reinstall the Rear Wheel

Place the rear wheel back onto the swingarm and secure it with the bolts. Make sure the wheel is properly aligned and spins freely.

9. Test the Repair

With everything reassembled, take your motorcycle for a short test ride. Pay attention to any unusual noises or vibrations that could indicate an issue with the repair. If everything feels and sounds normal, your output shaft repair is complete.

10. Routine Maintenance

To prolong the life of your output shaft and other components, perform regular maintenance on your BMW K100. Check for signs of wear and tear, lubricate moving parts, and adhere to the service intervals recommended by the manufacturer.
Conclusion
Repairing the output shaft on a BMW K100 can be a detailed process, but with the right tools, parts, and careful attention to detail, it is a manageable task. By following this guide, you can ensure your motorcycle continues to perform at its best and remains reliable for many miles to come.
If you encounter any difficulties during the repair or are unsure about any steps, consulting a professional mechanic or referring to the BMW K100 service manual is always recommended.
 




I take no responsibility for anyone following these instructions for repairing their output shaft.

Bill

Especially as the brake hose and speedo drive have been ripped apart.

Dai wrote:Especially as the brake hose and speedo drive have been ripped apart.

That's the first thing I noticed.....
Speedo sensor
Rear caliper
Rear shock.

Although you can simply unbolt the caliper then disconnect the speedo drive and take it off with the sensor still in place. However if its not drained the oil will end up everywhere too once you put it on its side.

Now then what about the rear shock.....got to disconnect that too...

92KK 84WW Olaf wrote:

Dai wrote:Especially as the brake hose and speedo drive have been ripped apart.

That's the first thing I noticed.....
Now then what about the rear shock . . .

That's the first thing? 

How about the missing description of the disassembly of the engine or transmission to inspect their output shafts? Is that satisfactorily covered by the phrase ensuring you note the order and orientation of any washers, bearings, and seals? Even BMW calls a drive shaft a feckin drive shaft. Never mind the company's struggle applying the term differential to a one-wheel drive component. Regardless, AI must be getting a break here, too, because it's new at mentoring. Let's look forward to the humanoid avatars and their various regional dialects eventually talking us through self-surgery.

From the people who invented the BSOD.

(Blue Screen Of Death)

It reminds me somewhat of an old Clymer manual which wasn't far off this outline: park motorcycle securely on stand, gather required tools, initiate repair, test ride.

Laitch wrote:

92KK 84WW Olaf wrote:

Dai wrote:Especially as the brake hose and speedo drive have been ripped apart.

That's the first thing I noticed.....
Now then what about the rear shock . . .

That's the first thing? 

How about the missing description of the disassembly of the engine or transmission to inspect their output shafts? Is that satisfactorily covered by the phrase ensuring you note the order and orientation of any washers, bearings, and seals? Even BMW calls a drive shaft a feckin drive shaft. Never mind the company's struggle applying the term differential to a one-wheel drive component. Regardless, AI must be getting a break here, too, because it's new at mentoring. Let's look forward to the humanoid avatars and their various regional dialects eventually talking us through self-surgery.

What he said.

It is an output shaft, not a drive shaft, that I intend to look at. 

Not that I seriously expected copilot to be helpful, but I thought I’d ask it for a laugh. 

Bill