Hi everyon



I have worked on my K100 for the past three weekends in an attempt to remove the gearbox. I was trying to figure out a way to support the bike. after much research on the internet, I decided to purchase two ratchet tie down straps. i placed the bike between two verandah posts and I tied a strap to the bike frame and to the verandah posts on either side of the bike..perfect solution....tightened the straps to keep the bike upright and used blocks of wood to support the sump. the bike faces the side fence and stops the front wheel from moving.

anyway, finally removed the final drive...splines are in excellent condition, but I noticed there was a small amount of oil which leaked from the final drive as I pulled it from the side arm. should i be concerned?

the splines on the driveshaft end are in excellent condition. i used a vice to try and remove the driveshaft from the gearbox...no luck..wouldn't budge!!!! managed to put a few small scratches on the driveshaft???!....finally gave up and decided to remove the gearbox with the driveshaft attached...

1st question..how do i remove the driveshaft from the gearbox?

2nd question. how do i remove the clutch arm fromn the gearbox..i removed the circlips..actually destroyed them...couldn't see anty other way of removing them......lightly tapped it with a soft head hammer..no luck..any ideas?

The gearbox splines are in excellent condition but i have what i think is the problem of the loose grub screw. the foot lever can be pulled out of the gearbox..is it an easy fix to open the gearbox or should i leave it for trhe experts.

i also noticed a build up of grease? around the clutch. it seems to have built up over many years..should i remove the clutch and inspect the rear main seal or could it be the clutch o-ring?

i am new at this caper and your opinions and advice is always appreciated.



regards

gabriel

http://www.flyingbrick.de/Video/Video.html
Gabriel- check these from u-tube, will help you, these guys are well practised.

Hi Gabes
I was a novice and had to take all back end off bike to replace a leaking rear output shaft seal, here is a link to the tutorial section that Crazy frog kindly posted last year. Even though its in German it gave me the confidence to give it a go which I did and it worked..

http://k100rt.aforumfree.com/t1407-replacing-the-output-shaft-seal

sincerely hope it helps in some way

ps.I wouldnt mess with rear output seal unless the buggars asking for it.

gabriel wrote:1st question..how do i remove the driveshaft from the gearbox?
2nd question. how do i remove the clutch arm fromn the gearbox..i removed the circlips..actually destroyed them...couldn't see anty other way of removing them......lightly tapped it with a soft head hammer..no luck..any ideas?

Driveshaft: Made a tool for this, to be used together with a slide hammer.



Brute force isn`t what`s needed, but a sharp snatch backwards.

Have a look at Bert`s restoration page for another metod.



Clutch arm: Try to add some heat to the "ears" on the gearbox.



Inge K.

hi everyone



thanks for all the suggestions..had a quick look at the videos..those germans made it look so simple..not certain if they were using a locking vice grip..they didnt even need a hammer..they used the face of the swing arm for leverage....i must be missing something..i just cant figure it out..i purchased the biggest locking vice grips i could find but they wouldn't lock.....so i exchanged it for a pair of the long handle vice grips..dont know if i will have enough strength to pull it out but will give it a go....the gearbox is out but im thinking perhaps i will leave the clutch arm in place..i don;t think i need to remove it to replace the rubber boot...any comments?

took me three weekends to remove the gearbox..those germans made it look like child's play...

cheers

You don't need to remove the clutch actuator arm to replace the rubber boot and to get the driveshaft place a large screwdriver into the space of the uni joint and lever against the gearbox with some thing to protect the gearbox case and give it a short but hard wack with your fist so as to lever the shaft rearwards and it should come off. To replace it put it on the splines and a sharp tap with the handle end of a hammer it will clip back into place.

thanks for the suggestions. i have removed the gearbox from the frame. i removed the swing arm and left the driveshaft attached to the geaarbox. i noticed that the rubber boot is not clamped onto the rer of the gearbox.

is it possible to reattach the driveshaft to the gearbox and then install the swing arm. that way, the splines can be aligned a lot easier that trying to guess.

any ideas about the gearbox..anyone have any experience opening the gearbox? not certin if i should give it a go.....i think all i need to do is replace the grub screw but i an scared i will mess things up as soon as i remove the end cover..

suggestions/ideas are appreciated.

cheers

Yeah you can attach the shaft and then put the swinging arm in place.

You should be able to do the grub screw by just lifting the lid on the gearbox but be careful not to lose the shims or mix them up. They often stay in the bearing recess and are not very noticeable.

Clean the area around the grub screw and use a good locktite on it.

When you put the lid back on use only the bare minimium of sealant.