Hi Guys
My K100 has only covered 24k and is a 1984 although to look at I guess the 24k must have been done cross country
The problem started when the clutch started getting hard to pull in and eventually it was tricky to get into lower gears on the change down. Having read through a few forums I was directed to the clutch spline which might need lubricating. I have had cars in bits but this was my first major bike overhaul.

I raised the bike up and supported the engine, then added weight to the front end and fastened it down, please bear in mind this was done as a field breakdown and with a minimum of tools and a trolley jack. I am really surprised how much you can achieve with a hex set and a few wrenches. I tend to dive in and see whats happening and then read afterwords

I took off the rear wheel and supported the drive shaft (rope to the frame) I did say this was a field repair, removed the seat,battery,module,mudguard, heat shield, left hand foot rest and the water expansion tank. I then took off the landing gear ( stand and side stand ). I then removed the big nut from the rear suspension (not the one holding the wrench) and a bolt eihter side going into the frame. Unclipped some wires. So far so good, I removed the plastic shield around the alternator and all the bolts around the gearbox/tranny. The purist among you now must be yelling at the screen by now, but just wait there is more....... I then figured that the gearbox was ready to be removed. I got a pice of soft wood and a hammer and gave the gearbox a few light taps to get it apart from the engine. That worked beutifully and the two seperated. The gearbox/tranny was supported by a trolley jack and the rope on the frame held the drive shaft at the right height. I rolled the gearbox away and I could see the spline, it was brownish and did not look too clean. With a tooth brush I set about cleaning the spline and the engine where it fit, a little Moly just to make the merest of lubrication. I checked and cleaned the clutch lever mechanism on the underside and put the thing back together. I checked the clutch action and the lever was easier but not quite right so I changed the clutch cable for a new one. This now did the job and the clutch action is smooth....nice. Time for a nice pint of warm beer and a cuban cigar....after all this field work I deserved it.

The bike runs great and all gears are working just fine, I will upload some pictures of the spline if anyone is interested. All in a days work for the novice field tech :pirat:

Very good for you.
I suspect that your only problem was the cable but since greasing the splines is very important, you made the right choice by removing the gear box. when removing the gear box, it's always good to reseal the switch for the gear digital display. Cleaning and greasing the clutch lever is also important.

Hope you enjoyed the warm beer and Cuban cigar. Did you give yourself a big pat on the shoulder?

As most of the time, the first big job on a K bike is very intimidating, but soon you discover that you need only few tools and minimal mechanical knowledge. On the plus side, if you really get stocked, you can quiz the people from this forum and within hours (sometimes minutes) somebody will come to the rescue.

Congratulation, and yes post some pictures.

Bert

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Hi
Thanks Bert, I enjoyed doing the job and I was surprised at how easy it was...beginners luck maybe