R100gs Gearbox removal.

barny · Mar 8, 2019

Hi to all

Just a few of questions from the font of airhead knowledge. I have just been reading the Haynes Manual (rightly or wrongly) regarding Gearbox removal and would like some information from the people that have done the job.

1 - do I need to remove the engine bolts and move the engine?
2 - does the exhaust need to be removed? Or is this due to the engine being loosened? I have the standard system but with "Y" piece.
3 - Any other information would be appreciated.
4 - Does anyone rebuild drive shafts or is Motor-works the best bet? Mine has just started to click when sitting on the bike and rolling forwards or back, not continually but approximately once a wheel revolution.

The reason for removing the gearbox is so Mikey can rebuild it.

Thanks to all for looking :beerjug:

Barny

B Murr · Mar 8, 2019

1-No. I removed after removing swingarm.
2-No
3 refer to manual
If it were me I'd buy onme of those rebulddable ones that motorworks sells

clutchspring · Mar 8, 2019

You could do a lot worst than watch this chap on U tube.
https://youtu.be/uVKPGcf0xag

Ian.

Tbolt · Mar 8, 2019

Talk to Mikeyboy. He can also sort your driveshaft.

cookie · Mar 9, 2019

1. You can move the engine forward or take the swing arm out. I do the latter.

2. Not if you take the swing arm out. You'll probably need to remove the silencer though.

barny · Mar 13, 2019

Thanks for all the tips, have now completed the removal and Mikey has the gearbox. Incidentally if any one wants to just grease the clutch splines you can take the swinging arm and final drive out in one (R100gs) it did it single handed. This is what I had to do as some one has secured the inner FD pivot so tight my 1/2" drive T bar bent, and yes I had spent 10 mins heating it first. Now this is also with Mikey for his expertise. Regarding the drive shaft it looks like new and bearings are fine so I will be looking at the pivot bearings.

Thanks all
Barny

clutchspring · Mar 13, 2019

Glad you managed to remove the gear box barny , I to had a job undoing the left hand paralever pivot bolt I thought the bike was going to tip over at one point but mine did undue .

Ian.

B Murr · Mar 13, 2019

If guess some folks are going a bit crazy with the loctite. Hence the bugger of a job to get them off.

Steptoe · Mar 13, 2019

A few years ago i was curious at how long it would take me to remove a gearbox..... 14 minutes

Mind you, it was a case of the Hare and Tortoise as it took me a lot of time finding all the bits i'd chucked out of the way while "cracking on".

Battery and exhaust can all be left in place, swingarm chocked back enough to pop off the gearbox and remove from the L/H side.

mikeyboy · Mar 13, 2019

Not a happy box :comfort

mikeyboy · Mar 13, 2019

The front out put shaft bearing has collapsed in the past,resulting in the rear casing being damaged,on rebuild it has had incorrect bearings fitted and not been shimmed up to spec.
The bearing collapse has resulted in damaged gears

Garry H · Mar 13, 2019

B Murr said:
If guess some folks are going a bit crazy with the loctite. Hence the bugger of a job to get them off.

If your struggling to undo it you have not got it hot enough...Never had a problem
You can remove the gearbox in 30 mins easily once you have took a couple out
Another 30 mins to strip it

mikeyboy · Mar 13, 2019

The poor shimming has allowed the shafts to shunt and has hammered the oil baffle into the casing void :blast

mikeyboy · Mar 13, 2019

I’m also suspecting the poor (loose) shimming and c1 bearings have spun in the case and wrecked the shim and case

mikeyboy · Mar 13, 2019

Also the shunting on the shafts has pushed the bearing off a bit(no circlip)

mikeyboy · Mar 13, 2019

Essentially the box needs casings,bearings ,primary gears,,etc
So we will fix it with an exchange unit.
The reusable parts will go towards saving another box. :thumby:

clutchspring · Mar 14, 2019

Hi barny , was your gearbox still functioning or had it gone caput before you removed it .

Ian.

barny · Mar 14, 2019

It was this going, I did 100 miles along the North Norfolk coast about a week or so ago. It was a bit notchy 1st-2nd and changing down but otherwise OK.I was as surprised as Mikey when I saw the photos of what was in side. I only got the bike about 9 months ago from a friend who found it locally but it had been off the road for about 5 years. I am certain the friend I got it from is innocent he only had it for about 3 months and got a Harley so he won't have a clue about notchy gearboxes. I will be picking up one of Mikey's gearboxes tomorrow and my FD with some revisions, so should be able to report on the improvements next week.

Barny

Voyager · Mar 15, 2019

I've seen boxes like that before - so you are not alone.

One box (now my spare) had been so bad the gears had machined a groove on the inside of the case.

Its amazing how they keep going and will usually get you home

.

Bob.

gog · Mar 18, 2019

bob - do you still have a workshop?

R100gs Gearbox removal.

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