Gearbox out and apart

Steptoe

What a waste.
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This bikes off to south america at the end of the month, and the gearbox detent spring broke, so the bike was stuck in 3rd , lucky for the owner it decided to break before he left -

here's a quick idea of what's involved fixing it


opening up the gearbox
 

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inside the gearbox , gearchange mechanism is on the right as you look in the box
 

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this is the spring, cost about a £1 ,
 

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this is the broken spring
 

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screwdriver holding the broken spring
 

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Whatton said:
New camera for your birthday? :)

same camera , got a book on "the history of motorcycles" , whats that all about - anyway, on with the lesson -

while the box is apart, as its a fare old trek around S/america, best change the output shaft, input end bearing, it takes a lot of load, and is usually the bearing that gives up .
 

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then the box needs shimming up,
 

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heat up the end cover, put it back on the box, and it's done --


here's a good use for those sandwich makers/brevel type things, heats up the covers evenly while you can be getting on with other things, pick them up from boot sales for pennies ;)
 

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New clutch as well while it's all apart -

you don't have to take the tank, battery or side panels off when you remove the gearbox -
 

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Top Stuff Steptoe...

... I have often fancied buying a written off bike just to strip the gearbox down and see how it works as I just can't imagine from the pictures in manuals. The best to date was on "A Harley is Born" when that Vet chap did up an old 750 Harley and his explanation of the gearbox including selectors was brilliant.(pity I didn't tape it.

Have Fun

AndyT
 
Well I'll ask as I bet theres a lot wondering.

Why do you have to heat the cover up?
 
Re: Top Stuff Steptoe...

AndyT said:
... I have often fancied buying a written off bike just to strip the gearbox down and see how it works as I just can't imagine from the pictures in manuals.

Did this with my old 1150 gearbox and it's still a mystery :confused: Think they work by magic.

Nice pix Steptoe.
 
heated metal expands so bearings etc will go on easier :) over shafts

that or he wants to fill it with cheese and ham
 
Whatton said:
Well I'll ask as I bet theres a lot wondering.

Why do you have to heat the cover up?


the bearings on the gearshafts and shims, fit into the end cover, they're a tight fit and heating it up causes the end cover to expand so you can just drop it on, without any force, that could damage the end cover or the bearings .
 
what's the owner going to do if it needs similar work in south america ? Wouldn't it have been good practice for him/her to have a go at it at least?
 
Before Christmas did a similar job on a 1979 /7 gearbox where the output shaft bearing had broken up.

After trying to find a good 2nd hand 'box decided to rebuild it.

Just a tip, try local bearing suppliers before you buy from BMW or specialist suppliers. Took all the bearings in and found that they are standard sizes. Don't bother quoting the numbers on them over the phone, these are BMW's own numbers and won't help. My local supplier even had the input shaft seal in stock, Had to order the output shaft seal but it was next day.

Total cost of bearings and seals was about £80. The bearing supplier even let us use their 60 ton press to press the new bearings on! (2nd hand 'box was around £180, no warranty).

The detent spring was replaced as a matter of course as advised by those in the know.
 


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