Clutch replacement YES/NO, tips-experiences?

Margus. Your black engine/gearbox. Is that standard finish?
I didnt think they made a black engined 1100. Doesnt look like a 'paint job'
Enlighten us. Or thousands gsfolk will spend the rest of the day confused and unable to concentrate on important things.

No it's not a paint job, it's a factory special :)

http://micapeak.com/bmw/gs/gs_tel1.html#specifications

gs11r94g.jpg


r11gsoff.jpg


So yes, there in fact was a factory black crank+gearbox casing version of 1100 (not sure if it was only GS) available on a special order. Apparently with no extra price at the time (I may stand corrected here), but not many people know this or didn't want it - dominant most of 1100s are with silver coating I've seen. Black engines are very rare among 1100s.

My previous one was silver engined, this one's a black and IMO it's a very special 1100 :thumb
 
Here's a couple of helpful tips.

No need to dismantle the whole drive train ( the driveshaft splines do not need lubing, i've never ever seen splines worn on any "R" series bikes).



To center the clutch plate, insert the clutch pushrod, and then using a suitable sized allen key go around the pushrod to center the friction plate.







I have a selection of used input shafts that i use for centering plates.



I also use two dowels ( two long bolts with the heads cut off), inserted into the two middle gearbox mounting holes on each side of the engine, to align and slide the gearbox/finaldrive into place





Also add some copperslip/antisieze paste on the two locating dowels, as the gearbox can, and does, get stuck fast on these. So you or any one else who ever has to take it off again in the future will be eternally grateful :D





On an 1150, refit the gearbox without the pushrod in place, you can slide it through the gearbox afterwards.
On an 1100, fit the pushrod in place, and slide the gearbox onto it, rather than have the pushrod in the gearbox and try to line up the pushrod and input splines, because it is very easy to bend the pushrod or dislodge the diaphram spring center. ( the picture shown below is of an 1150, because thats what i had in yesterday, and just for the purpose of showing you what i mean :D )





If your doing the job single handed, as i do everytime, use a trolley jack to lift the gearbox/final drive, and slide the whole unit back in place. I did this one yesterday, and managed to take the pictures with one hand and slide the driveunit back with the other.
Also insert two rear wheel bolts into the final drive, and have the gearbox in gear, that way you can turn the bolts and the gearbox input shaft to help the splines line up as you slot it in.







 
Very useful tips there Steptoe :thumb2

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If doing the work alone and w/o bike stand and specialized tools you need additional pair of hands if you take the whole drivetrain off together (much weight to carry) to keep in level and not to bend the clutch arm on removal or on installation. Separate long bolts with heads cut off would effectively elliminate this risk, like Steptoe uses 'em :thumb
 
"I also use two dowels ( two long bolts with the heads cut off)"

What is the size of these bolts?
( in order to be ready )

Pekka
 
Splein

This is a splein ,from the clutch to the gearbox..It had run 169000 KM,,(I think that is abouth 100000 miles)..
R1150..
The clutch plate was 5,5 mm..
img-1231708769.jpg
I did not do anything with the splein,,I`l hope it wil live 30000km,,then I`l buy a new bike..
 
What an excellent post, just found it and need to replace the clutch on mine. Going to give it a go.

Anyone know the part number for the complete clutch kit?

David
 
Thanks but as I don't live in the UK I don't usually buy from them (Postage too expensive)

I've sourced one of the Lucas clutches from EBay in Germany and I'm going to give that a try as this is my third BMW clutch in 160,000kms so it will be nice if the Lucas Item lasts a bit longer that OE one. I'll let you know :-)

What else is in the clutch kit that I might need to buy separately?

Thanks for any help! :)

David
 
Thanks but as I don't live in the UK I don't usually buy from them (Postage too expensive)

I've sourced one of the Lucas clutches from EBay in Germany and I'm going to give that a try as this is my third BMW clutch in 160,000kms so it will be nice if the Lucas Item lasts a bit longer that OE one. I'll let you know :-)

What else is in the clutch kit that I might need to buy separately?

Thanks for any help! :)

David

the 6 bolts that retain the clutch housing to the flywheel, loctite and Honda Moly 60 to lube the splines; also guiding pins for the gearbox.
 
Hi Steptoe,
I just found your post here about clutch replacement on the boxer twin - but the photos are missing.
Do you still have them after all these years?!
Thanks,
Jon
 
all u guys changing clutches................i'd pm esmir(cel0001) on advrider and have him send you the cnc machined spacer with rivets to engage the clutch splines 6mm deeper into the tranny input splines. he just sent me one for $90 us including rivets. solves a lot of problems, think about it.
 
Esmir's Spacer

all u guys changing clutches................i'd pm esmir(cel0001) on advrider and have him send you the cnc machined spacer.
Hi - I think you must be the lucky guy who's received the very last one of the final batch of spacers from Esmir, who says he doesn't plan to source any more in the near future. I only just saw this thread in late July whilst on hols in the UK and am chewing iron bars at having just missed the chance of a spacer to fit to my 6-speed clutch friction plate.
Meanwhile I'm trying to get a local UK CNC machinist to replicate the item - but it's such a pity that all the work and cost investment has already been done in Florida and those of us 6-speeders who are concerned about premature spline wear on clutch input shafts are left sucking our thumbs.
ALAN - soon returning home to s.e. Spain
 
Yerp just had my clutch done at 58000 miles, (I knew it was biting with less 'feed in' and later). Grahams (Taunton) also spotted slave was weeping, pushrod needed replacing and cush rubbers going in driveshaft so replaced(SH) so pleased I had that done before my Spain trip end Aug !:rob
 
So Hugh, how did your trip to Spain in late Aug work out ?

Here on the s.e. Med coast we had some stunning temps throughout September - up towards the top 30s most days and very VERY humid. You must have steamed a lot ! No mechanical probs I hope. My clutch plate hub spacer is about to arrive from Esmir in the US of A. Then I can get the nitrile gloves on and set to...
ALAN
 


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