Gearbox removal GSPD Classic

[Crapaud]

Took some step by step photos of my gearbox removal. Might be useful for someone? Amazingly quick and simple with no special tools needed.

Step 1
Get Proff's mechanic to help (although be warned the nutter might phone you at crack of dawn on a Sunday morning and turn up 30 minutes later).

Step 2
Loosen the clips and remove air intakes.

Step 3
As an aside, the3 mechanic noticed that excess oil from the breather had partially blocked the holes at bottom of carbs and needed to be cleaned out.

Step 4
Repeat on other side of machine.

Step 5.
Remove earth strap and speedo drive(?) infront of gaiter.

Step 6.
Remove side panel/ exhaust shield.

Step 7.
Remove air filter. This mechanic is so quick that if I blicked I might have missed a few steps.

Step 8.
Strip out airbox.

Step 9.
Remove base of airbox with two 6mm allen bolts.

Step 10.
Replace bolt in centre top of gearbox to prevent anything getting into gearbox.

Step 11.
Back around other sideof bike and remove 4 bolts to gearbox output. NB these need to be replaced on re-assembly.

Step 12.
Remove swing arm pivot bolts to allow drive shaft to move backwards.

Step 13.
Remove clutch arm etc.

Step 14.
Wriggle gearbox rearwards.

Step 15.
Move LHS carb to allow room for gearbox to slide out.

Step 16.
Job done! Gearbox removed.Don't forget to remove all oil before packinging it up (eh Thunder)

Check clutch and remember white grease will be needed for re-assembly.

Finished and packaged up in box for despatch:

Apologies for my numpty description of technical names for bits, I'm sure the purists are crying/screaming at all my errors and mis-descriptions of bits.

Probably took me longer to type this thread than it did to remove box.

 

[Rob Farmer]

Nice write up Sid and great photo's

 

[Kenny]

Yup...top write-up....did the same thing the other week ( Vern hampered my speed though )..as long as you have the special socket for the swingarm bearing nut, then all is fairly simple

Also the best 10mm spanner for doing up the swingarm to gearbox ( those four stretch bolts that Sid says need - and they do - renewing ) is the factory toolkit ring spanner

 

[ameldridge]

Very interesting, cheers for the info

 

[Rob Farmer]

That gearbox has had a rebuild in the not too distant past. There's virtually no dust on the clutch end and you can see it's been blasted.

 

[Kenny]

That gearbox has had a rebuild in the not too distant past. There's virtually no dust on the clutch end and you can see it's been blasted.

Must have been one of your rebuilds then?

 

[Crapaud]

That gearbox has had a rebuild in the not too distant past. There's virtually no dust on the clutch end and you can see it's been blasted.

Definitely agree.

It was noticably cleaner than the engine casings. Also those stretch bolts had done just that and were not tight. I'll pick up some new ones from Sherlock this week.

I suspect it must have been tampered with in Jersey. There is only one mechanic on the island who knows anything about airheads (ex police mechanic) and I think he has retired. I would never trust any of the othere so called mechanics to touch an airhead as I have had bad experiences in the past.

At least this time it will be done properly by an acknowledged expert.

 

[Rob Farmer]

Must have been one of your rebuilds then?

I'd never use anything as course as that. You'll be getting a few beads poured in your gearbox next time I see you for that

 

[MickDB1]

Fabulous write up Sid

It almost makes it look like a pleasure to remove - its so easy - to follow as well

Mines comin off tomorro for a COLA ( coat of lookin at )
5th gear has gone and 3rd whines like a windgin wife

Got to get it mended for the wee doo
Or I will have bring it on me XT for examination /repair - dare not come on an oilhead

 

[(RIP) Proff]

Yup...top write-up....did the same thing the other week ( Vern hampered my speed though )..as long as you have the special socket for the swingarm bearing nut, then all is fairly simple

Also the best 10mm spanner for doing up the swingarm to gearbox ( those four stretch bolts that Sid says need - and they do - renewing ) is the factory toolkit ring spanner

Great write up Sid..
Know what you mean about his speed Blink and it's done

The Special socket for the swingarm is available from Sherlocks
Same as the Alternator rotor removal bolt.
Very reasonably priced and make life a lot easier

My Mechanic { He's also my best mate of over 20 years }, MONK left his at Sids.. so he's borrowed mine now (

 

[Kenny]

MONK left his at Sids.. so he's borrowed mine now (

I wonder if Monk made it home










OK OK..I'll close the door behind me !!

 

[ameldridge]

The Special socket for the swingarm is available from Sherlocks
Same as the Alternator rotor removal bolt.
Very reasonably priced and make life a lot easier

I'd be grateful if someone could confirm if this is the correct part?

123027 Swinging arm 27mm socket, fits recess £7.76

As listed on the .pdf http://www.james-sherlock.co.uk/pdf/Tyres-and-other-parts.pdf page 5

Thanks

 

[(RIP) Proff]

I'd be grateful if someone could confirm if this is the correct part?

123027 Swinging arm 27mm socket, fits recess £7.76

As listed on the .pdf http://www.james-sherlock.co.uk/pdf/Tyres-and-other-parts.pdf page 5

Thanks

I'm sure

 

[toadjam]

stretch bolts

might sound like idiot here .

can the stretch bolts be fitted with a ring spanner ??? .
i,ve just done mine and struggled like buggery to get a socket on to them .

 

[Kenny]

Ring spanner is fine ( especially the genuine BMW one from the bikes tool kit )...just do them up very tight !!

( And stuff a rag into the rubber gaitor to stop a dropped bolt from falling down and inside the shaft etc)

 

[Rob Farmer]

i,ve just done mine and struggled like buggery to get a socket on to them .

You're my hero. Didn't know it was possible to get a socket in there.

 

[Voyager]

You're my hero. Didn't know it was possible to get a socket in there.

+1 (unless its one of those fixed sockets with a swivel head - about the size of a 10mm ring spanner ).


Nice write-up Sid.

Just one thing . . You didn't mention the clutch pushrod. I remove it completely before attempting to wriggle the gearbox out - just in case it gets bent.

I guess that's filed under "Clutch Arm etc. . . . ".

(thought I'd mention it in case someone was about to do this for the first time).


Bob.

(Think I'd better replace the timing chain before the 'do', in case Proff hears it ).

 

[bumpmuncher]

You're my hero. Didn't know it was possible to get a socket in there.

iirc when i did mine i refitted the shaft before putting the swing arm back on and used a deep reach 3/8 drive socket

1000 miles on and the gearbox is sweet

 

[Rob Farmer]

(Think I'd better replace the timing chain before the 'do', in case Proff hears it ).

You could always get Proffs mechanic to set it one tooth out. That'll slow you down

 

[(RIP) Proff]

You could always get Proffs mechanic to set it one tooth out. That'll slow you down

OOOOOOOOO MEEEOOOWWWW Bitchy !!!!!



It wasn't obvious and it was easily missed