Gearbox removal

[sigood]

Hi
I have attempted to remove the gearbox today to change the clutch.Removed the 6 bolts and replaced 2 of them with guide pins as per clymer manual.Dosn't seem as though it wants to budge in the bottom right corner.I have pushed and pulled but to no avail.
Have i missed something or am i not being brutal enough ?
It's a 98 GS 1100.
Any ideas very much appreciated !

Simon

 

[Steptoe]

are you asking for advice on removing ? or replacing -

there are locating dowels, that are a tight fit, which also get a build up of corrosion .

check it's just those holding it on, if so pull top out to get a gap, insert a small pry bar and lever and move gently down to you get to the dowels, you should now be able to see them.

Just lever box away - thats providing you've removed all the securing bolts ?

 

[Rob Farmer]

The earth cable gets wrapped round the battery tray mounting studs and makes it difficult to seperate because the studs prevent you moving the cases in any other direction but away from the engine...bet you bend the pushrod...don't ask how i know

 

[boxer]

The earth cable gets wrapped round the battery tray mounting studs and makes it difficult to seperate because the studs prevent you moving the cases in any other direction but away from the engine...bet you bend the pushrod...don't ask how i know

Here's a picture of the cable Rob mentions. It really does make the job much mre difficult. Removing the fuel rail also helps a lot.

I found that the use of guide pins restricted the amount the gearbox could be manoeuvred when trying to move the box around the cable.

Looking back I think it should be possible to engineer some sort of access to the caphead which retains the cable. The cable could then be removed while the box is removed and installed.


Russ.

 

[sigood]

Thanks !

It was just the bottom right locating dowel that was a bit corroded.
Managed not to bend push rod somehow.Although had to order some new bolts that hold fly wheel on as i rounded heads off a bit.
There is a lot of black sooty deposit,is this normal for clutch?
If there was a leak from crank case seal would it be obvious and wetter ?

Simon

 

[finglonga]

Have a look HERE and HERE lots of usefull info.

 

[sigood]

Wish i had seen that earlier.I would have left the swing arm on, final drive on and the wheel.
That's the trouble of going by the book.Not looking forward to putting it all back together.Still, all good experience !

Cheers !

Simon