BMW K bikes (Bricks)

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touchwoodsden

touchwoodsden
Silver member
Silver member
I am changing some of the gears in my gearbox because I need higher ratios for my Mercedes Smart Diesel engined K 100. I’m also changing the final drive ratios and one of the guys in Germany as had a whole gear set cut. It basically doubles the overall ratio.
 
The gearbox is done. Removing the large gear of the intermediate shaft (the centre top one in the gears shown on the photograph below) needs a lot of pressure. 10 tonnes wouldn’t. 20 tonnes wouldn’t touch it. It needs 40 tonnes. The centre shaft is non-serviceable-allegedly
 
Here is the cluster before changing the gears. You can see the new shiny years adjacent to what they are going to replace.
 
High Ratio gears and final drive. Changing gears and bevel box pinion removal. 27328616691_31ee898d16_cDSC04621
 
Taking the final drive apart is not for the fainthearted. I’m sure that shimming it up, on rebuild, is going to be “interesting”. Mine is now in a zillion pieces and ready for reassembly.
 
Don’t even attempt to strip the K 100 final drive unless you have a 36 mm impact socket, a long bar, and a tool to remove the 4 slotted ring nut which holds in the final drive pinion. I made the tool by welding 4 wings onto an old socket. They are both v tight. The manual says use heat.
 
High Ratio gears and final drive. Changing gears and bevel box pinion removal. 27157794503_3499494e7a_cDSC04816
 
High Ratio gears and final drive. Changing gears and bevel box pinion removal. 27156693004_a317e78ea4_cDSC04819
 
Because I’m replacing both the crown wheel and the pinion, all the parts which fit on the crown wheel and pinion have to be removed. The one job that took longer than anything else was removing the inner race of the nose of the pinion which fits into the needle roller bearing in the aluminium housing. There is nothing to get the bearing puller on.
 
The large bearing came off with the help of a 10 ton press and the centre part of the crown wheel (the aluminium bit) succumbed to a few tonnes less.
 
I’ve now got to think about putting it back together and doing all the correct shimming. Deep joy.
 
I do have one problem and that is that the input splines on the pinion of the final drive has 20 splines and my shaft is 16 splines. I may need to find another shaft. I’m assuming that all the front of the driveshafts are 16 otherwise I might have to change gearboxes or make hybrid shaft.
 

I just thought I’d share this little gem with you.



Last edited by touchwoodsden on Mon Jun 20, 2016 5:16 am; edited 1 time in total

    

Dai

Dai
Life time member
Life time member
Well, if shimming it up is as 'interesting' as shimming Guzzi drives, then put aside at least a half-day. Or a full one, if it decides to fight back.


__________________________________________________
'83 K100 upgraded to K100RS spec
Others...
'78 Moto Guzzi 850-T3, '79 Moto Guzzi 850-T3 California,'93 Moto Guzzi 1100ie California,
'03 Suzuki Blandit GSF600SK3 (NFS any more because wifey has claimed it)
    

RicK G

RicK G
VIP
VIP
What ratio are you using in the final drive?


__________________________________________________
"Man sacrifices his health in order to make money.
Then he sacrifices money to recuperate his health.
And then he is so anxious about the future that he does not enjoy the present; the result being that he does not live in the present or the future; he lives as if he is never going to die, and then dies having never really lived."   Dalai Lama


Bikes 1993 K1100 LT, 1998 K1100 LT, 1993 K75 RT, 1996 K75RT, 1986 K75 GS, 1979 Z1300 Kawasaki X 2 for now
    

touchwoodsden

touchwoodsden
Silver member
Silver member
I have the Clymer manual so I can see the process. I guess it’s a case of just doing it carefully and not rushing.
 
RE: Ratios,  I haven’t counted teeth but here they are.
 
High Ratio gears and final drive. Changing gears and bevel box pinion removal. 27697024341_4689b9b1a8_cDSC04609 
 
High Ratio gears and final drive. Changing gears and bevel box pinion removal. 27670845322_f53306395d_cDSC04608
 
High Ratio gears and final drive. Changing gears and bevel box pinion removal. 27159371354_c5b737c2d3_cDSC04607
 
 
High Ratio gears and final drive. Changing gears and bevel box pinion removal. 27771312425_dea36f79b3_cDSC04605
 

High Ratio gears and final drive. Changing gears and bevel box pinion removal. 27697068011_9273192a2e_cDSC04604

    

touchwoodsden

touchwoodsden
Silver member
Silver member
Assembled cluster with new gears  in situ. Pretty isn’t it? Background is the back of a roll of wallpaper.
 

High Ratio gears and final drive. Changing gears and bevel box pinion removal. 27772355285_c2ecc143b1_cDSC04809

    

RicK G

RicK G
VIP
VIP
That Crown and pinion is 13/31 (2.38) did you get them made and if not where the heck did you get them. I've never heard of a BMW ratio that high. 2.52 was the best I could come up with when I went looking.


__________________________________________________
"Man sacrifices his health in order to make money.
Then he sacrifices money to recuperate his health.
And then he is so anxious about the future that he does not enjoy the present; the result being that he does not live in the present or the future; he lives as if he is never going to die, and then dies having never really lived."   Dalai Lama


Bikes 1993 K1100 LT, 1998 K1100 LT, 1993 K75 RT, 1996 K75RT, 1986 K75 GS, 1979 Z1300 Kawasaki X 2 for now
    

rawdonball

rawdonball
Platinum member
Platinum member
Interesting thread - thank you 'touchwood'

Keep us posted please.


__________________________________________________
'88 K100RT, '86 K75C, '05 Yamaha TTR250
    

8Back to top Go down   High Ratio gears and final drive. Changing gears and bevel box pinion removal. Empty Diesel K100 on Mon Jun 20, 2016 5:21 am

touchwoodsden

touchwoodsden
Silver member
Silver member
@rawdonball wrote:Interesting thread - thank you 'touchwood'

Keep us posted please.
 Indeed I will. The story so far is here:
http://www.suckindiesel.com/thingy/viewtopic.php?f=31&t=3216

    

Dai

Dai
Life time member
Life time member
I should have kept my gob firmly shut. I just spent six-and-a-half hours shimming a Guzzi bevel drive. I really hope you have better luck than I did.


__________________________________________________
'83 K100 upgraded to K100RS spec
Others...
'78 Moto Guzzi 850-T3, '79 Moto Guzzi 850-T3 California,'93 Moto Guzzi 1100ie California,
'03 Suzuki Blandit GSF600SK3 (NFS any more because wifey has claimed it)
    

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