BMW K bikes (Bricks)

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touchwoodsden

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I am changing some of the gears in my gearbox because I need higher ratios for my Mercedes Smart Diesel engined K 100. Iím 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 wouldnít. 20 tonnes wouldnít 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.

DSC04621

Taking the final drive apart is not for the fainthearted. Iím sure that shimming it up, on rebuild, is going to be ďinterestingĒ. Mine is now in a zillion pieces and ready for reassembly.

Donít 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.

DSC04816

DSC04819

Because Iím 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.

Iíve 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. Iím assuming that all the front of the driveshafts are 16 otherwise I might have to change gearboxes or make hybrid shaft.


I just thought Iíd share this little gem with you.



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

    

Dai

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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.


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'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

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What ratio are you using in the final drive?


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"Every normal man must be tempted, at times, to spit upon his hands, hoist the black flag, and begin slitting throats."† from Mencken's 1919 Prejudices

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

touchwoodsden

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I have the Clymer manual so I can see the process. I guess itís a case of just doing it carefully and not rushing.

RE: Ratios, †I havenít counted teeth but here they are.

DSC04609

DSC04608

DSC04607


DSC04605


DSC04604

    

touchwoodsden

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Assembled cluster with new gears †in situ. Pretty isnít it? Background is the back of a roll of wallpaper.


DSC04809

    

RicK G

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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.


__________________________________________________
"Every normal man must be tempted, at times, to spit upon his hands, hoist the black flag, and begin slitting throats."† from Mencken's 1919 Prejudices

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

rawdonball

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Interesting thread - thank you 'touchwood'

Keep us posted please.


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

8Back to top Go down    Diesel K100 on Mon Jun 20, 2016 5:21 am

touchwoodsden

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@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

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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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