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1Back to top Go down   Transmission oil overfill/overpressure Empty Transmission oil overfill/overpressure on Fri Nov 09, 2018 5:00 pm

ERasberg

ERasberg
Silver member
Silver member
Hi everyone,

I have made a very basic mistake.

While changing transmission oil, I failed to follow the procedure of using the spanner as dipstick and hence filled 1.1L of transmission oil into the reservoir.

Coming home from the second trip since the oil change, see attached pictures of the leak. I assume I have overpressured the seal and it has burst.
That said, when draining the oil prior to the oil change, very little was left in the reservoir, so it is possible the seal was weak already. I bought the bike last year, this was my first transmission oil change.

I fear I have a pretty expensive problem on my hands and I am not sure how I should approach this in the most economical way.
Is this fixable or do i need to call give her to a garage ?
Can I drive her ?
About 2 dL of oil has poured out. I don't know how much has been lost while driving as I haven't drained the remaining oil yet.

Any input is highly appreciated.

Best regards,
Einar.Transmission oil overfill/overpressure 20181112
Transmission oil overfill/overpressure 20181111
Transmission oil overfill/overpressure 20181110


__________________________________________________
Present
1988 K100 RS SE - VIN# 0146971K100RS - 105,000 km
1998 R1200C
1971 R75/5

Previous
1999 Virago XV125
1981 R65
    

Two Wheels Better

Two Wheels Better
Moderator
Moderator
Since 900cc (+ or - 50cc) is required it seems you didn't add so much as to cause catastrophe. Did it simply leak out of the accordion boot at the clutch lever, or push past seals elsewhere? I'd drain off the excess, if still overfilled, and measure to the correct level, clean up the excess, and presumably the back tyre/brakes, and get yourself home.
It's unclear, other than wetness round the boot, where a leak is from the provided pictures.


__________________________________________________

1987 K100RS, '89 K100 w/K1100RS engine, '93 Framed K11/K12 engine 'Big Block', '96 K1100RS, '09 K1300GT, '13 R1200RT-P, '95 R100 Mystic & '77 R75/7.

    

duck

duck
Life time member
Life time member
Nothing to worry about. The transmission has a breather cap on top so it operates at ambient air pressure and can't "overpressure" to blow a seal.

When I purchased a K1100RS the prior owner had had it recently serviced at Ventura BMW where some dipstick techie filled the transmission up to the brim of the filler plug.  I rode it aggressively several hundred miles to friend's house before I checked all of the fluids and got the fluid back down to the right level.  Tens of thousands of miles on the bike since then and no issues.

It may just be that the boot at the back of the pushrod is old and worn out or there's a little too much oil in that..


__________________________________________________
Current stable:
86 Custom K100 (standard fairing, K75 Belly pan, Ceramic chromed engine covers, paralever)
K75 Frankenbrick (Paralever, K11 front end, hybrid ABS, K1100RS fairing, radial tires)
86 K75C Turbo w/ paralever
94 K1100RS
93 K1100LT (x2)
91 K1
93 K75S (K11 front end)
91 K75S (K1 front end)
14 Yamaha WR250R
http://www.ClassicKBikes.com
    

4Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Fri Nov 09, 2018 10:00 pm

Dai

Dai
Life time member
Life time member
Money's on a split clutch boot. Additionally, that looks like oil emulsion around the clip, so I'd drop ALL of the transmission oil, check it for water and start again.


__________________________________________________
'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)
    

ERasberg

ERasberg
Silver member
Silver member
Hi everyone,

thank you for the highly useful input, much appreciated.

@TWB : it looks as if the leak is from the accordion boot but I need to dry it all up and check it again as I can't see any immediate cracks in it. I will do as you suggest and refill it to the right level and test again.

@Duck : I was not aware there was a breather valve for the transmission fluid. It is definitely possible the spill is coming from there because, as earlier mentioned, I can't at the moment identify any visible cracks in the accordion boot.

@ Dai : You are right, well spotted, the oil is somewhat "white" in colour so I am wondering as well if there is emulsion or if it is simply dirt from the inside. The old oil that I drained out was dirty and possibly mixed with water. I should know more when I drain it again.


__________________________________________________
Present
1988 K100 RS SE - VIN# 0146971K100RS - 105,000 km
1998 R1200C
1971 R75/5

Previous
1999 Virago XV125
1981 R65
    

RicK G

RicK G
VIP
VIP
If the adjuster bolt at the back of that boot is too far in the seal around the rear of the boot is not good and it will leak oil.


__________________________________________________
"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
    

ERasberg

ERasberg
Silver member
Silver member
@RicK G wrote:If the adjuster bolt at the back of that boot is too far in the seal around the rear of the boot is not good and it will leak oil.

Hi Rick, thank you for the reply.
I will check that tomorrow first thing.
Is there a specific procedure to adjust that bolt ? I had it in for service at the beginning of the year and they changed the clutch cable. Could that have messed with the seal ?


__________________________________________________
Present
1988 K100 RS SE - VIN# 0146971K100RS - 105,000 km
1998 R1200C
1971 R75/5

Previous
1999 Virago XV125
1981 R65
    

RicK G

RicK G
VIP
VIP
It has to be correct at 75mm distance of the cable at the end of the actuating arm. If that is correct then check for a split. It is difficult to have an over adjustment on a K75 because the arm will hit the muffler and rattle.


__________________________________________________
"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
    

ERasberg

ERasberg
Silver member
Silver member
@RicK G wrote:It has to be correct at 75mm distance of the cable at the end of the actuating arm. If that is correct then check for a split. It is difficult to have an over adjustment on a K75 because the arm will hit the muffler and rattle.

Great, I will do that. Thank you for the pointer ! 
Much appreciated.


__________________________________________________
Present
1988 K100 RS SE - VIN# 0146971K100RS - 105,000 km
1998 R1200C
1971 R75/5

Previous
1999 Virago XV125
1981 R65
    

10Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Mon Nov 12, 2018 9:47 pm

duck

duck
Life time member
Life time member
From the BMW shop manual:

Transmission oil overfill/overpressure K_Bike_Clutch_Adjust


Any easy way to hold the clutch arm in place while doing this is to pull in the clutch and place a piece of wood between the clutch arm and exhaust to release the end of the clutch cable for adjusting it.

Good idea to grease the ferule on the end of the clutch cable before reattaching it.


__________________________________________________
Current stable:
86 Custom K100 (standard fairing, K75 Belly pan, Ceramic chromed engine covers, paralever)
K75 Frankenbrick (Paralever, K11 front end, hybrid ABS, K1100RS fairing, radial tires)
86 K75C Turbo w/ paralever
94 K1100RS
93 K1100LT (x2)
91 K1
93 K75S (K11 front end)
91 K75S (K1 front end)
14 Yamaha WR250R
http://www.ClassicKBikes.com
    

11Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Mon Nov 12, 2018 11:29 pm

Point-Seven-five

Point-Seven-five
Life time member
Life time member
@RicK G wrote:If the adjuster bolt at the back of that boot is too far in the seal around the rear of the boot is not good and it will leak oil.
And water can get in if you ride in the rain.


__________________________________________________
Present:
1994 K75RT
1991 K100RS
1988 K100RS SE

Past:
1994 BMW K75S
1992 BMW K100RS
1982 Honda FT500
1979 Honda XR185
1977 Honda XL125
1974 Honda XL125
1972 OSSA Pioneer 250
1968 Kawasaki 175
    

12Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Tue Nov 13, 2018 8:12 am

ERasberg

ERasberg
Silver member
Silver member
@ Duck : Thank you for that illustration Duck ! Very clear.

If I understand you correctly, in my case it should be a question of properly setting Adjusting Screw (7), as this is the one that can potentially compromise the accordion seal.

The distance relating to the below mentioned 75mm is that not for the clutch cable "slack" and potential clutch plate wear etc.?


@ PSF : Yes you are right, I ride a lot in the rain.  Hence a big concern to see potential emulsion as it does not suggest just an over-pressure situation merely bled off through the breather valve, but rather communication with the environment. Not good.


__________________________________________________
Present
1988 K100 RS SE - VIN# 0146971K100RS - 105,000 km
1998 R1200C
1971 R75/5

Previous
1999 Virago XV125
1981 R65
    

13Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Tue Nov 13, 2018 12:03 pm

duck

duck
Life time member
Life time member
Yes, that 75mm slack is supposedly only for a brand new clutch plate but I've done it many times with used clutch plates without issue.

It's rare but I've seen it where the tip of the bolt into the boot is not seated/centered properly so you should check that while you fiddling around down there.

Caution: If you let all of the clutch arm pressure off of a used boot there's a spring in the boot that can cause it to tear.


__________________________________________________
Current stable:
86 Custom K100 (standard fairing, K75 Belly pan, Ceramic chromed engine covers, paralever)
K75 Frankenbrick (Paralever, K11 front end, hybrid ABS, K1100RS fairing, radial tires)
86 K75C Turbo w/ paralever
94 K1100RS
93 K1100LT (x2)
91 K1
93 K75S (K11 front end)
91 K75S (K1 front end)
14 Yamaha WR250R
http://www.ClassicKBikes.com
    

14Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Tue Nov 13, 2018 12:08 pm

Two Wheels Better

Two Wheels Better
Moderator
Moderator
I think the last clutch release arm accordian boot I bought from the dealership set me back about US$30! (23 13 1 338 731) 

Mind the thin 40mm screw clamp is in good nick, too. (23 13 1 241 872)


__________________________________________________

1987 K100RS, '89 K100 w/K1100RS engine, '93 Framed K11/K12 engine 'Big Block', '96 K1100RS, '09 K1300GT, '13 R1200RT-P, '95 R100 Mystic & '77 R75/7.

    

15Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Tue Nov 13, 2018 3:19 pm

Point-Seven-five

Point-Seven-five
Life time member
Life time member
@Two Wheels Better wrote:I think the last clutch release arm accordian boot I bought from the dealership set me back about US$30! (23 13 1 338 731)
That was a long time ago.  The recent price increase added about $4.00, bringing the current price to $46.91.


__________________________________________________
Present:
1994 K75RT
1991 K100RS
1988 K100RS SE

Past:
1994 BMW K75S
1992 BMW K100RS
1982 Honda FT500
1979 Honda XR185
1977 Honda XL125
1974 Honda XL125
1972 OSSA Pioneer 250
1968 Kawasaki 175
    

16Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Wed Nov 14, 2018 7:38 am

Dai

Dai
Life time member
Life time member
Someone's pocketing a lot of additional money there; I absolutely refuse to believe that shipping costs make up the difference between U$19.01 (which is what is costs me from Motorworks) and what you guys are paying. If you buy from here, you'll pay U$15.20 plus the shipping (no VAT tax for overseas buyers) and there's no way is the shipping going to be U$20.


__________________________________________________
'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)
    

17Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Wed Nov 14, 2018 10:35 am

Point-Seven-five

Point-Seven-five
Life time member
Life time member
Dai, BMW has been doing absolutely bizarre price increases the past couple years.  Some parts have had their price raised 10% and 15% year after year.  I think that in 2016 they did two increases in one year.  I have receipts from 4 and 5 years ago for parts that have had their price nearly double at a time when inflation in the U.S. is less than 2%.

For example, on MAX BMW's official parts fiche, the tank badge was about $16 in 2014, they recently "adjusted" the price on it to $29.22.  If I didn't know better, I'd think they don't want to sell K bike parts anymore.

I sincerely feel bad for anyone trying to restore an old brick today with new factory parts.  So glad my bikes are in good nick and I have a nice stash of used stuff that should last me until I can't ride anymore.


__________________________________________________
Present:
1994 K75RT
1991 K100RS
1988 K100RS SE

Past:
1994 BMW K75S
1992 BMW K100RS
1982 Honda FT500
1979 Honda XR185
1977 Honda XL125
1974 Honda XL125
1972 OSSA Pioneer 250
1968 Kawasaki 175
    

18Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Wed Nov 14, 2018 10:46 am

Two Wheels Better

Two Wheels Better
Moderator
Moderator
That $30 accordian boot? I pay 5% over actual dealer cost (don't hate me, please) on OEM parts due to a long working relationship with my two local dealers, but am not shielded from their price rises of late. I had to buy a spare chipped, coded key for my K13. These keys used to cost under $50. A few months back I paid nearly $80. Nothing has changed but the price. I don't drop as much coin in there lately.


__________________________________________________

1987 K100RS, '89 K100 w/K1100RS engine, '93 Framed K11/K12 engine 'Big Block', '96 K1100RS, '09 K1300GT, '13 R1200RT-P, '95 R100 Mystic & '77 R75/7.

    

19Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Wed Nov 14, 2018 11:30 am

duck

duck
Life time member
Life time member
@Dai wrote:Someone's pocketing a lot of additional money there; I absolutely refuse to believe that shipping costs make up the difference between U$19.01 (which is what is costs me from Motorworks) and what you guys are paying. If you buy from here, you'll pay U$15.20 plus the shipping (no VAT tax for overseas buyers) and there's no way is the shipping going to be U$20.

BMW makes a decent markup on parts and then dealers make a huge markup on parts on top of that. It's part of the business model and helps pay for the brick and mortar.


__________________________________________________
Current stable:
86 Custom K100 (standard fairing, K75 Belly pan, Ceramic chromed engine covers, paralever)
K75 Frankenbrick (Paralever, K11 front end, hybrid ABS, K1100RS fairing, radial tires)
86 K75C Turbo w/ paralever
94 K1100RS
93 K1100LT (x2)
91 K1
93 K75S (K11 front end)
91 K75S (K1 front end)
14 Yamaha WR250R
http://www.ClassicKBikes.com
    

20Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Wed Nov 14, 2018 11:37 am

Two Wheels Better

Two Wheels Better
Moderator
Moderator
The average markup on OEM parts (from dealer cost to suggested retail)  to dealers from BMWNA is about 32%. 15 years ago it was closer to 40%. OEM are, of course, marked up beyond 'retail' pricing by some dealers, but with the advent of online OEM parts catalogues with published prices those are few and far between. The distributor makes the margin. For the dealers, it's in the aftermarket where margin is made.

An example of this is that for an item a customer pays, say, $100, the dealership has paid BMW $72. If the dealer has got it in for you on the VOR order programme (overnight), BMW tack on an additional 6% to the dealer's cost. But perhaps this is best shifted to another topic as we're running roughshod over the original post.


__________________________________________________

1987 K100RS, '89 K100 w/K1100RS engine, '93 Framed K11/K12 engine 'Big Block', '96 K1100RS, '09 K1300GT, '13 R1200RT-P, '95 R100 Mystic & '77 R75/7.

    

21Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Wed Nov 14, 2018 6:14 pm

ERasberg

ERasberg
Silver member
Silver member
Hi everyone,

Your continued replies have been really useful for my own understanding as well as troubleshooting of the issue on my bike.

I finally managed to identify the problem, there is a tear in the accordion boot on the upward facing side. I suspect overfilling it has caused it to go from a fracture to an open tear. It also explains the water emulsion.

Next question ; can i fix this (read ; change the accordion boot) myself in my parking garage with standard tools ? Also keeping in mind I would prefer not to mess too much with the clutch cable vs clutch plate adjustments. I'm trying to look for a how-to-guide on how to change it but so far unsuccessful. 

@TWB, some posts transforms into other topics and takes on their own lives, it's one of the things I love about this forum ! And now I already know the reference number and price of the faulty part. Bonus !

What @Duck said on BMW's business model. I frankly find their after service rather ridiculous here in France. It's premium pricing for not even average service.


__________________________________________________
Present
1988 K100 RS SE - VIN# 0146971K100RS - 105,000 km
1998 R1200C
1971 R75/5

Previous
1999 Virago XV125
1981 R65
    

22Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Wed Nov 14, 2018 6:23 pm

duck

duck
Life time member
Life time member
You can replace it without tearing the bike apart.

Advisable to drain the transmission first but you don't really have to.

Disconnect the clutch cable from the clutch arm.

There's a small hose clamp that attaches the base of the boot to the transmission that you'll need to undo.  You'll need a small regular (flat head) screwdriver to do that.

Transmission oil overfill/overpressure WQtahqO



Last edited by duck on Wed Nov 14, 2018 6:33 pm; edited 1 time in total


__________________________________________________
Current stable:
86 Custom K100 (standard fairing, K75 Belly pan, Ceramic chromed engine covers, paralever)
K75 Frankenbrick (Paralever, K11 front end, hybrid ABS, K1100RS fairing, radial tires)
86 K75C Turbo w/ paralever
94 K1100RS
93 K1100LT (x2)
91 K1
93 K75S (K11 front end)
91 K75S (K1 front end)
14 Yamaha WR250R
http://www.ClassicKBikes.com
    

23Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Wed Nov 14, 2018 6:31 pm

ERasberg

ERasberg
Silver member
Silver member
@ Duck : Awesome ! thanks for the quick reply. Sounds easy enough ! I'll give it a go once I'm back from travels and can source the part. 

HUGE relief for me, as I feared this would be an expensive affair.


__________________________________________________
Present
1988 K100 RS SE - VIN# 0146971K100RS - 105,000 km
1998 R1200C
1971 R75/5

Previous
1999 Virago XV125
1981 R65
    

24Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Wed Nov 14, 2018 6:44 pm

duck

duck
Life time member
Life time member
It's not THAT easy. Undoing and redoing the tiny screw of that clamp is kind of a pain and will cost you a swear word or two. Mad

But at least it's not an expensive or complicated repair.


__________________________________________________
Current stable:
86 Custom K100 (standard fairing, K75 Belly pan, Ceramic chromed engine covers, paralever)
K75 Frankenbrick (Paralever, K11 front end, hybrid ABS, K1100RS fairing, radial tires)
86 K75C Turbo w/ paralever
94 K1100RS
93 K1100LT (x2)
91 K1
93 K75S (K11 front end)
91 K75S (K1 front end)
14 Yamaha WR250R
http://www.ClassicKBikes.com
    

25Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Wed Nov 14, 2018 6:51 pm

ERasberg

ERasberg
Silver member
Silver member
Haha fair enough ! And thanks for the warning.

I'll brush up on colourful language before attempting the repair.


__________________________________________________
Present
1988 K100 RS SE - VIN# 0146971K100RS - 105,000 km
1998 R1200C
1971 R75/5

Previous
1999 Virago XV125
1981 R65
    

26Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Wed Nov 14, 2018 6:57 pm

duck

duck
Life time member
Life time member
I haven't done one in a while but I think the last time I did, once I got the boot seated, I reattached the clutch arm to keep things in place while tightening the clamp as there's a spring inside the boot pushing it out.


__________________________________________________
Current stable:
86 Custom K100 (standard fairing, K75 Belly pan, Ceramic chromed engine covers, paralever)
K75 Frankenbrick (Paralever, K11 front end, hybrid ABS, K1100RS fairing, radial tires)
86 K75C Turbo w/ paralever
94 K1100RS
93 K1100LT (x2)
91 K1
93 K75S (K11 front end)
91 K75S (K1 front end)
14 Yamaha WR250R
http://www.ClassicKBikes.com
    

27Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Wed Nov 14, 2018 7:01 pm

ERasberg

ERasberg
Silver member
Silver member
Good advice thank you. I will do that.


__________________________________________________
Present
1988 K100 RS SE - VIN# 0146971K100RS - 105,000 km
1998 R1200C
1971 R75/5

Previous
1999 Virago XV125
1981 R65
    

28Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Thu Nov 15, 2018 5:24 am

92KK 84WW Olaf

92KK 84WW Olaf
Life time member
Life time member
Also, for anyone reading this thread, if you are ever tempted to use a powerwasher on your K to clean out around the swing arm, you WILL blow the clutch boot off its mounting and get water in the transmission. Chances are you will also put water in the gear position indicator switch.



Last edited by 92KK 84WW Olaf on Tue Nov 20, 2018 9:36 pm; edited 1 time in total


__________________________________________________
1992 K100LT 0193214 Bertha Alaska Blue 101,000 miles
1984 K100RT 0022575 Brutus Baja Red bought 36,000 now 89,150 miles
1997 K1100LT 0188024 Wotan Mystic Red 58,645 now 98,780 miles
1983 K100RS 0011171 Fricka 29,495 miles Damn K Pox Its a Bat outta Hell No 32,600 miles
    

29Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Thu Nov 15, 2018 9:41 am

Point-Seven-five

Point-Seven-five
Life time member
Life time member
+1 on what Olaf said.  That is the one part of the k-bike that is better left dirty than clean.


__________________________________________________
Present:
1994 K75RT
1991 K100RS
1988 K100RS SE

Past:
1994 BMW K75S
1992 BMW K100RS
1982 Honda FT500
1979 Honda XR185
1977 Honda XL125
1974 Honda XL125
1972 OSSA Pioneer 250
1968 Kawasaki 175
    

30Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Thu Nov 15, 2018 11:46 am

duck

duck
Life time member
Life time member
@Point-Seven-five wrote:+1 on what Olaf said.  That is the one part of the k-bike that is better left dirty than clean.

There's a TON of road grime that builds up inside the back of K bike transmissions though.

I do agree that pressure washing them is a very BAD idea as I think water can also get in via the breather cap.

However, if I have time when doing a spline lube and have the transmission removed, I usually wash them with engine degreaser (Gunk), a sponge and a garden hose, being careful not to get any water in the breather cap or clutch boot.

Transmission oil overfill/overpressure YMsTpKt

I also do the same to the center stand assembly.


__________________________________________________
Current stable:
86 Custom K100 (standard fairing, K75 Belly pan, Ceramic chromed engine covers, paralever)
K75 Frankenbrick (Paralever, K11 front end, hybrid ABS, K1100RS fairing, radial tires)
86 K75C Turbo w/ paralever
94 K1100RS
93 K1100LT (x2)
91 K1
93 K75S (K11 front end)
91 K75S (K1 front end)
14 Yamaha WR250R
http://www.ClassicKBikes.com
    

31Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Tue Nov 20, 2018 6:42 pm

ERasberg

ERasberg
Silver member
Silver member
Hey guys,

Update on my progress, it is not an especially easy task so far. I hope I'm not in over my head.

I managed to take off the boot and remove the spring with a plyer after much hassle and by tearing apart the accordion boot. See attached picture. Transmission oil overfill/overpressure 20181115

As you can see I have very little clearance between the clutch arm and the seat of the spring.
To test, I tried to reseat the spring only, and but were unable to do so.

Any advise on how to proceed with the installation of the new boot ?

The main problem I will have is to get the spring into its seat while simultaneously fitting the accordion boot. See attached picture. Transmission oil overfill/overpressure 20181116

My bike is a K100RS, the clutch arm cannot bend out further as it's touching the exhaust pipe.
Is there an easy way to remove the arm completely that I have failed to identify ?

Your input as always highly appreciated.

Best regards,
Einar.

PS : ref the above discussion on cost, I paid a total of €40.73 for the boot, the spring and the clamp.


__________________________________________________
Present
1988 K100 RS SE - VIN# 0146971K100RS - 105,000 km
1998 R1200C
1971 R75/5

Previous
1999 Virago XV125
1981 R65
    

32Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Tue Nov 20, 2018 9:41 pm

Laitch

Laitch
Life time member
Life time member
Either the muffler is removed, or the muffler and header pipes are removed together, then the side stand retracting rod is removed before removal and installation of that boot is attempted. Transmission oil overfill/overpressure 177381 That allows the clutch arm to swing away from the piston. Just keep your head down, keep moving forward, and get a manual. There are a couple of them downloadable from this site.

Forget about easy or difficult.


__________________________________________________
1995 K75 73,000 miles
Transmission oil overfill/overpressure Usa-lo10
    

33Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Tue Nov 20, 2018 11:48 pm

MartinW

MartinW
Life time member
Life time member
While you are doing this do yourself a favour and fit a grease nipple to the clutch arm. Occasional greasing will stop water and road crap from getting in and lengthen the life of your clutch cable. Lubricating your cable with a PTFE based lubricant also helps along with greasing the cable nipples at both ends and the lever pivot points. Some non PTFE based lubricants can degrade the Teflon liner in the cable.
Regards Martin.
Transmission oil overfill/overpressure Clutch14



Last edited by MartinW on Wed Nov 21, 2018 2:37 am; edited 1 time in total (Reason for editing : Added Photo)


__________________________________________________
K75s Hybrid
    

34Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Wed Nov 21, 2018 5:56 am

ERasberg

ERasberg
Silver member
Silver member
@ Laitch : Thanks for the feedback, I will do that then. The reason I'm trying to anticipate the level of complexity is because all I have is a parking garage and standard tools.

@ MartinW : Good tip, I will look into installing one. Anything increasing the lifetime of these critical components is welcome.


__________________________________________________
Present
1988 K100 RS SE - VIN# 0146971K100RS - 105,000 km
1998 R1200C
1971 R75/5

Previous
1999 Virago XV125
1981 R65
    

35Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Wed Nov 21, 2018 6:35 am

92KK 84WW Olaf

92KK 84WW Olaf
Life time member
Life time member
@Laitch wrote:Either the muffler is removed, or the muffler and header pipes are removed together, then the side stand retracting rod is removed before removal and installation of that boot is attempted. Transmission oil overfill/overpressure 177381 That allows the clutch arm to swing away from the piston. Just keep your head down, keep moving forward, and get a manual. There are a couple of them downloadable from this site.

Forget about easy or difficult.

If you are on a 16v the standard muffler is a one piece so it comes off as one piece. Watch the procedure for refitting [its in the manuals too] it and may be advisable to have new mounting bushes. Lots and lots of WD40 on the header nuts before you go at them.


__________________________________________________
1992 K100LT 0193214 Bertha Alaska Blue 101,000 miles
1984 K100RT 0022575 Brutus Baja Red bought 36,000 now 89,150 miles
1997 K1100LT 0188024 Wotan Mystic Red 58,645 now 98,780 miles
1983 K100RS 0011171 Fricka 29,495 miles Damn K Pox Its a Bat outta Hell No 32,600 miles
    

36Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Wed Nov 21, 2018 6:42 am

ERasberg

ERasberg
Silver member
Silver member
@92KK 84WW Olaf wrote:


If you are on a 16v the standard muffler is a one piece so it comes off as one piece. Watch the procedure for refitting [its in the manuals too] it and may be advisable to have new mounting bushes. Lots and lots of WD40 on the header nuts before you go at them.

Thank you I'll keep that in mind. I'll read up and give it a go tonight and see how far I get.


__________________________________________________
Present
1988 K100 RS SE - VIN# 0146971K100RS - 105,000 km
1998 R1200C
1971 R75/5

Previous
1999 Virago XV125
1981 R65
    

37Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Wed Nov 21, 2018 6:47 am

92KK 84WW Olaf

92KK 84WW Olaf
Life time member
Life time member
The photo looks like its got clamps on the headers to muffler connection like on 2v but even with that most remove it as one piece. If you do find you are opening those clamps no problem apart from needing to make sure you line them up as they are jig saw pieces, be sure to get some good photos before you open any of them.


__________________________________________________
1992 K100LT 0193214 Bertha Alaska Blue 101,000 miles
1984 K100RT 0022575 Brutus Baja Red bought 36,000 now 89,150 miles
1997 K1100LT 0188024 Wotan Mystic Red 58,645 now 98,780 miles
1983 K100RS 0011171 Fricka 29,495 miles Damn K Pox Its a Bat outta Hell No 32,600 miles
    

38Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Wed Nov 21, 2018 6:53 am

ERasberg

ERasberg
Silver member
Silver member
Hi Olaf

It's a 2V and hence not a one-piece as you correctly identified. 

I'll see if I can get it off in one piece. And yes, taking plenty of photos should hopefully help with the reassembly. 

It says in the manual that there are sealing rings that must be changed. Is this strictly necessary ? I would have to order them in that case.


__________________________________________________
Present
1988 K100 RS SE - VIN# 0146971K100RS - 105,000 km
1998 R1200C
1971 R75/5

Previous
1999 Virago XV125
1981 R65
    

39Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Wed Nov 21, 2018 9:41 am

Laitch

Laitch
Life time member
Life time member
@ERasberg wrote: The reason I'm trying to anticipate the level of complexity is because all I have is a parking garage and standard tools.
You might find this video inspiring, regarding constrained work space.


__________________________________________________
1995 K75 73,000 miles
Transmission oil overfill/overpressure Usa-lo10
    

40Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Wed Nov 21, 2018 10:29 am

92KK 84WW Olaf

92KK 84WW Olaf
Life time member
Life time member
Its a job you can do roadside. The thing is to get lots of the WD40 on the stud nuts and studs .....but unless you have had that off in more recent times it may not be as simple...this is what I do. Before going at the exhaust I have new nuts studs and the sealing rings. The nuts can be split it needed, leaving the studs in, but sometimes the studs come out with the nuts. Having all new makes it easy and quick to put back. Copper paste on the studs before you screw them in. You are likely to end up with a few spare studs but always useful to have them. Now I am on Ks a while I slacken off the nuts and retighten every few months so I know if I have to get the exhaust off I won't have issues.

Watching this with interest because my K100RT needs a new clutch boot fitted. It got one in early 2017 when I did the clutch and rear main seal but its failed.


__________________________________________________
1992 K100LT 0193214 Bertha Alaska Blue 101,000 miles
1984 K100RT 0022575 Brutus Baja Red bought 36,000 now 89,150 miles
1997 K1100LT 0188024 Wotan Mystic Red 58,645 now 98,780 miles
1983 K100RS 0011171 Fricka 29,495 miles Damn K Pox Its a Bat outta Hell No 32,600 miles
    

41Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Wed Nov 21, 2018 10:57 am

ERasberg

ERasberg
Silver member
Silver member
@ Olaf : Thanks a lot for the encouragement and all the valuable advise. I lack spare studs, bolts and seals so I'll start by dismantling while the order is being processed. 

I'll find out tonight regarding the mechanical integrity of the exhaust. It looked pretty rusty but fingers crossed.


__________________________________________________
Present
1988 K100 RS SE - VIN# 0146971K100RS - 105,000 km
1998 R1200C
1971 R75/5

Previous
1999 Virago XV125
1981 R65
    

42Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Wed Nov 21, 2018 11:28 am

Point-Seven-five

Point-Seven-five
Life time member
Life time member
Being a lazy git, my approach would be to undo the muffler mount to the footpeg plate, loosen the clamps where the headers attach to the muffler inlet and angle the muffler down to gain clearance without actually removing it.  If I still need clearance, I'd loosen the nuts at the cylinder head so the headers can be angled down a bit as well.


__________________________________________________
Present:
1994 K75RT
1991 K100RS
1988 K100RS SE

Past:
1994 BMW K75S
1992 BMW K100RS
1982 Honda FT500
1979 Honda XR185
1977 Honda XL125
1974 Honda XL125
1972 OSSA Pioneer 250
1968 Kawasaki 175
    

43Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Wed Nov 21, 2018 12:52 pm

ERasberg

ERasberg
Silver member
Silver member
Hi PSF ; yes I too hope that it will be enough to bend or remove the muffler only.

I have decided to do it in two steps :
Muffler first - bend then remove
Headers second - bend then remove if necessary.

It's a bit more time consuming, but it might be easier for a rookie like me instead of trying to undo it all in one piece knowing the headers probably won't slide out of their seats like pistons.
Whether they can be bent remains to be seen. 

I'll probably be back in a few hours with more questions...bear with me... scratch


__________________________________________________
Present
1988 K100 RS SE - VIN# 0146971K100RS - 105,000 km
1998 R1200C
1971 R75/5

Previous
1999 Virago XV125
1981 R65
    

44Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Wed Nov 21, 2018 12:56 pm

duck

duck
Life time member
Life time member
On a K100 it is much better to remove the can and the headers as one unit.  Getting the headers lined up and attached to the exhaust can again can be a PITA.


__________________________________________________
Current stable:
86 Custom K100 (standard fairing, K75 Belly pan, Ceramic chromed engine covers, paralever)
K75 Frankenbrick (Paralever, K11 front end, hybrid ABS, K1100RS fairing, radial tires)
86 K75C Turbo w/ paralever
94 K1100RS
93 K1100LT (x2)
91 K1
93 K75S (K11 front end)
91 K75S (K1 front end)
14 Yamaha WR250R
http://www.ClassicKBikes.com
    

45Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Wed Nov 21, 2018 2:42 pm

92KK 84WW Olaf

92KK 84WW Olaf
Life time member
Life time member
I am totally with Duck on that one.

If you decide to bend the muffler to one side and that's not working for you I think I would bolt it back up again and then remove as one piece. The idea of separating the headers and clamps is well explored and its a real PITA getting it back together.

However, if you do end up with it apart.........POLISH THE DARN HEADERS while you have them off!!!


__________________________________________________
1992 K100LT 0193214 Bertha Alaska Blue 101,000 miles
1984 K100RT 0022575 Brutus Baja Red bought 36,000 now 89,150 miles
1997 K1100LT 0188024 Wotan Mystic Red 58,645 now 98,780 miles
1983 K100RS 0011171 Fricka 29,495 miles Damn K Pox Its a Bat outta Hell No 32,600 miles
    

46Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Wed Nov 21, 2018 3:22 pm

ERasberg

ERasberg
Silver member
Silver member
Hey guys, thanks for the advise. I'll keep that in mind while proceeding (with caution).

Just back from the garage now, and there are two screws too rusty to be removed. One on the muffler cover and one on the foot peg.

For now I have soaked the muffler clamps + screws in WD40 and loosened up the screws I could on the muffler cover and foot peg.

I will need to drill the two remaining screws tomorrow before I can proceed.
Will keep you posted once I get over this hurdle.

Einar/


__________________________________________________
Present
1988 K100 RS SE - VIN# 0146971K100RS - 105,000 km
1998 R1200C
1971 R75/5

Previous
1999 Virago XV125
1981 R65
    

47Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Wed Nov 21, 2018 5:24 pm

nobbylon

nobbylon
Silver member
Silver member
I honestly think it’s easier to just undo the 8 nuts and 2 bolts and take the complete exhaust off. Getting the silencer lined up and pushed on is a royal pita.


__________________________________________________
R1100GS Feb 1995
K100RS July 1989
R90s June 1975
R75/6 Feb 1976
F650GD May 2001
    

48Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Wed Nov 21, 2018 10:51 pm

duck

duck
Life time member
Life time member
@nobbylon wrote:I honestly think it’s easier to just undo the 8 nuts and 2 bolts and take the complete exhaust off. Getting the silencer lined up and pushed on is a royal pita.

Yep. After you've done it once you'll never want to do it again if you can avoid it.  It's one of those things that looks like it should be simple but isn't.


__________________________________________________
Current stable:
86 Custom K100 (standard fairing, K75 Belly pan, Ceramic chromed engine covers, paralever)
K75 Frankenbrick (Paralever, K11 front end, hybrid ABS, K1100RS fairing, radial tires)
86 K75C Turbo w/ paralever
94 K1100RS
93 K1100LT (x2)
91 K1
93 K75S (K11 front end)
91 K75S (K1 front end)
14 Yamaha WR250R
http://www.ClassicKBikes.com
    

49Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Thu Nov 22, 2018 1:25 am

nobbylon

nobbylon
Silver member
Silver member
Spray some penetrating fluid on the 8 nuts and leave for an hour or so. Start the bike up to get the studs and nuts hot and using a good quality socket they unscrew easily. Careful not to burn yourself.


__________________________________________________
R1100GS Feb 1995
K100RS July 1989
R90s June 1975
R75/6 Feb 1976
F650GD May 2001
    

50Back to top Go down   Transmission oil overfill/overpressure Empty Re: Transmission oil overfill/overpressure on Thu Nov 22, 2018 8:13 am

Dai

Dai
Life time member
Life time member
That procedure is recommended by Delkovic exhausts for removing the easily-broken studs on a Bandit but they say soak the studs every day for a week first. I'd add; at the end of the week (!) go out and ride it to get it seriously hot and then use a side-drive socket, not a 12-point one. With a side-drive socket you stand far less chance of rounding off the nut. I now only use 12-point sockets when I really have no other choice.


__________________________________________________
'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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