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1Back to top Go down   Output shaft repair Empty Output shaft repair Wed Nov 06, 2024 6:32 pm

indian036

indian036
Life time member
Life time member
Since Microsoft's new Copilot AI offered to help me out, I asked it to tell me how to repair the output shaft on my K100.
I thought I'd share the wisdom that Copilot gave me.

Repairing the Output Shaft on a BMW K100
A Step-by-Step Guide
The BMW K100, known for its durability and performance, sometimes requires maintenance, particularly on components like the output shaft. This guide provides a comprehensive step-by-step process to help you repair the output shaft on your BMW K100.
Tools and Materials Needed
·         Socket set
·         Torque wrench
·         Circlip pliers
·         Rubber mallet
·         Grease
·         Replacement output shaft parts (bearings, seals, etc.)
·         Service manual for BMW K100
·         Work gloves
·         Safety goggles
Step-by-Step Repair Instructions

1. Preparation

Begin by preparing your workspace and ensuring you have all necessary tools and parts. Make sure your motorcycle is on a stable surface, and use a motorcycle lift if available to make the process easier.

2. Remove the Rear Wheel

Use the socket set to remove the bolts securing the rear wheel to the swingarm. Carefully take off the rear wheel and set it aside.

3. Access the Output Shaft

Remove the final drive unit by loosening and taking out the mounting bolts. Be cautious as the final drive unit can be heavy. Once removed, you will have clear access to the output shaft and its surrounding components.

4. Disassemble the Output Shaft Assembly

Using the circlip pliers, remove the circlips holding the output shaft in place. Carefully take out the shaft, ensuring you note the order and orientation of any washers, bearings, and seals. It might be helpful to take pictures during disassembly to assist with reassembly.

5. Inspect and Replace Components

Once the output shaft is disassembled, inspect it and the related components for wear or damage. Replace any worn-out bearings, seals, or other parts with new ones. Clean the area thoroughly before reassembling to ensure no debris causes future issues.

6. Reassemble the Output Shaft

Reinsert the output shaft, making sure all components are in their correct positions. Use the rubber mallet to gently tap the shaft into place if necessary. Secure the shaft with the circlips you removed earlier.

7. Reattach the Final Drive Unit

Carefully reattach the final drive unit to the motorcycle, ensuring all bolts are tightened to the proper torque specifications as indicated in the service manual.

8. Reinstall the Rear Wheel

Place the rear wheel back onto the swingarm and secure it with the bolts. Make sure the wheel is properly aligned and spins freely.

9. Test the Repair

With everything reassembled, take your motorcycle for a short test ride. Pay attention to any unusual noises or vibrations that could indicate an issue with the repair. If everything feels and sounds normal, your output shaft repair is complete.

10. Routine Maintenance

To prolong the life of your output shaft and other components, perform regular maintenance on your BMW K100. Check for signs of wear and tear, lubricate moving parts, and adhere to the service intervals recommended by the manufacturer.
Conclusion
Repairing the output shaft on a BMW K100 can be a detailed process, but with the right tools, parts, and careful attention to detail, it is a manageable task. By following this guide, you can ensure your motorcycle continues to perform at its best and remains reliable for many miles to come.
If you encounter any difficulties during the repair or are unsure about any steps, consulting a professional mechanic or referring to the BMW K100 service manual is always recommended.
 




I take no responsibility for anyone following these instructions for repairing their output shaft.

Bill


__________________________________________________
1985 K100RT  VIN 0028991  My original Very Happy ROB the Red Old Bike   (Historic rego)
1985 K100RT  VIN 0029036  BOB the Blue Old Bike  (Historic rego)
1990 K100LT  VIN 0190452  Work in progress
1984 K100RT  VIN 0023022  Work needing lots of progress

1986 K100RT  VIN 0090542  Work needing lots and lots of progress
1993 K1100LT  VIN 0183046  Work in progress
1993 K75S  VIN 0213045  Tom the Triple (now on Historic rego too.)
    

2Back to top Go down   Output shaft repair Empty Re: Output shaft repair Thu Nov 07, 2024 8:18 am

Dai

Dai
Life time member
Life time member
Especially as the brake hose and speedo drive have been ripped apart.


__________________________________________________
1983 K100 naked upgraded to K100LT spec after spending time as an RS and an RT
1987 K100RT
Others...
1978 Moto Guzzi 850-T3, 1979 Moto Guzzi 850-T3 California,1993 Moto Guzzi 1100ie California
2020 Royal Enfield Bullet 500
    

3Back to top Go down   Output shaft repair Empty Re: Output shaft repair Thu Nov 07, 2024 10:07 am

92KK 84WW Olaf

avatar
Life time member
Life time member
Dai wrote:Especially as the brake hose and speedo drive have been ripped apart.
That's the first thing I noticed.....
Speedo sensor
Rear caliper
Rear shock.

Although you can simply unbolt the caliper then disconnect the speedo drive and take it off with the sensor still in place. However if its not drained the oil will end up everywhere too once you put it on its side.

Now then what about the rear shock.....got to disconnect that too...


__________________________________________________
1992 K100LT 0193214 Bertha Blue 101,000 miles
1984 K100RT 0022575 Brutus Baja Red 578 bought 36,000 now 89,150 miles
1997 K1100LT 0188024 Wotan Mystic Red 689 58,645 now 106,950 miles Deceased.
1983 K100RS 0011157 Fricka 606 Alaska Blue 29,495 miles Damn K Pox Its a Bat outta Hell Now 58,200 miles. 
1996 K1100LT 0233004 Lohengrin Mystic Red 38,000 miles currently 51,800 miles.
1983 K100RS 0004449 Odette R100 colours 58,000 miles. Sprint fairing now 63,390 miles

Past:
1968 Yamaha 80 YG1
1971 Yamaha 125 YAS-1
1968 Honda 125 SS
1970 Honda CD 175
1973 Honda CB500-4
Honda CX 500
    

4Back to top Go down   Output shaft repair Empty Re: Output shaft repair Thu Nov 07, 2024 12:36 pm

Laitch

Laitch
Life time member
Life time member
92KK 84WW Olaf wrote:
Dai wrote:Especially as the brake hose and speedo drive have been ripped apart.
That's the first thing I noticed.....
Now then what about the rear shock . . .
That's the first thing? 

How about the missing description of the disassembly of the engine or transmission to inspect their output shafts? Is that satisfactorily covered by the phrase ensuring you note the order and orientation of any washers, bearings, and seals? Smile Even BMW calls a drive shaft a feckin drive shaft. Never mind the company's struggle applying the term differential to a one-wheel drive component. Regardless, AI must be getting a break here, too, because it's new at mentoring. Laughing Let's look forward to the humanoid avatars and their various regional dialects eventually talking us through self-surgery.


__________________________________________________
1995 K75 90,000 miles
    

5Back to top Go down   Output shaft repair Empty Re: Output shaft repair Thu Nov 07, 2024 12:55 pm

duck

duck
Life time member
Life time member
From the people who invented the BSOD.

(Blue Screen Of Death)


__________________________________________________
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
91 K1
93 K75S (K11 front end)
91 K75S (K1 front end)
14 Yamaha WR250R
98 Taxi Cab K1200RS
14 K1600GT
http://www.ClassicKBikes.com
    

6Back to top Go down   Output shaft repair Empty Re: Output shaft repair Thu Nov 07, 2024 2:50 pm

Two Wheels Better

Two Wheels Better
Moderator
Moderator
It reminds me somewhat of an old Clymer manual which wasn't far off this outline: park motorcycle securely on stand, gather required tools, initiate repair, test ride.


__________________________________________________
The forest was shrinking, but the trees kept voting for the axe, for the axe was clever, and convinced the trees that because his handle was made of wood, he was one of them. -Turkish proverb
1977 R75/7-100, '93 K11/K12 Big Block, '93 K1100RS, '95 R100 Mystic, '96 K1100RS, 2 x '98 K1200RS, '06 K1200R & '09 K1300GT
    

7Back to top Go down   Output shaft repair Empty Re: Output shaft repair Fri Nov 08, 2024 5:14 am

indian036

indian036
Life time member
Life time member
Laitch wrote:
92KK 84WW Olaf wrote:
Dai wrote:Especially as the brake hose and speedo drive have been ripped apart.
That's the first thing I noticed.....
Now then what about the rear shock . . .
That's the first thing? 

How about the missing description of the disassembly of the engine or transmission to inspect their output shafts? Is that satisfactorily covered by the phrase ensuring you note the order and orientation of any washers, bearings, and seals? Smile Even BMW calls a drive shaft a feckin drive shaft. Never mind the company's struggle applying the term differential to a one-wheel drive component. Regardless, AI must be getting a break here, too, because it's new at mentoring. Laughing Let's look forward to the humanoid avatars and their various regional dialects eventually talking us through self-surgery.
What he said. 😁

It is an output shaft, not a drive shaft, that I intend to look at. 

Not that I seriously expected copilot to be helpful, but I thought I’d ask it for a laugh. 

Bill


__________________________________________________
1985 K100RT  VIN 0028991  My original Very Happy ROB the Red Old Bike   (Historic rego)
1985 K100RT  VIN 0029036  BOB the Blue Old Bike  (Historic rego)
1990 K100LT  VIN 0190452  Work in progress
1984 K100RT  VIN 0023022  Work needing lots of progress

1986 K100RT  VIN 0090542  Work needing lots and lots of progress
1993 K1100LT  VIN 0183046  Work in progress
1993 K75S  VIN 0213045  Tom the Triple (now on Historic rego too.)
    

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