Halo wrote:

Only people not doing anything are the ones not making mistakes.
Don't you think that I didn't make any mistakes when I rebuilt my K100?
The good thing is that we recognize it and share our bad luck with others.
Yes we feel sorry for you, but when you do this kind of restoration small mistakes are expected.
Just loosen the oil pan, pull the output seal and re-install the ring.

CF

Cheers CF the belly aching stops now , boy you are everywhere on this forum arn't you "omni present". Time to man up boy I love this forum

mentoring thrown in for free as well

Halo

Halo wrote:mentoring thrown in for free as well
Halo

How many people follow your thread, and how many of them gained experience by reading your posts?
You see you are a very good player when it comes to mentoring.

Most of us start as ignorant and progress because of people like you sharing their experience.

Cheers CF

Mistakes is done all the time...eg post 496, 497....have a look around in other forums.....I`ll guess it`s only a few that tells the story about their mistakes.

Since the seeger ring was dirty I would guess it`s from your spare engine parts,
but I`m quite shure that no one on this forum being in the same situation........
would have a good sleep untill they have checked.....to be shure.

Inge K. wrote:I`m quite shure that no one on this forum being in the same situation........
would have a good sleep untill they have checked.....to be shure.

This is true. I would loose sleep over an issue like this.
This only proves our dedication to restore a bike in perfect condition.
Nothing is ever easy and the challenge is what makes us proud of our accomplishments.
Road blocks are only a bump as we have the support of our mates (No, I am not an Aussie to use this word ). Here they are buddies. (in Canada, the word `mate`is well used on ships when everybody relies on each others for survival)

CF

Yes the strip down will commence and I have learn't that my quality control is flawled so I will revise. Expanded drawings with torque settings labeled to the relevant parts would help etc. Thanks Inge K for your help as well with this do I need to replace the circlip ? do I need to replace the nut on the clutch plate ?.

Halo

[quote= do I need to replace the nut on the clutch plate ?.

Halo[/quote]

According to BMW the nut should be replaced. Will I replace the nut if it was me?
Honestly NO.

This is your call.

CF

Thanks CF agreed it was new/ replaced a month ago from motobins CF in Australia eveyone is your mate until proven otherwise yes we do use the word loosely.

Halo

As a thumb rule a lock nut is a one time use................
But in real life some have used them more than once w/o any problem.........
and yours is rather "fresh".

When you have unscrewed the nut, turn it back in, and feel if you got a good resistance at the outer end of the threads...you don`t need to get the whole shaft through the nut....if in doubt you could add some Loctite.

About the seeger ring, it don`t seem to have lost it`s tension since you measured the same inside dia. as the unused I got.

Then you have the diaphgram spring (which also is a one time use), it should be good tension on this against the seeger ring....so it could be a bit tricky to get the seeger ring into the grove.

Cheers Inge K I will be stripping it right down again so reassembly should be ok it was finding all the torque settings that was time consuming.

Halo

Chin up mate.
In a few kilometres time it will all be behind you.

Thanks Saxon it was the first part of my rebuild done on a crummy old table before the metal benches were built (still no excuse) so it will give me a chance to check all parts again on the upside it will be a nice change to dismantle a clean engine on a proper work bench:D

Halo

This will cheer you up and give a laugh but it was far from funny when it was happening.
I bought the K1100 and it need some work doing as they do and decided to sell the K100 but wanted to keep the gearbox because it was part of the paralever set up that I wqas going to put in the K100.
I rebuilt a K100 gearbox and installed it in the K100 and sold it. Then removed the box from the K1100 and bought seals and bearings and clutch etc to do at the same time. Rebuilt the gearbox, replaced the clutch and reinstalled then found on the bench the new rear main seal for the K11 so out with the box and in with the seal and back goes the box and next morning I see a drip of oil under the bike so I investigate. Sure enough its gear oil so out comes the box and the clutch is covered in oil. I had not drained the box when I removed it and while sitting on the floor the oil had managed to get into the input shaft where the pushrod goes so when I cleaned it all and put the box back the oil had pushed through onto the clutch. Cool put it all back and all is OK
Next The lass that bought the K100 said the bike was making a strange noise so I said bring it back and I found it was clutch related so out with the k100 box and found I had not gerased the wire ring and it was making the noise . greased it and she went on her way.
next I rego the K1100 and go for a ride with bert and charlie ,alby etc and the clutch is slipping so next day out with the box and clutch. Problem was the pressure plate and drive plate had dished so that about 3/16inch was contacting round the outer edge so I used a good pressure plate and machined a drive plate to flat and all was well after I reinstalled and so far thats it.
All in all over about 4 weeks 6 gearbox removals and I was getting quick at doing them.
Now I can laugh at it but I certainly wasn't seeing the funny side at the time.

Yes thanks Rick G that did help you poor bugger I bet you didn't see the funny side of it at the time. Wish it wasn't so deep in the engine guts though.

Halo

A few weeks ago while I was in Sydney I took out the old cooling fan and radiator and put new ones in. It ended up being quite an involved job because of the sidecar mounts, Took a few hours in the end with the help of two mates. We had to take the sidecar off more or less so we could rotate the radiator forward to get it out etc...After all this....I took the bike for a ride around Palm Beach and then back to Paul's and let it sit and idle....and idle...and idle...but no fan cut in. Eventually the red overheating light came on...I wasn't a happy camper.
I rode it the 450 or km home, all the while vaguely worried about it, but not overly so as there's not much traffic up through Gloucester etc. Got it home and parked it in the shed in disgust with the people I bought the fan from. I am doing the ride from Guyra to Melbourne and all points in between over xmas and started to wrack my brains about what to do about it...another fan? Where from? Alby had suggested I get an aftermarket one with higher revolutions etc and I should have followed his advice in the first place. Something would have to be done...as summer on the flatlands is apt to get a bit warm.
Then came Charlie and Alby to visit. They insisted on having a look at the bike and giving it a going over with the carb tune kit etc. They did a great job and also adjusted the idle which was a little high at idle.

" Hey mate....your fan was never going to work, you know......"

" Oh ( says I) why not?"

" You need to plug it in first................................"

Saxon7 wrote:...You need to plug it in first...

Brilliant! Thanks for that belly laugh at 0645h! Nearly lost my coffee!

Halo, when you have your first ride on your bike all the setbacks will soon be forgotten, I have done a few full restorations in my time and the path to success is never easy. You will always have the odd thing like this happen. Walk away for a day or two and then get stuck back into it. It is going to be a stunning looking bike when you are finished.

Fantastic Saxon7 what a story, cheers
Steve you are right of coarse just abit of a shock at the time but l'm getting over it
Halo

Well the stripdown is going well you learn from doing the job once so the time spent was productive I did this after work





Halo

You're not wasting any time at all. Good on you for getting stuck right in to the job, mate!

Mate, you are better than me. That bike would have a tarp over it by now if it was at my house. Or ebay.

Did you get a new friction plate? The center looks very shiney. Cotton bud and tears again?

We`re all as excited as you about what hides behind the clutch.

woohoo looks brilliant halo

hope you remembered to seal up the lower tb runners with some drie bond .....(3 bond) works a treat ...hmm left mine at albys ...dang ....

Yes new clutch plate no tarp for this old girl thanks charlie see if I didnt strip her down again I wouldnt have used dry bond I still think they look just great when you have the whole drive train sitting there by itself.
Yes inge k cant wait to look i believe it wont be there as on my first page you can clearly see the part about a third down the page.
Halo

Halo wrote:Yes inge k cant wait to look i believe it wont be there as on my first page you can clearly see the part about a third down the page.

Yes, did see it at the bottom of the picture.

If it`s missing, your next step would be to search for the diaphgram spring.

This restauration thread amazes me more and more.

Halo, by reading through this thread I started to believe you're supernatural, but you fould us all by showing some humanes.... Only to showcase some more extraordinary efforts and before we blinked our eyes , you already teir appart you amazing "brick" and start to fix you supposed mistake.(if any)

Halo, you're my hero


Respect from up above
(since you are "down under")

Thanks Amster just learning along the way and sharing the journey, well the shed is a mess with parts everywhere. I managed to pull apart what I had done within two long movies that I hired to keep the wife and kids happy (read busy) for the last two evenings, but anyway the verdicts out



I left the circlip out





Halo

Phew........!

I would need planning approval from 3 councils to get a shed like that built in my back yard. Very jealous.
Looks like your cunning system for parts catalogueing is working.
I did not get my bike as stripped as yours, but I guess leaving that clip out would have resulted in some nasty metal grinding and sparks?
After all this you must be busting a gut to start that motor.

Rossco you are EXACTLY correct I really want to kick her over as I have never started her yet

Halo

Don't forget the water and oil seals when closing the engine
I just saw on the picture that one O Ring is missing

that was lucky a cheap fix just more inconvenience imagine if you actually fired the old girl up
well done mate

Yes lucky find but must learn from this one all parts inspection now to the catalog drawings
Thanks CF good catch there see your everywhere (It was stuck to the other mating surface)
Halo

Geez Halo i just read this, man what a good thing that you found the snap ring before starting it up.

Bad luck but i see you have it all sorted. Nice work.

I see you have the same shed storage designer as i do.

Keep up the great work and inspirational info and spirit. CF is right you know, the work you are doing and posting it up here inspires others to have a go too. All good i reckon.

was well worth it to check

Gents, I do believe we should select a day and time to have a beer or two with Halo. One to comisserate (belatedly) and one to honor his hard work. Good job on the clip, two days to tear down and correct. Cheers to you Halo.

keith

nice job going back in, I tell my son when we are working on his 69 MGB and run into tough problems "the key to success is perseverance", and you have it.

Good job!

Yes can't wait to finish the resto cafe racer so I can get my shed back!. Col the more I think about it I am very lucky to have checked and not started the engine as it was . Kfilipow shall I go and get an extra slub of beer for the beer fridge and be exspecting visitors?. Nice car Yankeeone yes you know whwt they say 10% brillance and 90% perseverence.

indeed halo

ably and i are still wondering about the lateral moovement of the output shaft ...how it affects the clutch ...vibrations and all sorts of things

a conundrum indeed !

love your work

Sounds to me Charlie like I should visit my local BMW shop and ask him if I should buy/fit in the SHIM, mine being the early model

CF?

Halo

charlie99 wrote:indeed halo

ably and i are still wondering about the lateral moovement of the output shaft ...how it affects the clutch ...vibrations and all sorts of things

a conundrum indeed !

love your work

You shouldn't have any lateral movement in the output shaft. There will be quite a bit before you fit the clutch carrier but after that is fitted it should be solid as a rock. If it isn't then go looking for why.

there is a shim between the output shaft and the clutch carrier.

yankeeone wrote:there is a shim between the output shaft and the clutch carrier.

Yes there is a spacer.
Here are the references (part # 19)



CF

perfect bert ...that explains it all ...

i must report that this moovement is reported to me , not witnessed

good to know there is solutions that should be applied ...thanks all

The shims was used on later models, the change was late -85., earlier models have a diaphgram spring.

Also the bearing and the seeger ring was changed around the same time.

I think I`ve read somewhere that the improved parts can be used on older models, exept the bearing which is different mounted in the engine halves.
(locating clip on early models, shouldered bearing on late).

Thanks Bert but I must be having a slow day as this shim is between the drive gear body and the bearing then the circlip the Haynes manual states the shim is not present on early K100's mine being an 84



Then we have thrust washer for the clutch which is present on mine



Halo

thats what i thought too inge ,,,but couldnt see a way to install the newer bearing to the older crankcase ,,,im guessing alby saw the older style

sorry for the hijack halo ....was just thinking whilst you were there.. .these things could be checked

No go for it Charlie I agree, I need to check for the presence of the diaphram spring that Inge K is talking about though I didn't strip down to the bearing after removing the circlip (dont know in restospect why I took of the circlip anyway). I'm guessing Inge K that the diaphram spring sits in the samre location as it shows the Shim that is before the bearing is inserted onto the shaft

Halo

Halo, have a look at the anti backlash spring at Bert`s resto page.
Check if it`s any movement between the gears on yours.

Then if it might be a idea to dismantle these parts,
while you have the shaft out.............again.

Then you could add shims instead, which should be an improvement.

Just some thoughts...................

Thanks Inge K I will do just that thanks for your help again.

Halo