On the way home from araluen I lost 1st gear. So I opened her up for a look see this morning. Not good news for me.

A few broken teeth, and some of the bearing s were obviously on the way out. making it home without any real problem is a testimate to the K engineering I had a real challenge not using 1 st gear!! here is some pics for those who want to see.

Oil Drain

One of several broken Teeth

One Sloppy Bearing

Some carnage from one of the bearing races



So if anyone has a gearbox I am in the market. (I already ordered parts for an overhaul of new one before installation)

ouch ....!!

That is bad news - however, it is a tribute to the engineering standards on these old K bikes that she still got you home safe and sound

That busted thrust washer is where the problem started, when you get too much clearance the gear jumps out.

Make sure the selector is good and not bent or you may just do it all over again. uneven wear marks on the fork faces are a dead give away. the forks cannot be straightened they are titanium and will break or return to the original position. Also make sure the selector drum doesn't have any of the hard anodising chipped of where the fork pin rests when engaged.

I may be able to help you out with gears but not a selector fork.

I have scores on one of the selector forks!!! I am going to look into it more tomorrow.

Ouch! Sorry to hear about the box Alby. Sounds like you're we'll on your way to getting it sorted out though. Post more pics if you get a chance?

OG

Busy day in the HesMadlab as my friends would call it. All bearings and seals replaced on new replacement gears. All assembled back into case but Having trouble getting it to shift properly though. Will go down to first, up second, 3rd and no more. goes back down to neutral no worries but might just be missing something.

Few more pics OG..
Used a bolt for the pullers to bear on



Do not forget about the shims.

I am slowly getting myself some special tools.

Be sure to clean the packing grease out of new bearings.

Nice new bearings and Oil seals

Almost back together.


I wil put more pics of the damage up later OG.

kinda sounds like you have got one of the forks reversed into the drum

Great pics Alby and thanks for sharing! Where did you source the parts?
Let us now when you discover the "gotcha"...


OG

Found the BLIGHTER!!! After much thinking and brain juice pondering (RUM) and going over things step by step and producing some some of the amazing Charlie speak (and dah! dah! dah!) It dawned on me..The SHIMS!!! Had to prove it. So I loosend off some of the cover bolts and tried to turn/shift. Went to the other side next to input shaft..loossed a couple of bolts and yes it was my lil demon. Had to pull a bearing again from the input shaft but the shim was the problem. making things too tight. Also the output shaft had not seated quite all the ways down.

OG- I was lucky to come across a second box same day I got home. Had to drive 4hrs return for it but. Our auz guys know it as the bee m shop. The bearings and seals came from a local supplier for around 70 auzzies. Kingaroy bearings and belts.

Having done this it was a lot smother and all gears were there!!
Per Charlies suggestion I checked forks in right positions.


A special tool I made up (coat hanger wire) for big mitted people to positioning selector forks.


Box is refitted now and I have to adjust the clutch a lil ore. Gave her a lil idle run without tyre fitted to get some oil in the channels and bearings. I can select each gear smoothly and no noise!. Road test in a couple hours. Gotta go find me some yummy lunch..

Good work alby , here's hoping that box runs another twenty something years without needing to be split.

oh wow ....!!! good work there alby mate ....congradulations ...clinks glasses !!



hey just as an asside ...i would really be interested in the amount of rotational free play on the back wheel ....whilst in 1 st gear .....to measure this we marked the tyre and just measured the distance between the mark and the end of the free play between one end of the travel and the other.....(lots of folks get about 50-70mm ) im just wondering ....with nice tight bearings - shims and maybe nice gears that play should be 40 mm ...perhaps ??



again great work mate .....

Will look into free play for you charlie. Just back from round town run and it seems to "Feel Tighter/Smoother?" No low growl of gears running. Just got to sort out this dam elec problem!!! Turned indicator on and got hazards, no driving lights and the starter relay is stuck on!!!

The starter relay stuck on will kill the headlights because of the load shed relay and the indicators, check all the fuses.

hmmm low battery ? this is usually the cause of the starter relay weld event ..??? you sure the altenator is connected alby? or an earth off somewhere ....maybe the g/box connection ?

Hey Sorted the problem The starter relay had finally died. It has stuck once or twice before and this time no amount of cleaning was helping. The contacts would close and no go. So onto the test bench as it were with 12v supply. There was no circuit over the poles when the relay closed. It had finally broken somewhere. I could turn the starter by jumping to it directly.

So I have replaced it with a 100 amp relay. There was plenty of room in the box for it. Really kicks into life now!


Back to the gearbox issue. Charlie, 50mm play!. I feel there is some play in the final drive and the take up of slack inn the box. Seems to be all good. I just need to go for a longish ride to feel better about it. Anyone want to meet for a burger at the servo between wivenhoe and summerset dams on the esk kilkoy road tomorrow?

hmm sounds like a plan alby ....later i can skidadle up to blakey and drop off his shirt ?

oh ? 50 mm ....thanks mate ....always good to keep these things in the back of my head ...i kinda notice that when just on cruise neither accelerating no decelerating i have a little area that i can feel the lash taking up ...

good to hear about the starter relay ......lights all good now ?

gimme a little while to clean "old gerty" first huh .? maybe by 12ish -1 pm or is that too late ? ive had a uneven week of early and late starts

Lights all good. Load shed was playing up because of starter relay. No blowen fuses. No Problem.. Ill get there about 12ish. Anyones welcome. They do large food!! Me had same week too. Look foward to sleep in!!

Give an address and I'll be there. 12ish.

It is the servo at the wall of summerset dam. Just as you head west out of Kilkoy you turn left onto the Kilkoy - Esk road. HERE

See ya there!

Albyalbatross1 wrote:. Really kicks into life now!

good work ...that would be th new relay ........and the new brushes huh ?

grin .... done good ol mate !!!

found some fuses in my tail today!!!

k ..."gertrude von clickandschifft " (gerty) ...is noticeably cleaner right now ...(second wind i guess ...or old drunk on second can )

see yas tommorra !!

"glorious-nebo" is looking good for the return journey

well im amazed ....!!!

alby's work has restored his beaut ride ....nary a shudder noise ...a clunk or a grind

three of us met up in the next valley over from the coast way back from the city noise and closer to albys home town .....good to meet ....after a bite to eat ,blakey left for other matters but alby and i went for a ride over hill and dale .

so good to see his handy work, work out ........this guy is amazing .....without experience in the delicate art of "gearboxes " he has ploughed into his repair and done the job fantasically ..

kudos ol mate



he reports that the box is or seems to be bedding in fine with less noise and seems to be getting smoother as he puts more miles on ...

did i say he has a grin on his face ....a mile wide ....giggles

cheers mate

Great result and good on all who contributed to the fix and for Alby's persistence.
Regards,
K-BIKE

Thanks to all who offerd help. The result is as Charlies says!!! It feels and handles and sounds completely different. If anyone else takes teh dive...by all means give me a yell.

Well three weeks have passed and as promised I am over my inital excitement. Took her out for a nice long run today (damnd HOT!! I could not get over the number of people young/old with t-shirts and shorts! on BIKES). Kingaroy-Deception bay -Redcliff - Villenview - Kingaroy( Nic has not been over the bridge). The gears worked and felt better/smoother than last trip.

nice one alby .....awww dang i was out riding too ....i shoulda headed north instead of south...

yep saw a real duffus ...shorts tshirt (not thongs) no gloves or anything else ....dodging and diving up the freeway out of the gold coast towards brisbane .....hope he made it .!!



way cool to hear about the g/box mate .....bedding in nice huh ? ^5s

Hello, this my first post on this forum.
I'm right in the middle of doing the same thing and look forward to following your thread.



Ride with joy,
Gwen

Shogs! Welcome to our humble Forum!

I've been following your exploits on other forums and I love your work!

My goodness, thank you kindly.
I'm really enjoying myself with that little tranny job.
Do you think anyone here would care to see what I'm doing? K100 and K1100 being not so much different. :shrug
We could compair notes and pics.

blakey wrote:Shogs! Welcome to our humble Forum!

I've been following your exploits on other forums and I love your work!

There are many here who would like to see what you are doing if even it only gives them a better insight into the workings of that largely mystical gearbox.
You certainly have a good approach to working on all things mechanical.

Thank you Rick, that's so nice of you to say.
It's other name is OCD :

Ok, I'll work on loading the thread here, and thank you again for the warm welcome.

hello shogs. My work is complete and bedded in well. makes for a very smooth and quiet ride now. lets see what you have been doing.

I would like to but it will have to want for 7 days, sorry.

New members are not allowed to post external links or emails for 7 days. Please contact the forum administrator for more information.

Albyalbatross1 wrote:hello shogs. My work is complete and bedded in well. makes for a very smooth and quiet ride now. lets see what you have been doing.

Albyalbatross1 wrote:hello shogs. My work is complete and bedded in well. makes for a very smooth and quiet ride now. lets see what you have been doing.

Here you are Alby a greeting like no other.
http://www.motobrick.com/index.php/topic,1808.0.html

Excellent link there Rick, plenty detail.

amazing detail ,,,thanks for the link rick ....

good on gwen for all her hard and detailed work

just goes to show that if you plan, ask for help ,have confidence in your own ability you can do anything you want
great to see someone having a go and fellow forum members giving advice where they can

Yes!! Thanks for the link..What a greeting! Lots of good work there Gwen.

Great work Alby you should be justifiably proud of that!
Regards,
K-BIKE