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Old 06-19-2009, 07:36 PM   #1
Shoganai OP
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Joined: Mar 2005
Location: Out riding with joy and breaking bikes
Oddometer: 1,751
Just for Shits and Grins; the ShogyGrid K1100 Frankin-tranny

The History…
In 2006 I stripped the input shaft on my 1993 K1100RS on my way to Alaska. After I replaced the tranny in a 10 day break down stay in Alberta, I sent the old tranny back home.


The story starts here >>> http://www.advrider.com/forums/showt...142933&page=39











http://www.advrider.com/forums/showp...postcount=1047




Off the Grid is giving me the tranny out of his K1100LT that has a stripped 2nd gear for the cost of shipping.


The Plan…
Set up a place in the basement where I can take the good input shaft out of the LT tranny and rebuild mine.


Liabilities…
I’ve never done this before.
I can't spell worth a shit.
Have left / right confusion
Have mildly Autistic behaviors
And don't have a dick

Assets…
I have access to BMW specials tools.
BMW Tech Manuel
Clymer Manuel
I’m meticulous and methodical.
I have Steve to help me.
I can count on you to find the funny.

The Goal…
Have fun learning while wrenching.



Pics and story to follow here. It will be a S-L-O-W process as I’m working 40-60 hours a week, painting / decorating our new home, we'll be building a deck this summer and planting a new landscape. Oh, and building a wood working shop.

I look forward to any good technical advice you have to offer including, “WTF are you thinking?!”




So the first thing I did was RTFM.

Then I started with trying to generate a list of parts I'll need.










I hope to also replace the stripped 2nd gear on the donor tranny just to see if I can do it.

I know I need a micrometer, but I don't know which one would be the best for this project.


This may very well be the only, fully documented K1100RS tranny rebuild on the web.
I've been looking for over a year for a Documentory / how to step-by-step and can't find even a whiff of one.


Mine will be more like a DocuDrama as it will have lots of cursing ,
throwing of hissy-fits
and tools
back-peddling ie.
WTF is this part doing outside that of part
and a metric ton of



You in the audience will be

And in the end we'll all And I'll be doing this




BMW Special Tool List

00 2 550 Under depth gage
00 5 500 Handle for drift
00 7 500 Universal bearing puller
00 8 560 Kukko support
00 8 563 Internal extractor
11 5 500 Clamping fixture
23 1 760 Drift for shaft seal ring on input shaft
23 1 770 Drift - bearing shell on tranny cover
23 1 790 Drift - seal on gear selector drum
23 1 820 Transmission guide pins
23 3 660 Transmission measuring plate


As of 2/11/09 at 0800 I've made arrangements w/ a third party to split the cost of these tools...
11 5 500 Clamping fixture
23 1 760 Drift for shaft seal ring on input shaft
23 1 770 Drift for bearing shell on tranny cover
23 1 790 Drift for shaft seal ring on gear selector drum
23 3 660 Transmission measuring plate

And have permission to use all the tools listed for this task.
He's aware of this thread and if he want's to identify himself, it'll be up to him.

This past week I scrounged some lumber from the trash bins at a construction site (with permision)
I still had to buy 2 sheets of 3/4" plywood and some deck screws.

Today I'm building two work benches.

I found this handy "how to" guide http://www.hammerzone.com/archives/w...below20xl.html

As Mick would say, "I am in the basement, Looking for the truth."

http://www.youtube.com/watch?v=2fNHXyVDg6o
I LOVE this song!!!


http://www.azlyrics.com/lyrics/mickj...hedoorway.html

First table finished.



Second bench done.



Project notebook and what I shipped back from Alberta in 2006.







Spline damage.






Many here already know the story of me blowing this tranny on my way to Alaska, but for those who don't, here's the link.

http://www.advrider.com/forums/showt...142933&page=36

I was broke down 10 days, got a replacement shipped in, traded them out and continued on with my trip.

Ok, I did this today.

I needed to make a mount for the tranny kinda like this, but cheaper.



Some stuff.



The pattern off the tranny.





Test fit.



U-bolt holes drilled.



Not without a "bit" of drama. :



Assembly.













Nothing fancy, but I believe it will work.

Stuff that fell out of the box when I unpacked the tranny.



I think everything is here.

Oooooo Shinny.







This will take months as time premits.
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Old 06-19-2009, 08:27 PM   #2
G.Kennedy
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cool ....
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Old 06-20-2009, 01:42 PM   #3
2ndSPACE
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So that's why you said you need to go lumber shopping. Something about tranny rebuild and construction site shopping didn't click

Those bearing prices look high. I assume they are dealer prices, if so you may be able to order them online or pick them up at a local bearing shop for less.

Good luck
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Old 06-20-2009, 04:49 PM   #4
kootenay kid
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Good for you! Wouldnt find me attempting that. Good luck.
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Old 06-20-2009, 07:51 PM   #5
booty0
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I really admire your spunk Shogs. There's no way I would attempt this today, but back when I was roadracing on a very limited budget, I wouldn't have thought twice about it. I guess I'm spoiled and lazy now. When my shit starts to go even a little wonky, I just trade it in something new.

Your patience with this old Beemer is admirable and makes for great reading. You go gurl!
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Old 06-21-2009, 03:43 AM   #6
Grinnin
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Quote:
Originally Posted by Shoganai
The Goal…
Have fun learning while wrenching.
Good goal. I bet you accomplish it.
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Old 06-21-2009, 06:23 AM   #7
cube_zombie
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Looking forward to this....subscribed!
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Old 06-21-2009, 06:38 AM   #8
Bueller
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I rebuilt automotive transmissions for a living for years (both auto and manual gearboxes). It will probably be easier than you think. Nothing magic happens inside of those boxes, and the reason you don't see a bunch of info about rebuilding them on the net is because by the time you acquire everything you need to rebuild one you can just buy a used one cheaper and without all of the hassle. But once you've been through one you'll probably realize you didn't need all of the special tools and can sell what you don't need. I got to the point where I didn't even use a holding fixture, and just wrestled them around on a bench.

A rebuilt gearbox with new bearings and seals is way better than a used gearbox.

Good luck!
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Old 02-15-2012, 12:14 PM   #9
Shoganai OP
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How about years.

Well life, time and money all got in the way but thanks to my loving husband who bought me the tools I needed for the project it's back on.

He got me these great tools for Christmas.



I bought this.



And together with these and a few of their friends...



Lets tear this transmission apart.
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Old 02-15-2012, 12:37 PM   #10
Shoganai OP
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First to work on the cover.

Since this Transmission is already been opened up, the processes will not follow the step by step from the manuals.

So I start with removing the input shaft roller bearing race and oil seal.







I didn't know how to hold it still and came up with this.





Heat to 100 degrees c. / 212 degrees F.



While I was heating it up the bearing puller became lose and I had to cinch it up to almost the max expansion to re-seat it.

Pop! It went very smoothly.





The seal was so gummy from the heat I just peeled it out.

All the parts I'll need to order go in baggies like this.

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Old 02-15-2012, 12:44 PM   #11
Foot dragger
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Yikes! That is indeed the project from hell! I suppose an 85 K100RS trans wont fit,Ive got most of one of those sitting here with 18,000 miles on it.
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Old 02-15-2012, 12:54 PM   #12
Shoganai OP
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Oddometer: 1,751
Next remove the detent arm and spring by removing the circlip.





Next drive out this plug and save it. It will be driven back in after the cover is reinstalled and will be needed to ensure the detent arm is in the right position.
(It's the little one in the back)



The one in the front here.





Again, I needed it held still.



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Old 02-15-2012, 12:57 PM   #13
Shoganai OP
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I'm doing this for fun and I hope to learn how to rebuild these.
Hang on to it, maybe I'll take up K100's

Quote:
Originally Posted by Foot dragger View Post
Yikes! That is indeed the project from hell! I suppose an 85 K100RS trans wont fit,Ive got most of one of those sitting here with 18,000 miles on it.
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Old 02-15-2012, 01:02 PM   #14
Dismount
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*makes note

Must meet shogs and steve must meet shogs and steve must meet shogs and steve.


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Old 02-15-2012, 01:04 PM   #15
Shoganai OP
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Oddometer: 1,751
I removed the detent bolt.



But the detent ball and spring had alreadly fallen out, so I bagged them all together.

Then to remove the oil seal cover.







I didn't have to, I just wanted to see what was behind it.
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