Just for Shits and Grins; the ShogyGrid K1100 Frankin-tranny

Discussion in 'Road Warriors' started by Shoganai, Jun 19, 2009.

  1. Shoganai

    Shoganai Let's do some livin'

    Joined:
    Mar 6, 2005
    Oddometer:
    1,761
    Location:
    Out riding with joy and breaking bikes
    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/showthread.php?t=142933&page=39

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    http://www.advrider.com/forums/showpost.php?p=2917817&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. :huh :eek1
    I can't spell worth a shit.
    Have left / right confusion :cry
    Have mildly Autistic behaviors
    And don't have a dick :shog

    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. :lol3

    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. :D

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

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    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 [​IMG][​IMG] [​IMG] [​IMG],
    throwing of hissy-fits [​IMG]
    and tools [​IMG]
    back-peddling ie.
    WTF is this part doing outside that of part [​IMG] [​IMG]
    and a metric ton of [​IMG] [​IMG] [​IMG] [​IMG] [​IMG] [​IMG]
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    You in the audience will be [​IMG] [​IMG] [​IMG] [​IMG] [​IMG]

    And in the end we'll all [​IMG] And I'll be doing this [​IMG] [​IMG]




    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/workshop/bench/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/mickjagger/goddessinthedoorway.html

    First table finished.

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    Second bench done.

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

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    Spline damage.

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    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/showthread.php?t=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.

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    Some stuff.

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    The pattern off the tranny.

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    Test fit.

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    U-bolt holes drilled.

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    Not without a "bit" of drama. :evil:

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    Assembly.

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    Nothing fancy, but I believe it will work.

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

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    I think everything is here. :D

    Oooooo Shinny. :D

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    This will take months as time premits.
    #1
  2. G.Kennedy

    G.Kennedy ...

    Joined:
    Oct 10, 2002
    Oddometer:
    1,850
    Location:
    LA, CA
    cool ....
    #2
  3. 2ndSPACE

    2ndSPACE Long timer

    Joined:
    Mar 28, 2004
    Oddometer:
    1,390
    Location:
    Berryville, VA
    So that's why you said you need to go lumber shopping. Something about tranny rebuild and construction site shopping didn't click:lol3

    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
    #3
  4. kootenay kid

    kootenay kid Lets Ride

    Joined:
    Oct 1, 2005
    Oddometer:
    2,614
    Location:
    kootenays canada
    Good for you! Wouldnt find me attempting that. Good luck.
    #4
  5. booty0

    booty0 Booger eater

    Joined:
    May 21, 2009
    Oddometer:
    174
    Location:
    Grant, AL
    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! :clap
    #5
  6. Grinnin

    Grinnin Forever N00b

    Joined:
    Dec 10, 2005
    Oddometer:
    3,045
    Location:
    Maine
    Good goal. I bet you accomplish it.
    #6
  7. cube_zombie

    cube_zombie Slave to the Cube

    Joined:
    Aug 25, 2008
    Oddometer:
    221
    Looking forward to this....subscribed!
    #7
  8. Bueller

    Bueller Cashin?

    Joined:
    Sep 25, 2003
    Oddometer:
    17,396
    Location:
    Hide Away Hills, Ohio
    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!
    #8
  9. Shoganai

    Shoganai Let's do some livin'

    Joined:
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    Oddometer:
    1,761
    Location:
    Out riding with joy and breaking bikes
    How about years.:lol3

    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. :clap

    He got me these great tools for Christmas. :crash

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    I bought this.

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

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    Lets tear this transmission apart. :wings
    #9
  10. Shoganai

    Shoganai Let's do some livin'

    Joined:
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    Oddometer:
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    Location:
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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.

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

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    Heat to 100 degrees c. / 212 degrees F.

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    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.

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    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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    #10
  11. Foot dragger

    Foot dragger singletracker

    Joined:
    Dec 27, 2006
    Oddometer:
    12,971
    Location:
    chico,just below rag dump(nor-cal)
    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.
    #11
  12. Shoganai

    Shoganai Let's do some livin'

    Joined:
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    Oddometer:
    1,761
    Location:
    Out riding with joy and breaking bikes
    Next remove the detent arm and spring by removing the circlip.

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    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)

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    The one in the front here.

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    Again, I needed it held still.

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    #12
  13. Shoganai

    Shoganai Let's do some livin'

    Joined:
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    Oddometer:
    1,761
    Location:
    Out riding with joy and breaking bikes
    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 :deal

    #13
  14. Dismount

    Dismount Boring bastard

    Joined:
    Feb 6, 2007
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    9,311
    Location:
    Beckley wv
    *makes note

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


    :deal
    #14
  15. Shoganai

    Shoganai Let's do some livin'

    Joined:
    Mar 6, 2005
    Oddometer:
    1,761
    Location:
    Out riding with joy and breaking bikes
    I removed the detent bolt.

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

    Then to remove the oil seal cover.

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    I didn't have to, I just wanted to see what was behind it.
    #15
  16. Shoganai

    Shoganai Let's do some livin'

    Joined:
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    Oddometer:
    1,761
    Location:
    Out riding with joy and breaking bikes
    Here's a pic of the detent bolt, spring and ball.

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    I removed the last of the two shafts for the gearshift forks. They look good.

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    And the last of three shift forks, and their gear pin sleeves.

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    Then I closely inspect the shift forks for wear or damage.

    A wear on the left.

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    To my untrained eye, I think these look REAL good. 181,000 miles and they look new.

    This is a badly damaged shift fork from OfftheGrids bike.

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    #16
  17. Shoganai

    Shoganai Let's do some livin'

    Joined:
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    Oddometer:
    1,761
    Location:
    Out riding with joy and breaking bikes
    I then lift out the gear selector drum.

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    Ok, I'm here now.

    At 0900 is the input shaft, at noon is intermediate shaft and at 1400 is the output shaft.

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    #17
  18. firstperigee

    firstperigee Fat Rat

    Joined:
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    84
    Location:
    SoCal
    That's F ' ed-up.:D
    #18
  19. Shoganai

    Shoganai Let's do some livin'

    Joined:
    Mar 6, 2005
    Oddometer:
    1,761
    Location:
    Out riding with joy and breaking bikes
    .

    Before applying heat to the seals to pull the gears shafts out I need to remove the gear position switch. (in the center here)

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    That's a 7mm head there and as soon as I put a socket on it the old plastic crumbled.

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    I used this on the right side.

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    Ok, it's off.

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    Then remove the housing grommet.

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    Push the grommet down the wire and over and off the connector at the end.

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    Then I pulled the connector back up through the hold in the housing and removed the whole thing.

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    It will need replacing.

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    See those tiny little pins, they have to be removed first. I very carefully removed them using hemostats and behind them were three tiny little springs. I used a tiny magnet to extract them from the holes.

    ONLY then can I safely remove the the rotor cap by lifting at the small bar in the middle.

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    .
    #19
  20. Shoganai

    Shoganai Let's do some livin'

    Joined:
    Mar 6, 2005
    Oddometer:
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    Location:
    Out riding with joy and breaking bikes
    .

    A word about manuals: I'm using both the BMW Service Manual and the Clymer.

    The Clymer NEVER says anything about the NEED to apply 100c to the seats of these shafts the release them. It just says they need to be removed as a unit, all together.

    The Service manual does give that critical information and doesn't say the MUST be removed as unit.

    Again with the heat.

    The input shaft falls out gently in my hand.

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    Then the other two do the same.

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    I'm setting them aside for now and will keep working on the case.


    .
    #20