K11 Owners Group

Shoganai · Last edited by Shoganai on Fri Apr 24, 2009 12:20 pm; edited 1 time in total

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

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. Shocked

I can't spell worth a shit.
Have left / right confusion Crying or Very sad

Have mildly Autistic behaviors
And don't have a dick Embarassed

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. Cool

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. Very Happy

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.
_________________
1993 K1100RS aka The Shop Whore
1994 K1100RS aka Blue Streak

The long road is a rainbow and the pot of gold lies there.
So slip the chain and I'm off again,
You'll find me everywhere. I'm a Rover. - JT

Nana korobi ya oki

rydor · Posted: Thu Feb 12, 2009 10:13 am Post subject:

WOW thats a helluva huge job to tackle Shocked

Shogs is my hero Very Happy

Shoganai · Posted: Thu Feb 12, 2009 10:22 am Post subject:

Rider · Posted: Thu Feb 12, 2009 11:02 am Post subject: Gearbox overhaul

Shog,

Wow, that's gonna make a spline lube look like replacing a light bulb.

We await the next installment of the saga.

And, congratulations on the new home.

Ed
_________________
2007 650 Burgman, 2003 400 Burgman

Some days you get the bear, some days the bear gets you.

BMGraeme · Posted: Thu Feb 12, 2009 3:01 pm Post subject:

Respect.

In years to come this will be the K-Tranny bible.
_________________
1980 CB900FA
1994 K1100RS
2008 R1200GSA

SugarHillCTD

drmalacarne · Posted: Thu Feb 12, 2009 6:55 pm Post subject:

Great project!
Very complicated, but feasible.
It's remember me a joke:

"A neurosurgeon takes his Jag with a bad transmission to the automatic shop, and the mechanic told him that the work will cost him U$5,000.00!!
The poor neurosurgeon almost lost this breath, and told "that's alot of money!!!"
And the mechanic:
- but you ask U$50,000.00 to operate a cerebral aneurism, and do that in 4-6 hours!!!
The Doc promptly spoke:
- OK!! I'll pay you the U$5,000.00, but you must make the job with the engine on and the gearbox in drive!"

Good luck with the project!
Guilherme.
_________________
1994 K1100LT SE n° 0267
1998 HD Heritage Springer 95th anniversary
Yes, a Hog and a Beemer can live together!

Jim · Posted: Fri Feb 13, 2009 1:47 am Post subject: micrometers

Gwen,

General has been around for a long, long time - and makes some pretty nice stuff: http://www.generaltool.com/Default.aspx?page=category%20search%20results&CatList=0&Parent=7724&tree=7723*Precision+Measuring+Tools*0@@7724*Micrometers*0@@

http://www.generaltool.com/Default.aspx?page=category%20search%20results&CatList=0&Parent=7732&tree=7723*Precision+Measuring+Tools*0@@7732*Calipers*0@@
_________________
Jim
1997 K1100LTSE 94,000 - still has gremlins!
1995 R100RT Classic 16,650 crashed - repaired!
1992 K75RTP 46,000

"We shall not all die, but we shall all be changed."

max · Posted: Fri Feb 13, 2009 3:37 am Post subject:

I think you can use Plastigauge for the shimming, which might be cheaper than buying the endfloat micrometer setups and the reference plates... Looks like around $9US for 40" of measuring "string",and then you'd only need to get a normal caliper mic for checking the shims you've already got (or just test without any shims, and then buy all new shims to suit anyway).

Just my 2c... good luck with the strip down; remember lots of assembly lube on the rebuild!

Max

(try www.plastigaugeusa.com,
or http://www.prostreetonline.com/x/mopar-plastigauge-assortment.asp for an assortment of sizes)

joeangi · Posted: Fri Feb 13, 2009 5:26 pm Post subject:

Great thread.

My limited advice is go for it! The mantra that I live by when tackling projects like this are: the part you are trying to remove "did not grow there" (that takes the surgeon). That it was originally assembled by mere mortals. Finally that someone with experience may be able to do it quicker, but the meticulous person will be able to do it just as well.

Good Luck!
Joe

Tim (Midland Section) · Posted: Sat Feb 14, 2009 5:50 am Post subject:

Go for it. There is nothing to fear, except fear itself. However, I have done Brit car & bike gearboxes before. Sod the decorating, get started.
As for practical advice, pay attention to the condition of the dogs that drive the selected gears.
_________________
Regards Tim,

Grey haired riders don't get that way by pure luck
1996 Guzzi Cali3 LAPD
1972 750 Commando
G6HRN
#485

hockeyshifter · Posted: Sun Feb 15, 2009 2:22 am Post subject:

my suggestion

1 have camera ready at all times. get cheapy digital with removelabe media
and take lots of pictures. that contain before and after.. take them while you are working on the project. if leave project for some time items can be forgotten.

2 put all lose parts into sepreate labled zip lock bags.

3 get a paint pen of someting to write with that will not wipe off easliy with oil rags. MARK all item as to their location or importance to other sections or parts.

4 while you are their think about swapping out gears to give better mpg or faster speed or quicker response etc.

Cheers
_________________
fix the problem not the blame ; fix what is messed up ; NO one is to blame.

Shoganai · Posted: Sun Feb 15, 2009 9:57 am Post subject:

Thanks for all the good advice and encouragememnt.

I really like the paint pin idea.
I already do the camera thing and baggie thing.
_________________
1993 K1100RS aka The Shop Whore
1994 K1100RS aka Blue Streak

The long road is a rainbow and the pot of gold lies there.
So slip the chain and I'm off again,
You'll find me everywhere. I'm a Rover. - JT

Nana korobi ya oki

Shoganai · Posted: Tue Mar 17, 2009 9:27 am Post subject:

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
_________________
1993 K1100RS aka The Shop Whore
1994 K1100RS aka Blue Streak

The long road is a rainbow and the pot of gold lies there.
So slip the chain and I'm off again,
You'll find me everywhere. I'm a Rover. - JT

Nana korobi ya oki

Off the grid · Posted: Tue Mar 17, 2009 9:29 am Post subject:

Shogs should be sending you your tranny out by the end of this week hun. Been crazy, but I didn't forget about you!
_________________
Bane of your existence since July 2006
2007 Triumph Tiger ABS. "Sabertooth"
2009 Husqvarna TE610. "The dirty Italian mistress"

Shoganai · Posted: Tue Mar 17, 2009 9:33 am Post subject:

dave n · Posted: Tue Mar 17, 2009 10:40 am Post subject:

since you will soon be up to elbows in trans - this may come in handy - if the e-bay bots don't drive price thru the roof.

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=220378771862&sspagename=STRK%3AMEWAX%3AIT&viewitem=
_________________
Dave Norris KOG 248
1999 Cagiva Gran Canyon
1993 K1100LT w/Hannigan sidecar
2008 Suzuki DR650

Shoganai · Posted: Tue Mar 17, 2009 12:45 pm Post subject:

Thanks Dave. Smile

First table finished.

_________________
1993 K1100RS aka The Shop Whore
1994 K1100RS aka Blue Streak

The long road is a rainbow and the pot of gold lies there.
So slip the chain and I'm off again,
You'll find me everywhere. I'm a Rover. - JT

Nana korobi ya oki

Shoganai · Posted: Tue Mar 17, 2009 8:24 pm Post subject:

Second bench done.

On a side note, I slipped and fell in the driveway during the last ice event here about two week ago. My right elbow has been hurting ever since. Well, two nights ago at work I got an x-ray.

Fudge, a small clip fracture of the distal lateral humerus.

So, I'm done for the day. I'm nursing my elbow with a Chocolatetini.

_________________
1993 K1100RS aka The Shop Whore
1994 K1100RS aka Blue Streak

The long road is a rainbow and the pot of gold lies there.
So slip the chain and I'm off again,
You'll find me everywhere. I'm a Rover. - JT

Nana korobi ya oki

Shoganai · Posted: Wed Mar 25, 2009 9:45 am Post subject: So it begins...

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/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.
_________________
1993 K1100RS aka The Shop Whore
1994 K1100RS aka Blue Streak

The long road is a rainbow and the pot of gold lies there.
So slip the chain and I'm off again,
You'll find me everywhere. I'm a Rover. - JT

Nana korobi ya oki