[MDairheads] Succesful Gearbox and clutch removal and replacement 1995 R100RT

[Alex Balmaceda]

Great write up, Chris.  You made it sound simple.  I'm next in line, but
going a bit further to deal with a stubborn leak that will probably mean I
need to replace the rear main seal.

Alex B.

On Tue, May 15, 2018 at 5:04 PM, Chris Kennedy via MDAirheads <
mdairheads at casano.com> wrote:

> Afternoon all,
>
>
>
> My new to me 1995 R100RT even with the low mileage showing, 19,750 mils,
> and
> running well was very difficult to shift. After making sure all else was in
> good order with a journey to Appomattox VA for the Horizon Unlimited
> gathering I tackled the gearbox issue. With help from Duane Wilding and
> some
> tricks learned from Robs gearbox removal and spline lube tech day in PA the
> gearbox removal went very smoothly. Glad I chose to do the full removal as
> the spline was remarkable rusty. Combine with the spline rust was the
> corresponding rust on the clutch plate housing.
>
>
>
> With the clutch removed I was able to remove the rust from the offending
> parts and was also able to use the clutch plate to slide back and forth
> over
> the spline to distribute the lubrication evenly. The other critical factor
> in removing the gearbox was it enabled me to remove the clutch actuating
> rod. Though the end closest to the release bearing piston was well
> lubricated the end closest to the clutch had dried up grease and was
> binding
> badly.
>
>
>
> Reassembly was mostly straightforward. Having a second person, Duane
> returned for more, made things go a lot easier. Apart from the usual
> struggle with the drive shaft bolts the job was over in short order.
>
>
>
> The test ride did not happen for two days but the difference in shifting
> was
> transformative. The bike now shifts with a positive "snick" with little or
> no resistance either up or down. Now it shifts better than any other
> airhead
> I have ridden.
>
>
>
> I took my time and incorporated other items at the same time so the bike
> was
> on the lift for a week. However if all you want to do is gearbox removal,
> spline lube and reassembly its less than a day's job if the parts are on
> hand.
>
>
>
> See you at the next gathering.
>
>
>
> Cheers Chris
>
>
>
>
>
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