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

[Jim McKinna]

Thanks Chris.

Pulling the transmission to grease the transmission splines is not the most fun maintenance task to contemplate.  I was forced into it years ago for the same maintenance issue you discovered with the clutch disk actuating rod.  In my case, suddenly no clutch action!!  The rod had accumulated gunk that compacted around the shaft and prevented any movement.  One minute I could shift and the next not.  So in the course of what I thought would be a spline lube, which turned out to be fine,  the culprit was something else entirely.  

And now that you have recent experience I might call you to help me reinstall my transmission which I took out months ago awaiting time in my life to examine and fix a few internal issues. Still waiting for that time so it will not be too soon.

Jim McKinna

> On 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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