Cleaning splines and question about the clutch

[BermudaBrick]

If you haven't put the swing-arm back on yet, this is a good time to pry the dust covers off the swing-arm bearings and force some fresh grease in there.

Thanks for the tip - I haven't done that yet.  I still have to clean it up and install a new boot (it was torn).  Right now I'm trying to figure out where this mystery breather/vent hose thing goes.  When I removed the transmission I found it hooked to nothing.  Anyone know? 

Torque the swing-arm pivot bolt as close to spec as you can. 7.2Nm.

Yeah, so that is a puzzle!  How do you tighten the bolt to such a low torque and not overtighten it when you torque the nut?

[TimTyler]

Yeah, so that is a puzzle!  How do you tighten the bolt to such a low torque and not overtighten it when you torque the nut?

Just firmly hold the bolt in-place with a hex wrench when you tighten the nut. I don't worry too much about the nut torque; I use a large adjustable wrench for that.

[rbm]

Right now I'm trying to figure out where this mystery breather/vent hose thing goes.  When I removed the transmission I found it hooked to nothing.  Anyone know? 

It's a drain hose that goes in the vent hole of a fully flooded battery, as would have come with the bike from the factory.  If you're using a AGM or other sealed battery, this hose is not necessary.

[BermudaBrick]

Ah ha!  That makes sense - I have a sealed lead acid battery. Thanks for clearing that up!

[Farmrjohn]

OK, I've been doing a full service with spline lube, fluid changes, valve inspection etc. on the '94 K75 I recently purchased since it has had several prior owners and an incomplete maintenance history.  I've run into the same issue getting the transmission back on.  The Polepenhollow alignment tool seems to fit and remove properly once the clutch mount bolts are torqued down and the clutch push rod will go into the bushing in the spring OK.  The transmission will only go as far as the input spline getting to the edge of the clutch spline while it's on the alignment pins.  I've tried turning the output shaft while the transmission is in gear to rotate the input shaft, hoping to get the splines to align, allowing the transmission to close the gap, with no luck.  It sounds like the transmission case is hitting something, but I can't see any obstructions.  I'll try the technique of loosening the clutch mount bolts slightly, mating the transmission without the pushrod, remove, re-torque the clutch, then install the transmission (hopefully).  That brings me to my question, while wiggling the transmission, attempting to get it to slide on, this plug fell down from the vicinity of the ignition coils.  It's about 3/4" in length.  What is it and where does it go?   

[BermudaBrick]

I wish you luck on getting the transmission back on.  As you saw - it took me quite a while. It sounds like you're close! Let us know how it goes.

That brings me to my question, while wiggling the transmission, attempting to get it to slide on, this plug fell down from the vicinity of the ignition coils.  It's about 3/4" in length.  What is it and where does it go?

Oh dear... I ran into this part while I was cleaning up yesterday and figured it must be from some other project.  Please let me know if you figure out what this is!!  :yow

[Martin]

John if you get two long bolt, longer than your original mounting bolts by at least an inch or two. Cut the heads off them you can then use them as guides to align your gearbox.
Regards Martin.

[Martin]

http://www.maxbmwmotorcycles.com/fiche/DiagramsMid/B0000134.png?v=07012015    Part No 9 padding 11 14 1 460 478 could be a possibility.
In the intermediate housing.
Regards Martin

[K1300S]

I wish you luck on getting the transmission back on.  As you saw - it took me quite a while. It sounds like you're close! Let us know how it goes.

That brings me to my question, while wiggling the transmission, attempting to get it to slide on, this plug fell down from the vicinity of the ignition coils.  It's about 3/4" in length.  What is it and where does it go?

Oh dear... I ran into this part while I was cleaning up yesterday and figured it must be from some other project.  Please let me know if you figure out what this is!!  :yow

Plug goes on top left between the engine and tranny.  Notch on engine.

[BermudaBrick]

Plug goes on top left between the engine and tranny.  Notch on engine.

I just went through my photos of the job and I found it (see below).  Not sure how I missed it.  Damn.  I got everything buttoned up this past weekend... or so I thought.  :falldown:

So what happens if it isn't in place?  It looks like I have a peep hole into the clutch... a new feature perhaps?

[Farmrjohn]

Thanks all for the replies.  I'll confirm that cushion/plug goes in a slot in the intermediate housing when I get back into the shop.

Martin-I have been using two long bolts as you suggest and as pictured BermudaBrick's post, and in then same holes.  I'm wondering if another combination of holes would be better.

[Martin]

You have nothing to loose by trying different holes.  Sometimes a change of attack will work.  :dunno
Regards Martin.

[rbm]

The transmission will only go as far as the input spline getting to the edge of the clutch spline while it's on the alignment pins.  I've tried turning the output shaft while the transmission is in gear to rotate the input shaft, hoping to get the splines to align, allowing the transmission to close the gap, with no luck.  It sounds like the transmission case is hitting something, but I can't see any obstructions.

The alignment of the input splines can be finicky.  It will require jogging the input shaft until the splines perfectly line up. 

Also, I found that you'll have to have no pressure on the clutch input shaft (1) while fitting the transmission.  This pressure is exerted if the clutch actuator arm (7) has been wired up to prevent the clutch pushrod gaiter from splitting.  Release the actuator arm, allow the pushrod to naturally retract (from spring pressure exerted by (4)) and retry fitting the transmission.  Don't allow the pushrod to remain unsupported for long as it can eventually tear the gaiter (6).

[Farmrjohn]

Success!  I resorted to loosening the clutch pack, removing the push rod, fitting the case, withdrawing the case, tightening the clutch pack, and re-install the case.  I found that the slight turning of the engine output shaft while re-torquing the bolts using the wood stopper method caused an issue.  When I turned it back to where it was when I loosened them (again using the wood stopper method) voila, everything slid into place.

I may have an issue with the clutch boot as the mechanism arm had popped out.  It visually checks OK with no apparent tears, cracks, or holes.  Another issue was cleverly deleting my photo of the battery tray, so it's a 50/50 chance I have it orientated properly.  I mounted it so the battery will be farther back from the alternator rather than almost touching.

Thanks for the assistance!

[BermudaBrick]

Nice job!  Now how about the dummy (me) who forgot about that padding plug?  What do you suppose the function of it is? Will my K burst into flames?

[BermudaBrick]

Another issue was cleverly deleting my photo of the battery tray, so it's a 50/50 chance I have it orientated properly.  I mounted it so the battery will be farther back from the alternator rather than almost touching.

A little late, but I found a picture I took of my battery tray.  In the picture, left is the front of the bike (you can just see the starter and alternator) and top is the coolant bottle.  Hope it helps.

[Farmrjohn]

Thanks.  I actually had it oriented properly with the two indentations to secure the bottom of the coolant tank on the right (correct) side.  I did run into a minor issue getting the drive shaft installed.  I couldn't get the spines to align with the swing arm tube installed, so had to do the shaft first, then the tube.  It's all buttoned up and back on the road, YIPEE!
   

[BermudaBrick]

Congrats!  Yes, that's correct - driveshaft first and then the swing arm slides on over it. Happy riding!