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Discussion Starter #1
Hi all.
I decided to dive in to do spline lube on the ol' brick. When I cracked her open I was pretty bothered by what I found. The clutch output splines look pretty awful and were bone dry. Naturally the input splines didn't look so hot either. The clock reads about 30k but I feel like a bike with that low of mileage wouldn't have a splines in that bad of shape, I suspect I might have been had. Never the less I would like to repair this and am looking for some advice on the next steps. I think my options are to replace the entire clutch, or can I just replace the section with the clutch splines? As far as the input splines I think I will need to farm that work out to get that repaired as I don't have a press and I want to make sure it is done correctly. Any advice will be greatly appreciated. As far as I know this is the first clutch but realizing I may have been fleeced on the mileage I don't know what is up to snuff at this point. Thanks in advance.
 

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Ouch....yep the tranny splines are bad.Not much milleage but not all that surprising, corrosion does build up there and then wears the splines.Seemingly worse on bikes that sit too long.

Someone in Canada does that kind of work:

http://www.brunos.us/gearbox_transmissions.html
 

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Discussion Starter #4
Thanks for the feedback guys. Next question since I know I have some work ahead of me. Can I just replace the clutch plate rather than the whole clutch assembly? and how difficult is it to replace the input spline on the tranny? I am a relatively confident wrench turner. I'm pretty sure I need a press but are there any more special tools I would need? The clutch guide tool I bet would come in handy for the clutch plate if that is the way to go. thanks again
 

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flyrigger said:
Thanks for the feedback guys. Next question since I know I have some work ahead of me. Can I just replace the clutch plate rather than the whole clutch assembly? and how difficult is it to replace the input spline on the tranny? I am a relatively confident wrench turner. I'm pretty sure I need a press but are there any more special tools I would need? The clutch guide tool I bet would come in handy for the clutch plate if that is the way to go. thanks again

Its a fairly labour intensive job, so do you want to take the chance on re-using parts of the clutch, your call I suppose, personally I'd replace the lot including any of the seals while I was in there.
 

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I have a BMW clutch pack here, friction disk is still within specs but......if you put a straight edge on the steel plates, easy to see that they are dished. So no replacing the friction disk only on that one, that would be asking for trouble.

I also had a slipping clutch on another BMW, trying to be cheap I replaced the friction disk only. Still slipping....had to reopen and replace the spring part. :(

So....not easy to mix & match used and new parts on them, altough it is possible in some cases I wouldn't recommend it.

Don't know if Motobins has them clutch parts,I think so.... could be a much better deal there.

http://www.motobins.co.uk/
 

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Discussion Starter #7
Thanks for the added info guys. I have decided to tackle rebuilding the input shaft on my own. I have my toyshop to wrench in and the desire to achieve. Still not sure how I'm going to go about the clutch yet but I can work on this for now. Chicago is getting colder and the season is winding down. Thanks again for some pointers.
 

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Spline repair finished, now new question

Well after several crazy work months I was able to finally get back to the clutch and shaft spline repairs. Was able to rebuild shaft assembly with new shaft and parts and after much measuring and head scratching decided to try and just replace the clutch plate. Took the bike out and feels damn good to not have the knocking sound coming from tranny anymore. Some slight clutch adjustments and I think I'm good to go. Ready to head back to the Blue Ridge Parkway again this spring. Feeling pretty happy with myself for tackling this project myself. Thanks again to all of you for the tidbits of info.
Since staring at the bike for a while now on the lift; I think now I want to find a tinted wind screen for the ol' S. Does any one have any leads? Thanks
 

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flyrigger said:
Since staring at the bike for a while now on the lift; I think now I want to find a tinted wind screen for the ol' S. Does any one have any leads? Thanks
Got mine from Max BMW
46 63 1 455 427 WINDSHIELD 1.29 1 $168.48
 
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