My Boxer is fugged

[Mountain 300]

Well its been a while but the time has now come to sort this bugger out.
Its half-term, I have an 18k mile gearbox sat on the garage floor, new clutch plate and bolts courtesy of Motorworks, its a Sunday, a Bank holiday and its pissing it down
Will keep you posted on how I get one, firstly need to make space in the garage to work, already shifted Lottys bike to a friends house and it looks like my kwak will be sat on the drive, now wheres the big hammers

[JamesL]

Judging from the forecast you've got two clear days - unless you get flooded out!

Hope it goes OK...

[Vince]

Good luck, watch those knuckles

[Mountain 300]

Progress so far, the box is out
How much swearing wasd there........................ loads
Its been 32 years since I was a mucanic, forgot how much spanner rash hurts
Having studied our folks photo's about g/box removal, I've definetly taken some shorts cuts, tank still attached, took arse end off complete with cans, down pipe and Y pipe. Thanks good for the dremel I bought 3 years ago and have never used it until today, gone through a few cutting discs chopping them bloody bolts that I used to fit the Y pipe ages ago, christ there a pain. Also took the back frame off with the complete arm and diff attached, prop shaft popped off the back of the box very nicely, which was a relief haven heaard about other folks trials and tribulations with that little circlip.
The clutch plate looked in really good nick to say that its done 61+k miles. I do have some piccies which I will post up later, only bobbed in to get the torque settings for the clutch assembly then I am gonhna leave the rest till tomorrow.
Nearly forgot, the old box is defintly fugged, theres more slack in the input shaft than Joan Collins, reckon the main bearing failed, the oil seal also also manged to work its way nearly out of its housing[/img]

[Mountain 300]

Piccies, hopefully

http://s289.photobucket.com/albums/ll214/Mountain300/Beemer/

[Ade B]

Brings back happy memories of two days spent in Jason's company

Hope it all goes back together without too many bits left lying about..


Like the workshop - if the fuel cans catch fire, there is a hose on standby.


Ade

[_IT_]

Looks like its going well are you going to rebuild the fugged box and sell it on?

[Mountain 300]

Looks like its going well are you going to rebuild the fugged box and sell it on?

Had'nt thought about that, don't know if I've got the time or the inclantion.

[Mountain 300]

Well the story so far.................
Replacement box fitted and removed and refitted, who's the turkey that put the release plate in the wrong way round
Its good to check things operate properly as you go along, rock solid clutch lever told me I'd made a cock up, 10 mins later cock up rectified.
Whipped the header pipes off so that I could drill out the remnants of the bolts to the Y pipe, sheared a stud off in the process, double bugger
Rear frame, paralever and wheel back on, just got to sort the exhaust, fit tail frame, trim and a million zip ties.

[_IT_]

nice work nearly there.

[Mountain 300]

nice work nearly there.

Nearlly but not quite, had bike running, all gears engage and disengage
Spent most of the afternoon hammering/grinding out the bolts from all the Y pipe and header pipes. Awaiting the arrival of friend with portable blow torch so that I can get some heat on the sheared header pipe stud thats protruding out of the cylinder head, hopefully this will come out easily
One thing I have found is that a 99 beemer ridden in all weathers and 61k miles on the clock, is gonna have more than its fair share of seized bolts, the twat "O" hammer has defintely had plenty of usage