keepemflying A kickstarter and a blocked fuel line
By Matthew Parkhouse #13272 THE
BAVARIAN
Mountain (Sipapu) Rally outside of Taos, N.M., was another good one. The weather was absolutely perfect, with
good food
served and the renewed connections with a number of old friends. The “What I Take with Me” seminar was well attended. In addition to showing what I carry with me on the bike when I’m out on a motorcycle trip, I picked up a couple of good ideas from folks in the audience. I also came home carrying a gearbox that turned out to have suffered what I’ve come to call “the usual 5-speed failure.” The “big bearing” at the forward end of the output shaft (missing the circlip) failed, allowing the shaft to move around. This in turn cracked the cover and damaged a cou- ple of internal parts. Prob- ably in a real-world shop situation, the transmission would be totaled and a good used one sought and renewed. Since I had most of what was needed in the form of good used parts, the transmission will be repaired for less than the cost of a good used one. Susanna is back east one more
hundred miles since then. The next few days look to be perfect Colorado weather for a couple-day run to the south of the state. I test rode the S and found everything still in order (except for the turn signal indicator lamp – loose bulb). Today I will wait until mid-day for things to warm up. I seem to be more and more sensitive to cold temperatures as I get older. I knew I actually had a week or so with
Two five-speed gearbox covers. The left side is set up with the needed parts for the kickstart system. All the parts remain available, except for the toothed gear on the input shaft. Of course, the parts, including the cover, represent a cost of over $600. A more practical route is to find a 1974 gearbox and take all needed parts from it, They will retrofit any five-speed up to 1980.
time, for a grandkid visit and high school reunion. I’m staying home. I hope to get one more motorcycle trip in before the Colorado winter door closes (and that will happen sooner rather than later). I want to put a few miles on the R 100 S I fixed up last winter. I have ridden it perhaps a
50 BMW OWNERS NEWS December 2015
no BMW repairs, so I spent some of that time reworking a pair of gearboxes into one unit. I picked up a 1974 transmission (with the kick start) a year or so ago. I have been planning on combining this one with a 1978 gearbox that I took the cover off of a while ago while working on it. While the kick start is really more for decoration than constant daily use, I do like how it looks on the bike. The internals of the ’78 are much stouter than those from the ’74 (the first year of the 5-speeds). A couple of weeks ago, I gathered up all the parts and spent a few pleasant hours on the project. First, I removed the cover (with the kick lever) from the earlier box. It comes off in
the usual manner. Lots of heat was applied with a torch after the output flange and all the bolts have been removed. With the cover off, I spent some time with razor blades and sandpaper, cleaning off the adhering bits of the 40-year-old gasket. I also pushed the input shaft up and out of the older gearbox. The cover linkage and shaft are what I needed from the ’74. I car- ried the remains of that box downstairs to sit on the shelf, with “74” scrawled on the side. I want to hang on to this partial box, along with one other from a similar, earlier project. Many of the gears and others inter- nals from that year are now no longer available (NLA). This means that should someone break teeth off a shifter cog or have a failing bearing damage a gear or two, the gearbox is usually written off and replaced with a used one from later years. With these two open gearboxes on the shelf, I could put a damaged 1974 transmission back into action. You can install any gearbox from 1970 (even if the first four
years were 4-speeds) to 1980 very easily into a 1974 BMW. This project was to have the kick start and the stronger gear train of the transmissions of the later 1970s in one unit. I then removed all the parts from the ’78
gearbox. After inspecting everything and cleaning up the parts, I put them back into the case, along with new seals and several new springs, detents and bearings. The bevel gear on the input shaft matches the angle of all the 5-speeds up to 1980. This means I could drop it into the later case and it would match up with the newer bevel-cut gears. With all the parts in place in the case, I set up the parallel bars and
TECH
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