1100i Clutch Job

[Kiwi_Roy]

My Brother has to replace the clutch in his 1996 1100i
We are wondering if he has to pull the motor for that or will the gearbox come out from the rear?

The clutch started to slip under hard acceleration and he noticed a drip of oil coming out the drain hole.

We are thinking replace rear engine seal
Front gearbox seal
6 flywheel bolts

Is there anything else to be done while apart?

Thanks in advance

[Antietam Classic Cycle]

We are thinking replace rear engine seal
Front gearbox seal
6 flywheel bolts

Is there anything else to be done while apart?

Thanks in advance

- clutch hub o-rings (2)
- clutch pushrod seals - I use a stack of six o-rings instead of the o.e. "cones" and will send you some for free.
- seal the cam plug with JB Weld

[fotoguzzi]

My Brother has to replace the clutch in his 1996 1100i
We are wondering if he has to pull the motor for that or will the gearbox come out from the rear?

you need to lift the rear of the frame about 5" to get tranny out the back..so lower frame rail bolts out w/the tranny bolt.. you "might " be able to pivot frame if you just loosen the front motor mount, that will keep frame aligned and a little easier to get back together. a hoist will be real handy.

[Old Jock]

Hi Roy

I'd take the end case off the gearbox & do the seal, all the O rings & return spring, in addition to what's been mentioned.

They are all easy, providing you have the appropriate sockets and a rattle gun for the input and output nuts

The difficult one is the peg nut on the input anyway and you'll need to remove that to do the gearbox input seal

Just summit to consider nothing too expensive and not a lot of extra work if you have the box off anyway

John

[Wayne Orwig]

You can crab the frame and pull the trans. Getting the airbox in/out is a large part of that job.

Engine oil is unlikely to contaminate the plate. Trans fluid can easily contaminate them. As mentioned, do the clutch pushrod o-ring kit, and rinse the clutch housing with mineral spirit. That may do the trick.
If not, then it is likely the o-ring and seal on the trans input. OR, the front bearing is starting to go out. Not uncommon.

[Kiwi_Roy]

You can crab the frame and pull the trans. Getting the airbox in/out is a large part of that job.

Engine oil is unlikely to contaminate the plate. Trans fluid can easily contaminate them. As mentioned, do the clutch pushrod o-ring kit, and rinse the clutch housing with mineral spirit. That may do the trick.
If not, then it is likely the o-ring and seal on the trans input. OR, the front bearing is starting to go out. Not uncommon.

Is that the gearbox front bearing?

[Kiwi_Roy]

Thanks Gentlemen for ll the great advice 

[Wayne Orwig]

Is that the gearbox front bearing?

Yes, the plastic cage on the balls fails.

[Old Jock]

If doing the bearing on the input shaft I'd do both and replace the output shaft too, replace with the all metal variety

Once the input & output nuts are off then the gearbox is not a big deal to strip & check

I feel like a self publicist God Knows why I did not get a penny for the article but if its any use

http://www.thisoldtractor.com/guzzitech.dk/gb_en_complex-technical_gearbox-rebuilding-pictures.htm


John

[Chuck in Indiana]

Here's what it looks like. You can pick the frame off the whole assembly.
2016-04-17_12-14-31 by Charles Stottlemyer, on Flickr

[fotoguzzi]

Here's what it looks like. You can pick the frame off the whole assembly.
2016-04-17_12-14-31 by Charles Stottlemyer, on Flickr

got any more pics of that fine looking dog?

[fotoguzzi]

I'm confused, thought a 96 1100i was a Cal1100.. is your bike a spine frame?

[Wayne Orwig]

I'm confused, thought a 96 1100i was a Cal1100.. is your bike a spine frame?

:1:

Is this a Spot1100i, or a Cali 1100i?

Not that is matters much.

[Kiwi_Roy]

Fotoguzzi, a Cali like the red one in your first picture I believe the first of the fuel injected with a P8 ECU
I should have a picture somewhere.
Here it is, a nice old girl.


It's in New Zealand, I'm in Canada
I'm sure my Brother will find the information very useful.

[oldbike54]

 Roy , why not convince your brother to join us here , might be easier to sort this out .

 Dusty

[Kiwi_Roy]

Roy , why not convince your brother to join us here , might be easier to sort this out .

 Dusty

He is on here, KiwiKev
Doesn't post much though.