F800GS front drive sprocket 'welded' to spline - Any ideas regarding how to budge it? - BMW F800 Riders Forum & Registry



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  1. #1
    Viferpilot's Avatar
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    Front sprocket appears to be 'welded' to the spline. Gear pullers won't budge it! Even after a bit of gentle heating
    - Anyone experienced this challenge before?
    - Any ideas on how to get this worn pinion off, safely?
    The bike is otherwise pretty well maintained.
    What would cause this pinion to 'seize' this firmly to the spline?
     

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  4. #2
    Viferpilot's Avatar
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    Found my own solution : Lubricant+gear-puller+patience (leave it for an hour or so)
    Cause = rust
    I might have thought it difficult for moisture to get in there? Particularly if there had been grease in there originally (?)

    Now what? i.e. rusty spline+shiny new pinion. Doesn't sound like a 'nice' union to me (just setting up for another 'welding by rust')
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  5. #3
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    i would clean it up thoroughly, and paint it with an antirust inhibitor to know it is all killed off. Then use something like Hammerite, or any other rust prevention paint and put a thin coat on it to prevent a resurgence of it.
    BMW F800ST, 2010, Black, Fuzeblock, Sat Nav, BMW Tank Bag, Givi Touring Screen, Denali Spotlights, Denali CANSmart, Wunderlich Crash Bars, 55K Miles & counting 

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  7. #4
    Dalesman's Avatar
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    Paint might work as DJ says.
    I would give it a good clean up with WD40 and some wire wool and then a thin coat of grease before reassembly. It'll come off more easily next time.

  8. #5
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    Anti-seize compound is what is commonly used by the construction (earthmoving) industry for these sorts of connections on heavy equipment. The are different kinds; the most common is finely ground aluminum in some sort on binder to form a paste. Probably grease. Also it is available in copper and nickel. Google the word anti-seize. This is truly the best treatment for any sort of metal to metal joints that need to be able to easily come apart when necessary.

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    In the garage: 1972 BMW R60/5 - 1983 Yamaha XJ650 Maxim - 2014 F800 GT
     

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  10. #6
    notacop is offline The original Schwartz Wald Troll
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    Always lube splines. Axles too. I've got a container of copper anti seize I've used for years and many bikes. Would I trust that the manufacturer properly lubed the splines on assembly, NO!

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  12. #7
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    Hi, dealt with this only a couple of days ago on my 09 R. I actually shattered my original sprocket mine was on so tight.

    Douse liberally in wd40 or other penetrating oil. Leave it, spray on again, aiming to try and force some between the teeth.

    Get the puller fitted (use a high tensile bolt in the bolt hole, not the original, and only about 18mm long so it does not trash the thread in the spline) get it under tension then heat. I only used a heat gun (air) but get the pocket smoking. Yes there is a gasket behind but so long as you just aim the heat at the sprocket should be alright.

    It may take a day or two of this, but it works.

    The key is to apply the heat whilst it's under pressure.

    give it a good clean with a wire brush then make sure to put plenty of high temp copper grease on the spline. 50nm torque on the bolt.

  13. #8
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    Quote Originally Posted by zoefoster View Post
    great
    You asked for it. Into the spam can for you.
    Richard - Current bikes: 2016 BMW R1200RS, 2018 16.6 kWh Zero S, 2011 Royal Enfield Bullet 500 Classic, 2009 BMW F650GS, 2020 KTM 390 Duke, 2002 Yamaha FZ1 (FZS1000N) and a 1978 Honda Kick 'N Go Senior. 

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