on Tue May 20, 2014 8:31 pm
What you are experiencing is what happened to my 2nd gear, and also to my 5th gear.
This is the failure mechanism:
- The gears are connected using rounded-square pins (dogs), and their corresponding profile slots (i think i posted all the relevant links in this post)
- The shift forks slide this dogs into their slots.
- BMW made two cheapo errors:
1- the dogs/slots should have a 5 degree slat (dove tail) so that the gears are pressed together when the load increases.
2- the slots were machines from the bottom and the top, but they had a machining error, and they meet in the middle at an angle, so instead of providing a flat surface for the dog to pass all the load, the tip that formed starts to erode the dogs.
So, if you remove your gearbox you will find that all the dogs are rounded. So when you apply torque, the load makes the dog jump out of the slot (because of the new angle they form).
If you take it to the dealer, or some independent mechanic, they'l replace the shift forks. That solves the problem momentarily, as the forks will be less worn, and keep the gears in place.
Don't keep pushing your bike. When the gears come violently together after they spin in that false neutral, they destroy themselves.
They might snap and wreck/seize your gearbox. If that happens, well...
Now, the options you have:
- Replace the gearbox: BMW made a design flaw. They will replace the gearbox and give you a one-time warranty. That is, it can only fail once. They'll replace it once, and then you are on your own. Also, you have to shell out: $4,200 or something ridiculous like that.
- Fix your gearbox at R&D Motorsports. You have to call, Mark doesn't have email. That should be around $1,600. Also, the design flaws are corrected. Give him a call (http://www.r-dmotorsports.com/
If you go this route, please buy one or two shifting forks. BMW has a long delay in making them. Perhaps your dealer have some.
BMW doesn't sell the individual parts. They want to thief you for a whole gearbox.
I think Mark is working in machining some of the most common gears that fail: 2nd and 5th. You could be lucky and he might have the gears you need if they are cracked.
Maybe you can baby the 1st gear (weird that failed).
I think you can use the gearbox and clutch basket of the improved K1300, but even those are having issues. I went the route to rebuild the gearbox as I intend to keep my K12R forever.
Malo dugačko ali možda pomogne nekom