K1200LT gearbox problems - BMW Luxury Touring Community
 
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post #1 of 16 Old Jan 25th, 2009, 9:49 am Thread Starter
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Red face K1200LT gearbox problems

Hello all!

Well - last summer on the German autobahn - I had to make a fast downshift from 5' to 4'. I was to fast - and gave it a full throttle - before the gearbox had settled in 4'.

As a result - It smashed out of the gear into neutral with a "bang"

After that - it was really impossible/difficult to get it into 4' gear - and If I "found it" - it would jump out again - after a few seconds.


I therefor assumed that I had bent a selector fork in there. This weekend I opened the gearbox and found the selector fork - not to be bent more than 0.5mm - but has a strange sign of wear.

And the gearwheel also has some damage.

High resolution Photos from all this is found on http://tour.my-mc.com/gallery2/v/steinar/gearbox/


So what do you think - will a new selector fork do it, or do you think I also need a new gearwheel ??


Thank you for you help and wisdom ;-)

regards
STeinar
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post #2 of 16 Old Jan 25th, 2009, 10:34 am
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Re: K1200LT gearbox problems

Obviously both are damaged. Replace both. If I were rebuilding it, that's what I'd do. I replace gears like that in Honda trannies all the time and shift forks, too. Even the automatic has a shift fork for reverse. Good luck...........

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post #3 of 16 Old Jan 25th, 2009, 11:04 am
 
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Re: K1200LT gearbox problems

I can't give you any advise on this as it is a little outside my area of expretise, but I really would like to thank you for the pics as I had never seen an LT gearbox (at least part of it).

good luck
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post #4 of 16 Old Jan 25th, 2009, 11:17 am
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Re: K1200LT gearbox problems

I have never seen the insdie of a LT gearbox until now, so thanks for the amazing photography. Also, I have only had my 2000 LT for a short while so I really don't have a lot of experience on it.

That said, I just rebuilt the transmission on my Jeep. Understanding they are completely different animals, I replaced everything that had damage. Strangely enough I had damaged forth gear (although, not on the Autobahn ). I replace several damaged gears, damaged forks, all seals and bearings, even though they appeared undamaged. It cost a little more to replace the seals and bearing but I don't plan on getting in there again and wanted to know for certain they were undamaged.

I salute you for being able to do the work yourself. I had a lot of help.

Enjoy the ride.

2007 R1200R

2000 K1200LT

1978 R100S (long gone, but not forgotten)
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post #5 of 16 Old Jan 25th, 2009, 12:07 pm Thread Starter
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Re: K1200LT gearbox problems

Hello everyone - and thank's for replying ;-)

After reading this - I will suply more photos of the internal of the gearox later on when I start the rebuild.

regards
STeinar
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post #6 of 16 Old Jan 25th, 2009, 2:28 pm
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Re: K1200LT gearbox problems

Interesting. Selector fork is clearly damaged, but not much. Other parts as well. These pictures do not explain reason for damage neither why gear will jump out. Why selector is damaged?

What I would do? Change selector into a new one. Gears? I do not see so much damage that replacing them would be only solution. Grinding those small damages should so it. But replacing these parts by new ones is always best solution.

And thanks for good photos.

Regards
Leiboshi
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post #7 of 16 Old Jan 25th, 2009, 3:00 pm
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Thumbs up Re: K1200LT gearbox problems

Hey ST--I can't give advice BUT GREAT PHOTOS. THXS!!
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post #8 of 16 Old Jan 27th, 2009, 12:31 pm
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Re: K1200LT gearbox problems

That little bit of wear on the fork and the rounded edges of the gear will couple up to be enough wear to kick that gear out. They are close tolerance. Don't waste your time if you're not gonna replace the worn parts.........

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post #9 of 16 Old Jan 27th, 2009, 2:27 pm
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Re: K1200LT gearbox problems

On the gearbox. Does anyone know if it is possible to install a lower first gear in the LT. Is there another bike( RT RS GT...) that would work. Just a thought as this would be an ideal time to take care of that tall first gear.

Duane Taylor
Sebastopol, California

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post #10 of 16 Old Jan 27th, 2009, 4:28 pm
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Re: K1200LT gearbox problems

The tall first gear looks after the clutch surely?

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post #11 of 16 Old Jan 28th, 2009, 10:23 am
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Re: K1200LT gearbox problems

Having rebuilt many automotive standard transmissions. My advice is to listen to Rattler he has got it right. Usually you will find a tapered spring loaded device that will positively maintain engagement. From the looks of the photos I'd say some piece of aforementioned device escaped from it's holding cell and damaged the shift fork. First gear ratio could stand to be a little steeper. This would promote clutch life not wear it out as infered by cook1. Don't believe me try taking off in second gear.
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post #12 of 16 Old Jan 28th, 2009, 11:05 am
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Re: K1200LT gearbox problems

Quote:
Originally Posted by EdAnderson
First gear ratio could stand to be a little steeper. This would promote clutch life not wear it out as infered by cook1. Don't believe me try taking off in second gear.
Yep, I see what you mean - I was thinking he was going to go the other way with it.
I find the fears on the LT so different to my other bike. You really have to work them. My ST1100 can be put in top at just 15mph and comfortably do the job all day from there. The K really needs working. Not complaining mind, keeps the mind active!

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post #13 of 16 Old Jan 28th, 2009, 12:38 pm
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Re: K1200LT gearbox problems

It is those uphill fully loaded two up starts into fast moving traffic that a lower first would help, and a lot less slipping of the clutch would take place. If I knew of a way to get a lower first I would do it this week. Besides that stoplight races would be a lot more fun!

Duane Taylor
Sebastopol, California

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post #14 of 16 Old Jan 28th, 2009, 1:03 pm
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Re: K1200LT gearbox problems

ST,
I had a similar problem in August of '08.
Your photos are good , but what do the cogs look like where 4th gear engages into 3rd gear? That is where mine had the most damage. That is also why mine would not stay in 4th gear. Also check for damage on the selector drum.
If you intend to rebuild your gearbox, I suggest changing 3rd, 4th, the shifting fork ,and the selector drum.
I just replaced the whole gearbox, allot less work.
good luck,
Don
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post #15 of 16 Old Jan 28th, 2009, 2:34 pm Thread Starter
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Re: K1200LT gearbox problems

Hi all - and tnx for all comments!

Well - yes the selector drum do have some damage.
And only from the 4th gear engage side ?

No damage on the cogs for the 3rd gear at all. Looks new!

I think that the bad gear shift of mine - made all the damage found on the drum, the fork and the 4th gear cogs.

All other parts look like brand new. The bike has some 100' Km now - so some usage has to be seen.

BUT - the 3-4th gear is NOT possible to change. I need to get a whole new intermediate shaft as one unit. $$$$


What I will do is :
Change the fork and the drum. And Grind the "small" damages on the 4th gear cogs the best I can.

If this is not working - I will look for a used gearbox and replace it !


More photos (from the drum and 3th gear) is now located at my site : http://tour.my-mc.com/gallery2/v/steinar/gearbox/

Well - one of them is from my garden - and is not giving any hope for riding for a few weeks !

regards
STeinar





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post #16 of 16 Old Feb 12th, 2009, 10:52 am Thread Starter
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Re: K1200LT gearbox problems

More photos from the assembly of the gearbox this time.

Here you will have a close look from the original BMW tools - used to insert the new seals.

First putt on a protector so the internal of the seal is not damaged on it's way into position.

Then the seal is seated into the guide, and a driver/drift is used to put the seal into it's finale position. This drive is also a position-guide so the seal will end up in perfect position.
You will anderstand from photo :
DSCN1025.JPG => DSCN1026.JPG => DSCN1027.JPG

This is showing the same ting :

DSCN1029.JPG => DSCN1030.JPG => DSCN1031.JPG

Photo DSCN1032.JPG is showing my collection of these seal inserting tools.

DSCN1022.JPG is showing the reverse gears.


Link to the photos !

regards
STeinar F
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