Chronic transmission failure - help please..

[Ade B]

Whilst enjoying my renewed relationship with the S after tinkering with the electrics and cleaning it on sunday, thought I'd take it to Nottingham today for a meeting (back in time for 5 aside).

It was not to be... after cruising up the M1 at about 5-5.5k rpm, as I get to the outskirts of the city, after about the 5th set of lights, engage 1st gear and try to pull away..

funny whirring noise, no connection between engine and rear wheel in any gear, noise persists with clutch pulled in, back in neutral I coast to a halt and wheel the bike to a nearby industrial unit and leave it with security, get a cab into town, have meeting and return to sort out recovery with Carole Nash.

Get them to drop the bike and me back in London... (thankyou Carole Nash and SOS for actually turning up after an hour this time).

After various conversations with Pidcocks, SOS Recovery Drivers and their mates, apparently it is not unheard of for the clutch to jump off the drive shaft and disengage from the splines (This is paraphrasing what they said a bit..... they made it sound more plausible.)

No one appears sure as to whether I need a new gearbox (at £1200) or whether its simply a strip and replacement clutch (options vary from £800 and 5 weeks at Pidcocks or 'under a grand' from Bracken in London).

So... any of you veterans out there have any suggestions, better still any of you have the offer of garage space, tools and know how as this time I really am tempted to try to fix this myself to save money.... Bike is 2000 model SS, 34k on the clock and has an extremely expensive FBMWSH...

It is of course out of warranty

There is booze/repayment in kind/used tenners in it for any obliging board members.

Cheers

Ade

[julian]

Ouch - doesn't sound very nice.

Can't help with garage facilties but would be happy to lend a hand with the strip-down if you decide to tackle things yourself.

Jason, Steve & myself completely stripped my old S in about 2 hours. Clutch replacement is at least a whole day's work.

JK

[Merecat]

Hi Ade.
Sorry to hear of the problems.

Im no expert on the workings of engine to wheel thingies.....but clutches jumping off splines does sound a little drastic.
It may be more plausable that one of the drive shaft UJs has failed which would give the same symptoms, and 34k.....even with FBMWSH

No doubt Jason will be along soon with his trusty twatting stick to give his opinion.

Hope its not too bad and doesn't result in too much open wallet surgery.


Mick

[boxerpan]

The Americans have had several instances of the splines stripping from the shaft, might be worth a search on Pelican.

[bigblackfalco]

Deffo the splines on the clutch/gearbox input shaft.Happened to me on old 2 valve!
You don't have much luck eh.
Any way up it's gonna be expensive.
Options are either DIY secondhand gearbox(saves dismantling old gearbox) or dismantle old one and get new input shaft(major headache).
Give bike to Jap&German and get same done.
Hope all goes well.
Bailey.

[twodear]

I can't comment on the nature of the failure, but if the problem is indeed stripped splines on the transmission input shaft, I have two spare transmissions. Both transmissions came from wrecked bikes; the housings are cracked and therefore unusable as complete assemblies but the components are okay, I'm willing to part with portions of one of them.

If you are interested drop me a PM.

twodear

[Ade B]

Cheers for the responses

checked out Pelican

http://forums.pelicanparts.com/showthre ... box+clutch

Am slightly nauseous and strangely excited....

Amazes me that it is a problem that occurs with apparent frequency... I guess London use (lots of stop start & gear changes) doesn't help.

Although I could probably do without the challenge at the mo' am seriously contemplating putting up a large tent in the yard and making a temporary garage... (since the landlord has fixed the gate..)

Reckon forming an engine stand and getting the exhaust bolts off will be the most time consuming bit.. and contemplating getting started.. and doing all those other household chores (ironing the dog, fixing the tv aerial etc.) which always get put off but become suddenly pressing...

Will make some calls tomorrow and see what gives.

Any ideas as to ancilliary parts I might need - reckon the exhaust bolts will need to be drilled/ground off, will I need gaskets, seals etc.??

Also any specialist tools required - have a reasonable spread of the usual stuff (sockets, spanners, allen keys etc.) do I need any bearing pullers etc.

Twodear may well take up your offer if I can't source cheap parts in the UK..

Thanks again

Ade.

[twodear]

Ade B,

I don't envy your task but admire your ambition.

All bolts in the exhaust system all came off okay for me but obviously the climate is somewhat different here. Breaking off the transmission isn't that hard once you can see it, but all the stuff mounted on top of it (battery/motronic module/airbox/rear C frame) will be frustrating to say the least.

You'll need to remove the pivot bearings the swinging arm in order to get full access to the rear of the motor and the transmission. The pivot bearings are sensitive to adjustment during reassembly and will be quite fiddly.

There are some special tools shown for these tasks in the repair manual. Honestly, unless you are quite good with your hands and have a full tool box I'd advise paying the money for your shop to handle it. My local shop was willing to install parts that I'd bought elsewhere, perhaps yours may be as flexible? It is worth asking the question I think. Perhaps you could reduce their shop fees by reducing the bike down as much as you can before delivering it to them.

twodear

[Jason M]

Ade

I've got a garage (up in Southampton mind) and the tools if you want to do it here with some help. I've also got a spare (but partially knackered) gearbox - the spline was OK but one of the bearings has obviously gone inside as the oil came out like mercury and it was making a nasty noise when I changed it.

I guess the easiest thing would be to get the bugger appart then decide on the next course of action after that depending on the findings. I've got all the stuff we would need if you want to give it a go.

I reckon it would take the best part of a day to dismantle (though this would be the 3rd time I've done this now so it might be a bit quicker) then the same to reassemble. Whatever the problem you have the option of just fitting a gearbox from a wreck, getting my gearbox bearing fixed, replacing the shaft (not sure about doing this - never dismantled a gearbox but willing to give it a go!) or just replacing the clutch. Hopefully it'll be the clutch and you just need to pay Motorworks £100 and it's job done. Whatever - it will be much cheaper than paying Mr BMW to do it for you!

Jason

[Ade B]

Jason, your a star.

sent you a pm.

Ade (light at the end of the tunnel...)

[Jason M]

Hi Ade.
It may be more plausable that one of the drive shaft UJs has failed which would give the same symptoms, and 34k.....even with FBMWSH
Mick

I was thinking the same thing myself Mick - though I'd have thought that noise would be quite obvious - though maybe not with a helmet on.

If it turns out to be the shaft.... as luck would have it... I have a complete spare shaft off another 2000 S in the garage

Jason

[crucial]

Afternoon, haven't been around for a while (ever expanding family) but saw this post and thought i'd insert my 2p worth.

The splines on my clutch went at about 75k which in itself is not to bad,(as Jason says it's about £100 all in) unfortunately in my case it damaged the splines on the gearbox input shaft as well. After some deliberation (opening and dismantling the gearbox doesn't look like fun) the easiest course of action was a gearbox from Motorworks (£400).

The only special tools I needed was a piece of 2" x 4" wood with some holes drilled in it and two axle stands to support the engine. It's actually not a difficult job, just time consuming Lots to unbolt and put back together!!

Good luck. Paul