Repairing K1200S/R Transmission [copied]

[mboye]

I too find myself in this same spot, broke 5th gear on a 06 K1200S with less than 10K miles. Waiting for BMW to reply . It bothers me to be treated like a second rate customer as I didn't buy the bike new from this dealer(07 didn't come in the color I wanted).I have spoke with R&D about the fix , anyone out there have parts broke that couldn't be fixed?

I have a spare transmission with 5th gear that is fine but second is destroyed, cost for the whole transmission would be a few hundered US$ (I need to check what I paid for it) plus shipping (which would be reasonably expensive given the weight of the transmission form Aus to USA)

[broke1]

I too find myself in this same spot, broke 5th gear on a 06 K1200S with less than 10K miles. Waiting for BMW to reply . It bothers me to be treated like a second rate customer as I didn't buy the bike new from this dealer(07 didn't come in the color I wanted).I have spoke with R&D about the fix , anyone out there have parts broke that couldn't be fixed?

I have a spare transmission with 5th gear that is fine but second is destroyed, cost for the whole transmission would be a few hundered US$ (I need to check what I paid for it) plus shipping (which would be reasonably expensive given the weight of the transmission form Aus to USA)

Thanks for the information. I should hear back this week from BMW and that will start the process. Maybe I can buy the gear cluster from you which should be less to ship? I still hope for the best from BMW. The gearbox hasn't been removed so not sure what the damage is.THKS

[peterb305]

mboye, can you please advise who in florida repaired your gearbox ? I have the same problem with my 2006 k1200s
regards/peterbaugh@texinter.com

[broke1]

Guess I should have updated this post. BMW did nothing for me, my local shop stepped up and found a good used one and made it right. With that said, I will be happy to pay it forward and for a very small cost I have a used K1200 transmission with 5th toast. hdave34@yahoo.com

[JayK12S]

Yep, failed on 37000km's. 5th gear started slipping, and box was replaced with a K1300S box.

2007 model though... no option there for me to select.

Hi Trojan,

this gearbox failure has always worried me as it is expensive here in SA to replace the box. BMW say they can undercut the box for R1500.00
As a matter of interest did you have to pay for that K1300S box? As my friend had a 2006 K12S that had the box replaced after 30000km.

[K12Sdude]

I had a failed transmission with about 20000km on the clock. For AUS$5500 it was too much to replace the transmission as it was outside warranty so I had it fixed myself. I managed to buy another ruined transmission off ebay in Nth America, I then had it stripoped down and the shaft with 2nd 3rd and 4th 5th sent off to a tranmission specialist in florida. They magnufluxed the gears welded and undercut 2nd/3rd and 4th/5th. It was then reassembled with a new 2nd/3rd gear selector fork. Normally the issue with undercutting is that the gears are harder to change or get into nuetral but my transmission is the best it has ever been. Gear changes are smooth with out clunks and the risk of the gear damaging itslef again should be reduced. It is suprisingly easy to remove the transmission from these bikes. I have some photos of the failed and new transmission if any one is intersted. even with $200 shipping to Australia it was still a fraction of the price of a new transmission.

Since my 2006 K1200S is out of warranty and I am out of money, I am hoping to find a way to repair it without replacing the tranny with a new one. I am interested in your repair procedure and the name of the transmission specialist in Florida. I have not started the project as yet so trying to avoid any hard acceleration (very hard to do) in 2nd gear. I will quit driving it until it is fixed.

Thanks

Found your write up and photos and will put it to good use!

Many thanks,

[mboye]

I had it rtepared at r&d motorsports http://www.r-dmotorsports.com/ I did pull apart the tranmission first and only senty them the effected gear cluster.

I still have a spare transmisison here in australia if you find you need one for any reason. Good Luck

[K12Sdude]

Thanks for the much needed information.

Thanks also for the offer on your spare trans. I don't know what I need yet but I will let you know as soon as I get mine apart. It will probably be within a week as I am waiting for my friend to loan me space on his lift.

[elp_jc]

Hey folks. sorry to hear about your transmissions, but have a question for you: Did the damage occur without any provocation? And by that I mean if you never missed any shifts, accidentally hit the gear shift lever while under WOT, had an accident on the left side where shift lever hit on the asphalt, or any such incident that cold justify the damage? BMW transmissions have always been pretty robust.

Hope the one on my '09 K1300S is better. The only 'accident' I had was when checking out the Quick Shifter for the first time. I went progressively faster in 1st gear until I went WOT at about 5K rpm, and since I had my boot already resting on the shift lever for a quick shift, I accidentally shifted to N, and engine banged on the limiter for a fraction of a second. I must have done it so lightly than instead of shifting to 2nd it just went into N. I didn't hear a bang or anything, like when the tranny pops out of gear, but wonder if I caused any excessive wear on the shift fork. Tried it once more after that, just to make sure everything was fine, and it was. I obviously put my boot a little lower that time .

[mboye]

I probably had a few missed shifts on mine, and I did accelerate as hard as possible from a standstill onto an entrance onto a freeway numerous times which probably didn't help however the bike should have been able to withstand this. Also the poor bushing in the shifter meant that the shift was not clean due to a lot of play in the joint, which I fixed using the bearing fix that is available and which I think was fixed on the k1300. When I replaced my shifter fork I noted that they had also slightly changed the design of the shift fork which to me says that they did have an issue. I believe all these issues were fixed on the k1300 and it also has a slightly different clutch.

[mondrage]

My K12R (81,000km), slips out of gear in second gear, and then fall back violently back in gear at about 6,500 to 8,000rpm.

I have not opened the gearbox.
What should I replace, the gear selector for 2nd/3rd?
Anything else I should be looking at?

[mboye]

do not just replace the shifters, this is what I did only to have to buy a new set of shifters and do the job properly. note it only takes a small amount of rounding of the gears to cause them to disengage (see pictures from earlier thread).

good luck

[Eka]

In new K1300 gearbox dogs should be undercutted. It force gears stay on. I guess dogs from your second gear is rounded. It could happen from false neutrals gear raddling on etc. I guess it's possible get those gears fixed and machined by professionals like this (don't start to file yourself):

[pgetty]

K13 Trans totally and finally properly engineered and redesigned, as is the new K16&rr, for 170+ RWHP by outside tech company, as you already well know. Only the very poorly original under (?designed) 20,000 mi life K12 needs its trans rebuilt including gear undercut for lock-in...please back me up after confirming with BMW Motorad Tech dept, if still in existance.

Even our famously proud H-D smartly consulted Porsche AG before dumping their new water cooled engines, unlike our $15K BMW 05-07 K12 worthless long range $200 junk , onto the world MC market. Worst yet BMW NA refuses to back us poor customers and the "few really good well intensioned" US dealers("good will" repairs made out of their pockets).

Comments welcomed.

On a positive note...many thanks to the K.COM admin, workers and contributors...wonderful job extremely well done!

Love(d) my K12(redesigned&rebuilt then sold/given away), Good value K13(sold), New great K16GT(keeper) and fresh S1000rr(latest keeper)

Peter G. PE
PMG Engineering

Sorry for any negitiveish and typos, all-night late overspent USGov project on my dime. Alls going to be well, starting this wk-end, riding the Bemmer

[mondrage]

In new K1300 gearbox dogs should be undercutted. It force gears stay on. I guess dogs from your second gear is rounded. It could happen from false neutrals gear raddling on etc. I guess it's possible get those gears fixed and machined by professionals like this (don't start to file yourself):

Eka, Mark, thank you very much for all the explanation.
I finally got all the tools to do the job properly, driver lock, crankcase locating pin, clutch basket locating pin, and the eccentric gauge for the oil pump chain.

I thought it was a matter of just replacing the selector fork (2nd/3rd gear is damaged).
But I'm glad I re-read this thread.
I didnt' understand what "under cut" meant, but Eka, now it's crystal clear.
So, let me ask.

- If I find that the dogs are rounded off, what should I do? There are no specialized shops in Nicaragua. So, if I take them to a rectification shop, I have to explain.
- Should the dog be first "filled in" and rectified?
- Can the dog just be undercut? Without first filling-in the rounded-off part?
- What is the appropriate undercutting angle?

Thank you in advance for the help.
Awesome guys, I promise to post pics, procedure and test results.

Eyvind

[Eka]

I have not done such a things. I guess you should machine those equally untill there is no rounded corners. I don't think it has to be so much angle than in that picture. Ir you do that angle in both ends, then it won't also jump into neutral while engine breaking.

[mondrage]

Eka,

Thanks.
So, I need to do the undercutting, (same angle of course) in all the gear dogs right?
Might as well do it for all other gears.

Also, the undercutting needs to be done in the slots?

Thanks,