Gearbox Rebuild

[Smudge]

Gonna have to pull the gearbox on my 2006 GSA (50000 miles). and strip it down, due to a very grumbly bearing in there somewhere
Anyone know where I can get a list of Gearbox tolerances for when I shove it back together
Not much info in my Haynes manual
Ta very much

 

[Deleted account 190920001]

Get the reprom and all the information shall be yours.

 

[Bendy toy]

Also check out the "dodged a bullet in my gearbox" thread.

 

[Smudge]

OK ... Thanks Guys
2 questions Marki ...
What the feck is a reprom? and where do I find it?
Checked the thread Bendy, interesting to say the least. I will be having a good look once I get inside

 

[Smudge]

Found a reprom now

All sorted ..ta

 

[Bendy toy]

Grannies & eggs mode:
You have of course checked the final drive and driveshaft UJs.
Mine were rebuilt by MikeyBoy at 50K. Gearbox was ok.
Mode off.

 

[Smudge]

Cheers Bendy .. always good to have someone prompting so no problem there

Mikeyboy sorted the Driveshaft UJ's a couple of weeks ago and the final drive seems very smooth, nice clean oil, etc.
The gearbox oil was clean as well ... so .. gearbox off, fettle, back on .. noise gone .. sorted .. still noisy ... off to mikeyboy for final drive rebuild
Should be like a new bike when its done

 

[Bendy toy]

Mine at 52K has a lot more drive backlash than my brother's GS at 25K. Its never got any worse but I do wonder how it would be with new clutch and rebuilt gearbox.

 

[Magwych]

The older RepRoms provide a max lenght fir the shaft assemblies, which can be adjusted by the use of shims. They seem to be comoensated for variances in machine length of the gear components and sliding dogs. Unless you are changing those the rebuild is quite straightforward. If you are, the shims come in 0.1 mm differences, a vernier that can measure 196mm to 0.02mm accuracy should be fine.
I have a spare set of BMW bearings if anyone wants. The 63/22 s are hard to find.

 

[Smudge]

Thanks Magwych.
I am trying to put the job off until winter, we have got the big trips out of the way so should be local trips from now till winter.
Just gonna see how it goes, thanks for the info. on use of shims, I will bare that in mind when doing the initial measurements.
Do you have a full set of gearbox bearings?
Might get in touch nearer the time, if you still have them

 

[Magwych]

Yep. All BMW parts, 2 bearings for each shaft. I cocked up and got 2 sets. One from BMW and one from a mate who works in a bearing suppliers. Not a lot of difference in price TBH. I just prefer the likes of SKF and KOYO to the oem NSK bearings

 

[Smudge]

Cheers mate ... I've got a contact in Kent bearings, up your way, who I was going to tap up for a set when the time comes

 

[Magwych]

You will need one of each 6204, 6304 and 6305; and 3 off 63/22. All are 2RS. The 63/22 are the harder to get ones. the size is 22x56x16. My friend could only get Koyo bearings to supply.

 

[Smudge]

You will need one of each 6204, 6304 and 6305; and 3 off 63/22. All are 2RS. The 63/22 are the harder to get ones. the size is 22x56x16. My friend could only get Koyo bearings to supply.

Brilliant .. cheers mucker ... top man

 

[Smudge]

One month on ..... This is a good 'un, wait till you here this.
Noise didn't get any better or worse, the bike was booked in for the rear flange thingy recall, get that out of the way then take it off the road and sort it properly.
Quick chat with the mechanic prior to starting the flange work, "I will have a good look and take it up the road", says he. "Checked the gearbox and final drive, no problem there" says he, "but, did you know your rear tyre is fitted the wrong way round" "Would that make a noise like a gearbox bearing failing" says I, "probably" says he "it would make a sound like in Crocodile dundee when he was spinning that noise maker on a string round his head" .... "for fucks sake", says I, "that is exactly what it sounds like"
Long story cut short, tyre turned round to correct direction, noise gone, all is good and I have money to spend that I wont be spending on the gearbox/final drive

 

[Bendy toy]

You will need one of each 6204, 6304 and 6305; and 3 off 63/22. All are 2RS. The 63/22 are the harder to get ones. the size is 22x56x16. My friend could only get Koyo bearings to supply.

I just found this
http://www.ebay.co.uk/itm/63-22-2RS...-2-bearings-/281108876513?hash=item4173650ce1

By the way, my rear TKC-70 was fitted the wrong way around causing a failed MoT test. It's now correctly fitted with new MoT but I can detect absolutely no difference in noise or handling.

 

[Smudge]

Nice find there Bendy ... but hopefully I wont be requiring them now
The tyre was a Metzeler Tourance Next, and I kid you not .... the noise was feckin awful !!!!!! and the handling suffered as well