Gearbox trouble R1100GS

[tulekera]

Hi,

I ride a ´96 R1100GS (52KMiles), that has developed a nasty gearbox problem, perhaps someone has had similar experiences in the past and can shed some light of what is happening.

All gears except 3rd work quite ok, but if I get to third then trouble strikes, it always engages flawlessly, but sometimes it just drops out of gear and then re-engages a moment later just by itself, and at the same time the box makes quite a loud bang. It mostly likes to do that when driving normally, it has never popped-out-in when accelerating heavily. What vould be the problem?

The problem developed very unexpectedly, so far I've tried changing gearbox oil but it did no visible improvement. The magnetic oil-drain-plug has had small metal shavings every time I've changed the gearbox oil, is that an indication of a problem, or is it fairly normal?

br,

kristjan

 

[unshift]

yup thats the early 1100 gearbox for you - a known problem as far as i am aware - the problem was resolved in later models, which i guess means sourcing a "newer" one and replacing it (unless there is another way )

mine is of similar vintage but still running fine - Steptoe mentioned it was making a "noise/rattle" and might start doing the same as what you mentioned or it might keep going fine for a while yet

am sure someone more mechanically minded might give more info

 

[Rob Farmer]

The original gearbox (94-95) had a problem with the taper roller bearings squibing the oil oil out which eventually destroyed the bearings, most went between 20 and 30K. the 96 gearbox had O rings to try and cure a rattle but this resulted in the gears slowing down too quick and made the boxes clunky. The gearbox didn't really get sorted untill 97 when conventional bearings were fitted.

I had my 95 gearbox upgraded to the later 97 spec by Mick barr in Leicester. It cost around the £300 with me taking the gearbox too him.

 

[Rob Farmer]

I knew I had a link somewhere http://www.micapeak.com/bmw-gs/trans.html Gives quite a good overview of the 1100 gearbox (and it's faults). Couple that with the weak front end and the head gaskets being prone to blowing and it might knock some of the smug grins from the 1100 riders who fail to appreciate the superior 1150

The Gearbox designers, Getrag, had a similar problem at the time the early 1100 gearboxes were playing up with their Audi gearbox. A friend of mine was an Audi technician and reckons the symptoms suffered by the early R series were the same as Audi gearboxes from the same era. If the shimming was too tight the Taper roller bearings forced the oil out from the bearing surface causing the bearings to fail once the case hardening wore through. The gearboxes could be noisy for quite some time with no obvious problems. Mine started making a noise at 20k but I ran it to 30k before having to admit that it really was shagged.

 

[(RIP) Kaister]

so 97-99 1100's truly are the best overall ??

 

[ktmmark]

How's it go ' thank god i brought the 1200 & reading this site i was lead to believe the 1200 was the only gs to ever go wrong

 

[Sea Lion]

I knew I had a link somewhere http://www.micapeak.com/bmw-gs/trans.html Gives quite a good overview of the 1100 gearbox (and it's faults). Couple that with the weak front end and the head gaskets being prone to blowing and it might knock some of the smug grins from the 1100 riders who fail to appreciate the superior 1150

.

What weak front end?

Never heard about that one. But you did miss the abs start up problems.

 

[Rob Farmer]

You're obviously not trying hard enough. Mine used to get "fork walk" if I rode it really hard. I always fancied an 1100 with 1150 forks in.

 

[Tsiklonaut]

You're obviously not trying hard enough. Mine used to get "fork walk" if I rode it really hard. I always fancied an 1100 with 1150 forks in.

Tarka just put 1150 forks for his 1100 - sure the 1150 forks look and probably are stronger.

But back to this thread - i've heard also the gearbox was hugely revised on '97+ models, one of the reasons which makes many miles R1100GS experinced guys say the 97-99 models are the most ironed-out ones out there. Some revision history can be found: http://www.micapeak.com/bmw/gs/gs_tel1.html#history

Altough the gb issues doesn't seem to be that serious on early ones, but lot of miles done ones seem to have some gb probs if you read here or on the BM forums. But on contra-example one guy on ADVrider put more than 500 000 kilometres on his very early '94 and only with one gearbox falure for that excessive amount of miles, so i guess it also varies on different models... I guess it has ALOT to do with gear changing "style" as well, the bloody agricultural BM gearboxes tend to need slower shifts unlike most of japs.

If you somehow DO need to get new gearbox then certanly check the eBay.de - i've seen one or two low mileage '97 and '99 gearboxes going around there, auctions ended around 500-700EUR if i remember it correctly.

 

[tulekera]

But back to this thread - i've heard also the gearbox was hugely revised on '97+ models, one of the reasons which makes many miles R1100GS experinced guys say the 97-99 models are the most ironed-out ones out there. Some revision history can be found: http://www.micapeak.com/bmw/gs/gs_tel1.html#history

Should have checked the list carefully before buying, but hey, the '96 was an important year as well, revised tank decals! too bad my tank has been without decals for who knows how long.

Anyway, can somebody confirm that a later, ´97-´99 gearbox will be just a bolt-on job? Or perhaps there could be some differences and the holes-bolts don't lineup right?

br,

kristjan

 

[Tsiklonaut]

Yep, should be as far as i'm concerned, relatively easy job as well. But the 1150 and 1100 gearboxes aren't interchangable.

But i've came up with an idea - James Sherlock in UK offers shaft kit to convert from tapper roller to ball bearing (product code 205604) 52.88£

Maybe sending them your gearbox comes out cheaper? (United Motors here in Estonia doesn't do those kind of jobs, very probably only replacing the full gearbox with excessive amount of money)

Also Sherlock offers complete gearbox reconditioned exchange 405.38£ (product code 205001) if you DO need to replace the full gearbox and you get the brand new one, the improved version, but i'm quite sure it isn't neceserry and unlikely if your gearbox acctually works, but just with some fault - they'll inspect your own old gearbox and probably know the solution just replacing few bits. Also converting to ball bearings with additional cost is a an excellent idea to extend your current gearbox lifetime once you've already sent them your gearbox.

Margus

 

[tulekera]

Hi,

Does anyone know, if the 1100GS /R /RT /RS all share the same gearbox? And is it a straight-forward swap to put a '97 RT box on a '96 GS?

BR,

Kristjan

 

[Steptoe]

Also Sherlock offers complete gearbox reconditioned exchange 405.38£ (product code 205001)

Not anymore . To much grief.

Hi,

Does anyone know, if the 1100GS /R /RT /RS all share the same gearbox? And is it a straight-forward swap to put a '97 RT box on a '96 GS?

BR,

Kristjan

All the same box

 

[Vern]

I've got an 1100 gearbox kicking about in the back of the garage.It looks brand new ie not cleaned up,but apart from that,it's an unknown quantity.A mate of mine paid £400 for it,to replace his that had a broken casting,and when he moved,he left it with me.

It could be a pup,but all the gears engage from what I recall,and you're more than welcome to take a chance with it if you don't mind doing the work.It sounds like your box is going to come out anyway.

Give me a bell if you fancy a go with it

01905 612705

 

[tulekera]

I've got an 1100 gearbox kicking about in the back of the garage.It looks brand new ie not cleaned up,but apart from that,it's an unknown quantity.A mate of mine paid £400 for it,to replace his that had a broken casting,and when he moved,he left it with me.

It could be a pup,but all the gears engage from what I recall,and you're more than welcome to take a chance with it if you don't mind doing the work.It sounds like your box is going to come out anyway.

Give me a bell if you fancy a go with it

01905 612705

Hi Vern,

can You please check the gearbox number? it's written on the right side, on the part that "wraps" around the clutch-disc. here is a link to a picture that shows the place where the number is stamped: http://www.largiader.com/tech/oiltrans/trans-sn.jpg

BR,

kristjan

 

[ozrob]

I have a R1100GS 1998 (with ball bearings) 194,000 Km ,Also with exactly the same problem, where it appears to pop out of gear at 4200 rpm, the problem only started occouring after I changed the type of synthetic oil I was using, I have rebuilt the box a few times to replace the rear input shaft bearing and the last time I did it I noticed that the gears on the intermediate shaft were a bit tight, perhaps this is the issue, for now I have to option to ride it gently or rev out 2nd gear to 6000 prm then change to 3rd, I am not too sure what the problem is untill I need to strip down the box,
Has anyone actually had the problem fixed and what exactly was the problem?
Changing the box is not realy a solution at this stage.
Cheers.

Hi,

I ride a ´96 R1100GS (52KMiles), that has developed a nasty gearbox problem, perhaps someone has had similar experiences in the past and can shed some light of what is happening.

All gears except 3rd work quite ok, but if I get to third then trouble strikes, it always engages flawlessly, but sometimes it just drops out of gear and then re-engages a moment later just by itself, and at the same time the box makes quite a loud bang. It mostly likes to do that when driving normally, it has never popped-out-in when accelerating heavily. What vould be the problem?

The problem developed very unexpectedly, so far I've tried changing gearbox oil but it did no visible improvement. The magnetic oil-drain-plug has had small metal shavings every time I've changed the gearbox oil, is that an indication of a problem, or is it fairly normal?

br,

kristjan

 

[nelj]

HAs your problem been resolved?

 

[tulekera]

Yes, the problem has been solved, I bought a used M97 gearbox from eBay.de, cost me some 540.- EUR, have ridden it for 1100 kilometres, works fine so far, the damage in the original gearbox can be seen here:

http://alpha.future.ee/r1100gs/1.jpg
http://alpha.future.ee/r1100gs/2.jpg
http://alpha.future.ee/r1100gs/3.jpg

Will see if the shaft can be pulled apart to machine the parts into better shape...

br,

kristjan