In technical terms - I think it's 'fu**ed

Muppet said:
I didn't think the sort of reasonably gentle track riding I do would warrant the TT hard part - guess I was wrong.
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Even BMW knew about this weakness when they were making the bikes.

As motomartin may have, by now, spotted, later R1100GSs sold in the Australian market were fitted with BMW's own hardparts. I'm sure that someone on this board can come up with the part numbers.

Greg
 
As motomartin may have, by now, spotted, later R1100GSs sold in the Australian market were fitted with BMW's own hardparts. I'm sure that someone on this board can come up with the part numbers.
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Apparently the BMW part was actually made by Touratech but painted black instead of the usual Yellow. They were fitted to Australian and Canadian bikes.

When I did the BMW off road course Nick Plumb broke an 1150 gearbox going down a very gentle descent, of course the 1150 had probably had some serious grief before that.

Good link on the Micapeak site http://www.micapeak.com/bmw/gs/gs_tel3.html#framekit

Scroll down to near the bottom or search for "australia"
 
Your gearbox is in the welding bay Muppet, our welder Dave is going to see what he can do this afternoon. If he can't reweld the lug then I may be able to turn down an alloy threaded boss on the lathe then mill out the casing and get it welded in to replace the existing mounting point. Either way we will do our best mate.
 
No pics the moment Roddy, our welder thinks he can't put enough strength back into it due to the nature of the lug fracture and the weld penetration required as he is not a casting repair specialist, he is mainly a sheet metal fabricator.

I'm going to ask another guy who's more specialised in the 'other' workshop tomorrow if he can do it. Failing that, I will turn down a new lug from aluminium alloy bar, then machine or saw off the old lug and get the new one welded on. I shall make a jig to ensure alignment of the subframe before I cut off the lug. Besides, I enjoy a challenge. ;)

The weld repair will be obvious, but as long as it gets Muppet back on two wheels again its a result. The other option is a new gearbox but thats the expensive option.

I'll take some pics if and when repaired and post for the benefit of future gearbox failure owners.
 
In technical terms - I think it's 'fu**ed

Not anymore its not. :) :wave :hapybnce:

Respect to Luke the welder, if he couldn't glue it back together, no one could.
 
Adam, thanks. I'll pick it up tomorrow as arranged. Don't worry about pics, I'll take some and post them up.

Can't thank you enough mate.
 
Welding

You could try :--

Fabtech eng Ltd
London Hill
Stockbridge
Hants

SO20 6EN

Tel Rob Colgate (Also a biker)
01264 810257

He's S---t hot at welding.

Tim
 
moo said:
cant wait to see the pics sounds like an excellent result
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Georgia cartwheeled her R850R & broke g/box mount, had it welded & also fitted R1100GS TT hard part (modded to fit) for extra support.
(Thanks Hadrian)
Repair lasted for over 12,000 miles that we know of. Only visual sign of repair was discolouration of g/box paint (slight yellowing)
Hope repair works for you.
 
Here is a few pics of the lug repair to Muppets gearbox. The threaded lug had cracked through its centre and was both difficult to repair and prone to further failure. It was decided to make a new lug of bigger diameter to add strength, then weld it on in place of the old lug. The welding may not look pretty, but it is very strong and should prevent a reoccurance when the Touratech hard part is added for reinforcement.
 

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I don't know man. Looks a bit on the weak side to me.

Jim :cool:

PS Sorry for the negative first post. I didn't realize I hadn't posted here before!
 
Nippy Normans supply Touratech, Wunderlich, Desert Fox and many other makes of accessories.
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