pitted 2 gear in 1100gs gearbox

[kostas_patra]

can i do anything about the 2gear of my intermediate shaft, which is badly pitted?
i am planning on changing all the bearings and after measurement reshimming the shafts.
it is my first attempt and every help is needed and most wellcomed

here are some fotos from my 97 1100gs gearbox 's shafts


http://4.bp.blogspot.com/_--O1d0Wssas/S4D5rzuWqeI/AAAAAAAABCM/o-yP4pGuEfM/s400/DSC05204.JPG

http://1.bp.blogspot.com/_--O1d0Wssas/S4D5raohZgI/AAAAAAAABCE/E34F8u5nxvM/s400/DSC05203.JPG

http://1.bp.blogspot.com/_--O1d0Wssas/S4D5q8UL2CI/AAAAAAAABB0/E3OaSg4H81I/s400/DSC05201.JPG

http://1.bp.blogspot.com/_--O1d0Wssas/S4D5qdDJEYI/AAAAAAAABBs/YFD0tWIiXno/s400/DSC05200.JPG

 

[kostas_patra]

do you think-know if this gear is repairable?
or if it is worth on spending money?

 

[DrFarkoff]

Kosta If you try www.motorworks.co.uk or www.james sherlock.com or www.motobins.co.uk they are specialist BMW dismantlers and spares agaents tey may be able to supply you a good used 2nd gear for much cheaper than a repair??

do you think-know if this gear is repairable?
or if it is worth on spending money?

 

[kostas_patra]

Kosta If you try www.motorworks.co.uk or www.james sherlock.com or www.motobins.co.uk they are specialist BMW dismantlers and spares agaents tey may be able to supply you a good used 2nd gear for much cheaper than a repair??

hi jaythro

i order parts from these stores all the time

i don't think that the gears of the intermediate shaft can be dismalted, according to haynes manual

you can only change it's two bearings and nothing else

is there is a pboblem with it, you must replace it with an other.

that's why bmw does not give part numbers for spares about the intermediate shaft


everybody says that if a gear is bad, you should also change the opposite 2 gear, of the output shaft, but it looks ok, weird i know, but that's so

do you know if anybody could fill it somehow with metal or this is a worthless action?

 

[DrFarkoff]

Kostas there is a process of metal spraying and grinding to finish You would probably be better contacting a company that does engine repairs or rebuilds
That process is commonly used with crankshafts and camshafts that are badly worn

 

[kostas_patra]

jaythro

do you know if they can also fix worn shaft splines?

like this one?

 

[kostas_patra]

here you can see that no other part about the intermediate shaft is available except shims and bearings

 

[Steptoe]

i don't think that the gears of the intermediate shaft can be dismalted, according to haynes manual

If a man can put them on the shaft, then a man can take them off.

 

[kostas_patra]

i thought that they were pressed and fixxed permanently somehow, from the factory, because i read this from my pdf repair manual, 218page/464

Removing and installing deep-groove
ball bearing and race/roller bearing for
idler shaft
L Note:
If defective, the complete idler shaft must be
replaced.

according to your knowledge, is the gear repairable or at least changeable?

 

[Pekkavee]

i thought that they were pressed and fixxed permanently somehow, from the factory, because i read this from my pdf repair manual, 218page/464

I have the same manual.
BMW doesn't tell you everything.
But Steptoe knows it much better


Pekka

 

[kostas_patra]

I have the same manual.
BMW doesn't tell you everything.
But Steptoe knows it much better


Pekka

i know that, that's why i 'm asking!!!
: )

 

[Littledumptruck]

You need another gearbox. Those gears are shagged as is the spline. Any repair would at best be temperary, unlikely to last very long at all.
Think you need to bite the bullet and find a replacement box.

 

[kostas_patra]

You need another gearbox. Those gears are shagged as is the spline. Any repair would at best be temperary, unlikely to last very long at all.
Think you need to bite the bullet and find a replacement box.

i have another box on my bike now

this is my previous gearbox and the technician who saw it said, that it was worthless repairing

i dont want to give it up
while riding with this gearbox, a use to hear a big bang-clak, when changing from 2 to 3 gear, up or downshifting

it never jumped any gear and the dog teeth look ok, not rounded at all

when changing the oil gear, it looked like dark brown, not the same colour like final drive, and and at the magnetic drain plug i could see metal past, not big metal pieces

i want to fix this gearbox for spare and to see if i am capable for fixxing my fuctional gearbox

after jeythro's recommendations, i read about stores that involve with repairing shalf splines and gear teeth.

i have close an appointment with them, to show them my staff, if they can do something about them

i am intrigued about what steptoe said, if a man can replace the bad gear

can somebody and if so, do we have a phone or a email of his?

 

[davegs]

Assitance

Look at the bottom of steptoe's posts, he is the gss shop his address or e mail is there. Or become a subscriber and send him a PM.
dave GS.

 

[Steptoe]

i am intrigued about what steptoe said, if a man can replace the bad gear

I'll say it again. And i'm not just talking about your gearbox, i'm talking about anything mechanical.



If a man can put the gears on a shaft, then a man can take them off.

If a man can put something together, then another man somewhere can undo the same thing.

 

[Littledumptruck]

I'll say it again. And i'm not just talking about your gearbox, i'm talking about anything mechanical.



If a man can put the gears on a shaft, then a man can take them off.

If a man can put something together, then another man somewhere can undo the same thing.

Thats ok steptoe, and quite true, but in this case I feel your comment is confusing the poor guy. He thinks you're saying you know someone that can fix it. I don't disagree that a man assembled the shaft and in theory someone somewhere can disassemble it, but if BMW don't offer replacement gears or shafts then whats the point.

He's replaced the box, the old one is shagged, if parts aren't available then surely nothing more can be done, unless you know of a suitable company/man that can help. But I would have thought you'd have said so by now if that was the case.

 

[Steptoe]

, unless you know of a suitable company/man that can help. But I would have thought you'd have said so by now if that was the case.

The man is located in Greece. Not exactly local.

 

[kostas_patra]

i have read more or less everything that has been written about 1100 in this forum
steptoe is well known about his expertise and his mechanical knowledge on gs
i could address directly to him over by email, but this would not help a gue with the same problem
nowdays postage isn't quite expensive and the intermediate shaft weights less than 5kg
davegs, i will follow your suggestions
littledumptruck, exactly that, i could't say it better

steptoe and everybody who knows:
pitted gear is a result of
-worn bearings
-worn bushings
-manufacturer's fault
-jump gear
-else

steptoe, do you think that works on shaft gears have a drastic effect on their durability, like littledumptruck suggests?

 

[kostas_patra]

The man is located in Greece. Not exactly local.

just 3700km far from neighbour! semi local!

 

[Mick Fagan]

Kostas, in the not so distant past with gearboxes showing the lay shaft with a gear or two pitted like that, I hunted around for another lay shaft out of another box in good condition, or at least with the gear you need in good condition.

Then it is simply a matter of pulling both lay shafts apart and assembling one good shaft.

You will need the use of a very good press, it will take a few tonnes of pressure to pull and push them apart and back together.

I’ve done this myself twice and I have a friend who has done it at least three or four times. I’m sure there are other ways and means, but pulling the shaft apart and putting it back together is the easy part, getting a gear that is alright is the hard part.

I haven’t done this to an 1100 or later box, just the earlier models from 1969 through to a 1982 model, which was the latest I did this repair to.

As it appears you have another box in your bike, you now have the luxury of time to find the bits and pieces and then repair your box.

Mick.