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  #1  
Old 16 Aug 2003
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R80G/S Nasty G Box Noises

Hi I am in Novosibirsk, Russia. Gear box has developed sound like bolts in a tumble dryer when on constant throtle or on the overrun. All gears still work..has oil! Any suggestions about what to look for as I begin my next mechanical adventure on the vintage bike!

Lake Baikal impossible now! Have to have it fixed before going to Kazakstan, prior to russian visa expiring.

http://users.netlink.com.au/~asimpson
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  #2  
Old 16 Aug 2003
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simmo,
check gbox output bearing. seems most likely culprit.

check whether there is a shim on the gbox output shaft spline. there were some years (on paralevers '88 to '94) where bmw built in this design fault by not having a shim which would have prevented lateral movement of the gears.

if you take the back cover off the gbox housing, you'll need a new gasket.

what debris is there on the magnet on the gbox drain plug?

good luck,
ChrisB

good luck,
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  #3  
Old 17 Aug 2003
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DON'T ride it!

Chris is almost certainly correct in his diagnosis, it's the usual problem. Unfortuantely his comment re the shim is in error - there was a series that eliminated a circlip and it's corresponding groove, not a shim.

For your purposes for now, there are two paths - one, get an exchange gearbox shipped in, probably best from www.Motobins.co.uk - tell them we sent you - or if you know anyone in Aus go that route.
Second option is rebuild on the spot. Bearings should be no problem to get, just make sure they're quality bearings, e.g. FAG SKF NSK etc. and not locally made.

Excellent instructions on how to do it are available: Joerg Hau has a very nice page on how to overhaul a BMW gearbox in your own workshop, including a lot of clear photos, drawings (and links to drawings) of the few necessary tools etc.

Good luck, it's a difficult job, but if you can find a local mechanic / workshop it's certainly doable. You'll need a hydraulic press, a source of heat and the usual workshop tools.



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  #4  
Old 17 Aug 2003
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Hi Chris and Grant

Well bikes shops are rare in Novosibirsk! Found someone who does japanese bikes and we have removed the gearbox and dismantled it.

I couldnt tell wether the bearings were good or not..they spun around...and there were no metal parts in the box.

The mechanic tells me that the bearings are no good and the large one 62x17x17 on the output shaft is the worst culprit. It is also the one I cant seem to source here!

Also the output shaft oil seal is damaged and was leaking into the drive shaft..I had been checking my gearbox oil level everyday because of the earlier seal problem..so oil quantity wasnt a problem.

I only have 9 days left on my visa and I am told DHL etc take ten to get to Novosibirsk..but we will see.

I shall go to the site you recommend and see how I go!

stuck in siberia...alec
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  #5  
Old 17 Aug 2003
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alec,
we are in touch personnally
but for others i copy my answers to you here

alec
no worries, no panic my friend, well, easy to say from here !
i had gear box probs, you remember

i got my bike repaired in novo (not the gear box) at NBS MOTOR, they did quite miracles, very helpful people. FRANKLY THEY ARE YOUR BEST CHANCE, almost every biker in novo knows them.
http://www.nbsmotor.ru/
nbs@nbsmotor.ru
manager roman dobriw
tel company : 593 953
tel shop : (3832) 902 192 / 902 148 (maybe fax)
mobile : 007 383 250 55 84

if they can t help you because you need spare parts and/or special tools
they ll tell you logically to order something from bmw Russia
http://www.bmw.ru/ (in Russian)
main office in Moscow : ARTEKS BMW DEALER address : 22, b. yakimanka moscow 109180 tel (095) 238-9919, 230-3554, fax (095) 230-3453, no email sorry
forget them, unless they are quick , they weren t quick at all with me

what you are doing is i guess not traditional, like what i did in mongolia.
therefore if i were you i would order some parts from someone just in case your
local repair fails after a while (what i don t wish you). for the gearbox bearings, i know that in europe they sell the whole set.

YOUR BEST CHANCE TO ORDER SOMETHING QUITE CHEAP AND FAST IS THOSE 2 SHOPS IN ENGLAND (for example, simon and georgie ordered a starter in Kazakhstan in 4 days):

1- motorworks
http://www.motorworks.co.uk/
admin@motorworks.co.uk
Motorworks, The Old School House, Meltham Mills Road, Meltham, Huddersfield,
UK, HD9 4AT
Phone +44 (0) 1484 353600 or 0845 458 0077 (local rate) Fax +44 (0) 1484 353604

2- motobins
http://www.motobins.co.uk/
sales@motobins.co.uk
Moto-Bins Ltd
16 Surfleet Road,
Surfleet,
Spalding,
Lincolnshire PE11 4AG UK
Email Moto-Bins Limited
Tel. +44 (0)1775 680881/680580
Fax: +44 (0)1775 680860


and don t play being illegal in russia !!!
for visa extension, i almost did it but did not have to at the end, go to the immigration office (ovir i guess is your best chance).
if you have to, leave the country with the train.



since you re going to Kazakhstan after
Here s the bmw dealer AUTOCENTER BAVARIA
(he s mainly into cars but does bikes, I was there too for a minor prob, they are helpfull
eric lim, general manager : address 147, raymbec av, 480016 almaty , tel +7 (3272) 39 05 50 / 39 02 67 , fax : +7 (3272) 391 420 , email : Bavaria@bmw.kz
other tel numbers : 007 3272 50 00 22 mobile : 007 333 222 9110

in other –stan countries, no bmw dealers (Yamaha, Honda, yes, some)


good luck
take care

vincent.danna@free.fr
http://vincent.danna.free.fr/


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  #6  
Old 17 Aug 2003
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if time is a prob leave the country get delivered in kazakhstan at the bmw dealer and repair at the bmw dealer, i guess he ll have the proper tools
you can maybe arrange this between motorworks / motobins / bmw kazakhstan / bmw russia ...

good luck
there s always a solution when travelling ...

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  #7  
Old 18 Aug 2003
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Hi all..the only part I couldnt get was the bearing 6403-C3. I have orderred it from Motobins. Hopefully it will arrive in time to put the gearbox back together and ride to Kazakstan. If not its the train or a truck to the border. They will not under any circumstances extend a tourist visa.

Just for info..spares available for Japanese bikes here, Africa twin xt600 etc.
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Old 22 Aug 2003
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Hi all..still waiting for parts! Further to Vincents information, Roman Dobriw the owner of NBS motorcycles was murdered last month by Russian mafia. Obituary in this months Russian "moto" magazine.
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Old 23 Aug 2003
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Hi spoke to motobins last night...appears they sent the part by post not courier as requested..therefore a future R80g/s overlander in Novo should be able to get a large Output shaft bearing as I wont be here to get it! They are going to try to fit a bearing with the same outside diameter but larger inside diameter and put it on a sleeve then onto the output shaft. I think inside diameter of 6403-c3 is 0.62mm the one they can get 0.65mm so a sleeve of 0.03 mm will have to sit between shaft and bearing. A bit dodgy me thinks but they reckon good for about 2500kms before it falls apart! I think good enough to ride to the train station. Expensive short term repair.
Looks like I will have to do this again in Almaty, where my Visa is for 2 months.

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Old 2 Sep 2003
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Hi Sleve for bearing pure fantasy...the old dud 6403-c3 bearing was put back in. The Gearbox has a slight whine but no longer has gears striking bearings. Appears a circlip was left out at the last rebuild. We will see if it lasts ..its made it to Almaty already.
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Old 11 Nov 2003
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In Turkey and here we go agaýn..looks lýke I have done another Gbox bearýng...stop laughýng honda rýders!
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  #12  
Old 12 Nov 2003
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Simmo,

Previous problems re getting correct parts noted...

Go to the /tech pages for a link to how to rebuild a BMW gearbox. Be sure to get it shimmed right - they are fussy! Also recommend replacing ALL bearings this time round - in other words do it right - once! .

Good luck,

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  #13  
Old 12 Nov 2003
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Hý Grant

yep ýt would have been great ýf I could have waýted for the part ýn Novo but I had to leave the country. I am ýmpressed that ýt lasted thýs long really. I expect the coast roads ýn turkey and my enthusýasm wýth the throttle fýnýshed ýt off.
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Old 1 Apr 2004
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Question re the C6403 large output shaft bearing. I am now back in Melbourne and will shortly be going over the bike. The new bearing has some lateral play in it...is this normal? possibly for heat expansion ?
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Old 1 Apr 2004
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Yes, it's a deliberately loose bearing. If I remember correctly, it's a C3. Should say on it somewhere. C3=loose tolerances.

If there is no play (e.g. a C1) it will disintegrate rapidly due to sidethrusts from the helical gear.

Don't second guess the bearing numbers, just make sure they are identical to the originals, or better, as CURRENTLY Specified by BMW. Yes they have changed the specs once or twice, but primarily re shielded or not, or double shielded.


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