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  #1  
Old 1 Oct 2012
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Higher 5th gear for airhead gearbox
Hi,
I fitted a 5th gear to my R100GS PD output shaft back in December 2007 that gave a 6% higher ratio. Since then the bike has done 100,000 miles (340,000 miles in all) and it continues to function well. It is a simple and straightforward swap once you have dismantled the gearbox.
The gear (part number: 23221242992z) was supplied by S Meyer BMW; S.Meyer GmbH (limited company) - BMW motorcycle spare parts - Homepage
Meyer's in those days also listed a pair of gears, one for the lay-cluster and one for the output shaft that would give a 10% higher ratio. I fitted the 6% one because at the time they only had that in stock and I couldnt wait.
Airhead gearboxes are quite easy to work on, but it is important to remember to get the endfloat on the three shafts shimmed correctly, so as to ensure longevity. Also bear in mind it is worth checking to see if the outputshaft bearing at the clutch end has provision for a circlip to retain the bearing (BMW went through a phase of manufacturing some shafts without a circlip groove, which can cause premature bearing wear). If it dosen't then (as was the case with my shaft) you should make provision for a circlip on the shaft.
Regards to all
Guy
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Old 2 Oct 2012
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Originally Posted by plainshorse View Post
....
Also bear in mind it is worth checking to see if the outputshaft bearing at the clutch end has provision for a circlip to retain the bearing (BMW went through a phase of manufacturing some shafts without a circlip groove, which can cause premature bearing wear). If it dosen't then (as was the case with my shaft) you should make provision for a circlip on the shaft.
Regards to all
Guy
Yep, that was the reason for my gearbox repairs after only 18 kkms The '93 models had no circlip fitted.

Since then I have done over 120 kkms without any problems.
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Old 21 Jan 2016
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High 5th Gear
Did you ever fit the tall 5th Mark? If so how did it fare, did the 800 manage to pull it?
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Old 22 Jan 2016
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"tall" is somewhat exaggerated The revvs drop by about 500 rpm which saves a bit of fuel. Power-wise no probs, but when about to overtake fast moving traffic I have to change to 4th gear ;o)

Now the R80 isn't exactly a racing machine, but with the shorter 1st and longer 5th I'm happy. When the pistons are worn down I'll fit 1040cc, which I found a couple of months ago. Then it might make sense to fit the rear drive of the R100without changing the gearbox.
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Old 22 Jan 2016
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Originally Posted by BMurr View Post
Did you ever fit the tall 5th Mark? If so how did it fare, did the 800 manage to pull it?
Not yet, I thought at 100,000 miles my gearbox would need an overhaul but it was fine, I thought the same at 150,000 when I asked this question, it has now done 170,000 and still seems fine so as it isn't broken I won't fix it.
As for the higher gear my monolever G/S has higher gearing at the bevelbox which it pulls no problem so I am expecting the paralever GS to do the same even if it is a little heavier.
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