Worn splines through starter hole w/ video

[BMWR502]

So I did the spline inspection last night through the starter hole. As you can see in the video below, my input shaft is badly worn. For anyone that has been wanting to do this, but was unsure of what to look for I hope this helps.

remove starter
zip tie clutch
trans in 1st gear
rotate outer edge of the clutch disc with thin screwdriver
watch for the clutch disc hub rotating in unison with the input shaft

Spline Video

[1100s nut]

Thanks for posting that...I have wondered what to look for, or how it should not look. Is that your 99 or your 03?

Lane

[BMWR502]

2003 BCR w/ 36.5k miles

Looks like I may be holding onto the '99 for this riding season. Don't know how soon I'll have the funding to replace/rebuild the transmission.

[flatbutt]

Is it the opinion that the "slop" you saw there is too much? Thanks for the vid!

[cele0001]

Originally Posted by flatbutt

Is it the opinion that the "slop" you saw there is too much? Thanks for the vid!

The slop there is way too much.

[Jozef Schumann]

I agree, that's far too much slop.

At the next oil service I'll pull my starter and see if there's enough componentry visible (due to the hub spacer) to video the difference. 5k miles so far, and of course - nothing to report.

J.S.

[JimMoore]

Hey OP, you mind if I link this to a few other sites? That's a damn good video.

[BMWR502]

Originally Posted by JimMoore

Hey OP, you mind if I link this to a few other sites? That's a damn good video.

Of course! Be my guest. And while it is in the state it is in, I'd be happy to take more photos/videos if anyone has any requests.

[sgoodwin]

Failure is imminent, video it while doing a burn out so we can watch the final destruction. At least that way you're at home when it dies.

[cele0001]

Pull the transmission out, install modified clutch plate, move on. Total cost $300. No doom and gloom.

[oneye]

Excellent video, many thanks. Scary.

[ricky racer]

Originally Posted by cele0001

Pull the transmission out, install modified clutch plate, move on. Total cost $300. No doom and gloom.

[Jozef Schumann]

Originally Posted by ricky racer

He's referring to this:

The plate on the right is fitted with a 6mm spacer he offers - which I and several others on the ADV forum have purchased and installed.



However. I also opted to replace my input shaft which was knackered as well. He feels the existing splines in conjunction with the previously unused portion is sufficient. Maybe so, maybe no. It would be a source of angst when I'm out there in the vast Mojave - now plagued with the knowledge of somewhat minimized spline area engagement with limited integrity. We shall see how well mine holds up when I pull the trans for an inspection - It would be interesting to compare against a machine with 'as scalloped' shaft.







J.S.

[metropolis2k]

Great video, thanks for sharing. I suspect I might be doing the same thing on both of my boxers this weekend!

[cele0001]

Originally Posted by Jozef Schumann

I agree, that's far too much slop.

At the next oil service I'll pull my starter and see if there's enough componentry visible (due to the hub spacer) to video the difference. 5k miles so far, and of course - nothing to report.

J.S.

There is still a little bit of the input shaft visible. You have to have a good small flashlight.

[sykospain]

I'm one of those who bought a coupla those beautifully-made 6mm thick clutch friction disc hub spacers from Esmir Celebic on the ADVRider forum. Great solution to an inherent design problem that BMW has consistently failed to address with a "Technical Revision". Like asking Sachs AG to supply a plate with a longer hub.

Incidentally, I hope you don't mind Dan, but I've slightly tarted up your excellent little 25 second clutch spline wear investigation video to make it clearer to other readers on forums like UKGser, R1150R.net, etc.

https://youtu.be/dw6xP7a4EfM

AL in s.e. Spain

[WandererR11S]

Are non of the replacement clutches from any manufacturer made with an improved longer splined hub..?
I find it amazing, and annoying that BMW haven't addressed this problem in any way, so we buy new expensive replacement parts and there still crap... WTF....

[850dunstall]

so i pulled the starter , just had to see how it looked in there, with the clutch tied back, i could only get it to move about 1/8' from click to click. then the whole clutch turned, so with 52k km mines still good

[cele0001]

Originally Posted by 850dunstall

so i pulled the starter , just had to see how it looked in there, with the clutch tied back, i could only get it to move about 1/8' from click to click. then the whole clutch turned, so with 52k km mines still good

I am not sure about your measuring, but if what you are saying is true, there is some wear in there.

[op48no1]

I did this inspection today. There is no visible rust or metal shavings around the splines, but some rotational slop at the edge of the clutch disk. Does anyone know how much slop is "normal?"

Thanks.

-Henry