2005 R1200ST - which clutch disc do I need?

[Ran_Bush]

Apologies if this has been discussed recently, I didn't see it:

 

The driveshaft came apart on my 2005 R1200ST, the bike has about 90K miles on it, and I thought "as long as I'm in there", I'll install a new clutch assembly. I bought the clutch disc, pressure plate, spring assembly, etc from Beemershop in Scotts Valley, CA. When I got the parts from them, the new disc won't fit on the old gearbox shaft. I called Beemershop and they sent me another disc, in case I had gotten a bad one. The new disc doesn't fit either.

 

I thought maybe the splines on the gearbox shaft were bad, so I bought a low mileage 2005 R1200ST gearbox from Cycle R Us in Ohio, but the new disc won't fit on that gearbox either. The Beemershop website specifically says the disc will fit the R1200ST, and is a replacement for BMW OEM p/n 21 21 7 697 737. Ted says they have sold eleven of this disc to R1200RT owners, but I'm the first R1200ST owner to buy one. The Max BMW fiche shows the same p/n for a RT and ST _clutch disc_ but a different p/n for a RT _gearbox_ and a ST gearbox.

 

My old disc is from Sachs, and when I search on the Max BMW fiche, the Sachs p/n 21 21 7 692 852 comes up as "clutch disc", but doesn't show a replacement  part number. The EME site shows the same BMW p/n 21 21 7 697 737 for their clutch disc. Other BMW sites I've searched show the Sachs p/n 21 21 7 692 852 as replaced by BMW p/n 21 21 7 697 737, but that's not working for me.

 

The last seven digits of my bike's VIN are ZM30046, bike was produced in 01/05 for the USA market. I know BMW sometimes uses up existing inventory in the early production runs, before upgrading or changing to newer parts, but would they do this on a major component like a gearbox?

 

Soooo - which clutch disc do I need for a 2005 R1200ST?

[dirtrider]

12 hours ago, Ran_Bush said:

Apologies if this has been discussed recently, I didn't see it:

 

The driveshaft came apart on my 2005 R1200ST, the bike has about 90K miles on it, and I thought "as long as I'm in there", I'll install a new clutch assembly. I bought the clutch disc, pressure plate, spring assembly, etc from Beemershop in Scotts Valley, CA. When I got the parts from them, the new disc won't fit on the old gearbox shaft. I called Beemershop and they sent me another disc, in case I had gotten a bad one. The new disc doesn't fit either.

 

I thought maybe the splines on the gearbox shaft were bad, so I bought a low mileage 2005 R1200ST gearbox from Cycle R Us in Ohio, but the new disc won't fit on that gearbox either. The Beemershop website specifically says the disc will fit the R1200ST, and is a replacement for BMW OEM p/n 21 21 7 697 737. Ted says they have sold eleven of this disc to R1200RT owners, but I'm the first R1200ST owner to buy one. The Max BMW fiche shows the same p/n for a RT and ST [I]clutch disc[/I], but a different p/n for a RT [I]gearbox[/I] and a ST [I]gearbox[/I].

 

My old disc is from Sachs, and when I search on the Max BMW fiche, the Sachs p/n 21 21 7 692 852 comes up as "clutch disc", but doesn't show a replacement  part number. The EME site shows the same BMW p/n 21 21 7 697 737 for their clutch disc. Other BMW sites I've searched show the Sachs p/n 21 21 7 692 852 as replaced by BMW p/n 21 21 7 697 737, but that's not working for me.

 

The last seven digits of my bike's VIN are ZM30046, bike was produced in 01/05 for the USA market. I know BMW sometimes uses up existing inventory in the early production runs, before upgrading or changing to newer parts, but would they do this on a major component like a gearbox?

 

Soooo - which clutch disc do I need for a 2005 R1200ST?

Morning Ran

 

My book shows the first U.S. 1200ST was  a 2006 so there is some question there? Is your 1200ST a USA motorcycle? 

 

All my parts books show the hexhead 1200RT & 1200ST use the same clutch disk. 

 

Is the spline count the same between your old disk & the new disk??????

 

Try to post us side by side pictures of both the disks (new & old) that you have.

 

Also post a picture of your 1200ST as well as picture of your engine if possible. 

 

If you PM  (Personal Message) me the last 7 digits of your VIN (Vehicle Identification Number) I will run the numbers then try to figure out exactly what you are working with. 

 

 

 

 

[Ran_Bush]

12 hours ago, dirtrider said:

> All my parts books show the hexhead 1200RT & 1200ST use the same clutch disk.

Thanks for the reply, I've seen that too.

 

The Sachs disk in the bike has the p/n 21 21 7 692 852 which maps to the current BMW p/n 21 21 7 697 737. A BMW mechanic friend of mine says that a new clutch disk may need some lube, gentle hammer taps, waving the rubber chicken, and other installation "finagling" to go on to a older output shaft. Maybe that's all that's going on here? Finagling?

 

Thanks again.

 

 

 

 

[dirtrider]

Quote

The Sachs disk in the bike has the p/n 21 21 7 692 852 which maps to the current BMW p/n 21 21 7 697 737. A BMW mechanic friend of mine says that a new clutch disk may need some lube, gentle hammer taps, waving the rubber chicken, and other installation "finagling" to go on to a older output shaft. Maybe that's all that's going on here? Finagling?

Morning Ran

 

There should be no "finagling" for the clutch disk to slide on, it needs to slide on & move smoothly. If it sticks, or is difficult to slide on the trans input shaft splines then you will not a get good clutch release & it will be difficult to get it into neutral with engine running.

 

Thoroughly clean the transmission shaft splines using brake clean & a small stainless steel or brass wire brush then once clean re-clean again using some WD-40 & a small stainless steel or brass wire brush. Then wipe off to be clean & dry. 

 

After the cleaning then the clutch disk should slide right on easily, if it doesn't then find out why. 

 

Then for final assembly put a very thin (very thin) layer of high-moly grease ( like Honda M-77)  on the transmission splines in the disk travel area. Caution: don't overdo the moly grease as you don't want it flinging off contaminating the clutch friction surface. 

 

 

[Ran_Bush]

OK happy ending. As often happens, the cause was operator error and I'm the operator.

 

Because it has been awhile since I opened up the bike, I ordered clutch parts, the clutch parts arrived, they didn't fit on the old gearbox, I ordered a low-mileage gearbox, and I tried to install the new parts, I had forgotten that the disc only goes on _one_ way. The old disc went onto the old gear box shaft either way, because they had been together for 90K miles and were worn and sloppy. The _new_ clutch disc on the new-to-me low mileage gear box will only mate up ONE way, and I didn't realize that until today. I don't understand why, but the new disc fits perfectly when I put it on correctly. Duh!

 

The good news is that I have a low-mileage gearbox and a new clutch disc. Now I need to get back to installing the new driveshaft!

 

Hope this info will help somebody else, thanks for your replies.

[beemer chuck]

I would check wether the new disc slides on as far onto the input shaft as the old one does.

I think you have an incompletely machined spline in your new disc. Possible they rolled a burr into the spline during cleanup.

Absolutely no reason that clutch should not slide on both ways. You stand a real chance of axially overloading the trans input bearings if I the clutch does not let the input slide all the way in. This may be hard to detect that the trans does not rest freely on the motor as you tighten up the bolts that hold it together.

BMW clutches actually move toward the transmission as they wear since the fixed plate in on the trans side. It will move back about 1mm during its service life. Most American engines have the fixed plate on the motor side so the clutch disc moves away form the trains as it wears.

I would check with the supplier to see if they can send another disc to check if yours is bad.

[dirtrider]

10 hours ago, Ran_Bush said:

OK happy ending. As often happens, the cause was operator error and I'm the operator.

 

Because it has been awhile since I opened up the bike, I ordered clutch parts, the clutch parts arrived, they didn't fit on the old gearbox, I ordered a low-mileage gearbox, and I tried to install the new parts, I had forgotten that the disc only goes on _one_ way. The old disc went onto the old gear box shaft either way, because they had been together for 90K miles and were worn and sloppy. The _new_ clutch disc on the new-to-me low mileage gear box will only mate up ONE way, and I didn't realize that until today. I don't understand why, but the new disc fits perfectly when I put it on correctly. Duh!

 

The good news is that I have a low-mileage gearbox and a new clutch disc. Now I need to get back to installing the new driveshaft!

 

Hope this info will help somebody else, thanks for your replies.

Morning Ran

 

Something still very wrong there, it still doesn't look like it goes all the way on. It also looks like you still have a dirty trans input shaft so see my post above about thoroughly cleaning that input shaft. Then once squeaky clean try the disk both ways, if it still doesn't slide on then look/feel for burrs or something causing the hang up. 

 

If you can't get that disk to slide on smoothly both ways then at the very least take that disk & extra transmission you now have to a motorcycle shop (preferably a BMW shop)  & have them look at what you have. 

 

My guess is that you have couple of little burrs on one side the new clutch hub spline that is preventing it from sliding on, possibly being made worse by dirty transmission  input shaft splines.

 

You POSITIVLY need to figure this out BEFORE you reinstall the clutch & transmission.