matanuska Posted May 7, 2006 Share Posted May 7, 2006 This post is about a problem on my newly acquired K Bike, but there has been so much talk about spline failure on Oilheads as well that I figure this would be the appropriate place for the discussion. Last Wednesday, I was riding home from the store on my “new” ’00 K1200RS (owned for 2 ½ weeks – bought with 32k miles on the odometer). I was coming out of a right turn, gave the throttle a little gas (definitely not gunning it) and heard a ZZZIIIPPPP!!!! I was able to pull over on a quiet side street and found that I could race the engine with no power transfer to the rear wheel in any gear! After shutting down, locking up, and a 3 mile walk home, I called Jerry on the phone and we discussed several possible failure modes, but the most likely seemed to be the dreaded SPLINE FAILURE! On Thursday, I took the day off work, rented a trailer, towed the bike home and started the long disassembly process. Last night, I finally removed the tranny and disassembled the clutch. The clutch plate spline is shot! Interestingly, the matching external splines on the trans input shaft don’t look all that bad and could probably be reused in an emergency (see pictures), but the excess clearances would likely lead to an early failure again. I checked the parts fiche and a new transmission input shaft is not all that expensive ($228) and it would make sense to replace it as long as everything is apart. I’m also going to replace the engine rear seal as well, although it really wasn’t leaking too badly. I’ve been looking over the procedure for installing a new transmission input shaft and while not terribly complicated, it does involve a few special tools for measuring and calculating shim thickness (assembled shaft length tolerances is .002”), as well as special seal installation tools. While this might be a job possible for the home mechanic, having the correct know-how would certainly be a benefit. I would hate to reassemble everything only to have a leaking transmission oil seal due to incorrect installation. I’m almost thinking about calling up a dealer and asking how much they would charge if I dropped off the tranny with them. So what do you guys think? Replace the transmission input shaft myself? Bite the bullet and pay a dealer to do it? Leave it alone and reuse the shaft as is? I can think of advantages and disadvantages to each choice (particularly economic), but in the end I’m ultimately concerned with reliability of the repair. Here are links to large versions of the pictures: Clutch & Tranny Trans input shaft splines Clutch plate splines Clutch plate splines Thanks Derek Ps. On my old R 850R, I recently suffered the almost unheard of Motronic failure. Now on my new K bike I just suffered the equally elusive (but frequently talked about) spline failure. Are the Motorcycle Gods trying to tell me something? Link to comment
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