Endurance test BMW R 1200 GS gearbox damage

BMW R 1200 GS long-term test news

Gearbox damage after 44,000 km

As already read in MOTORRAD, the BMW R 1200 GS did not survive the long-term test kilometers without serious incidents. A major gearbox damage after 44,000 kilometers made it necessary to replace the entire core engine.

Small cause, big effect. A connection in the case of the endurance test BMW R. 1200 GS is fatally true. A major gearbox damage recently occurred on a stretch of the motorway at higher speeds, the cause of which was very likely a simple ball bearing on the gearbox input shaft. After the reconstruction by the MOTORRAD technicians, the process was as follows: First, the said bearing blocked, the inner ring overheated on the shaft, and lots of balls, cage and sealing washer crumbled.

BMW R 1200 GS long-term test news

Gearbox damage after 44,000 km

BMW R 1200 GS transmission offered a picture of horror

Because of the higher speed and earplugs, the driver initially did not notice the impending disaster, the machine was running under full load, and the noise of the airstream drowned out any mechanical noises. Only a jolt and the loss of propulsion made him sit up and take notice, but then the BMW R 1200 GS rolled out onto the hard shoulder of the autobahn, accompanied by ugly clanking and grinding. Although the engine still ran perfectly with the clutch pulled, the gearshift got stuck in sixth gear.

The clutch was acknowledged with a brutal crash from the gearbox. The endurance test BMW R 1200 GS was then brought to the BMW branch in Stuttgart by van, where it was dismantled in the presence of MOTORRAD. The transmission was a horror; you don’t see such a slaughter every day. In any case, the driver, PS colleague Robert Gluck, was very lucky. One cannot imagine the effects of a transmission blocking in traffic at high speed. Why the ball bearing broke remains unclear. BMW is not yet aware of such damage. At the moment it is more likely to be a regrettable individual case than a constructive weak point.

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Endurance test interim report BMW R 1200 GS (2014)

How does it look after 35,000 kilometers?

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All that remains is to replace the entire engine

But what about the endurance test BMW R 1200 GS, which at the time of the engine failure was almost 44,000 kilometers before the end of the targeted distance? Rebuilding the engine with replacement parts does not seem particularly useful in view of the extensive damage. Also because chips and scrap parts have spread out in the engine block. Consequential damage could never be completely ruled out, even after thorough cleaning. As a reminder: The long-term test K 1300 GT had been repaired after a clutch damage, a little later dirt residues caused bearing damage to a connecting rod bearing.

You want to avoid such consequential damage with the BMW R 1200 GS. So all that remains is to replace the entire engine. BMW confirmed that in such a case GS customers would proceed in the same way within the guarantee period. At the end of the endurance test, the new engine will only have 6000 kilometers on the clock, so the usual dismantling and measurement makes no sense. Instead, the MOTORRAD technicians hope that the sick engine has got away without damage to the crankshaft drive and cylinder heads and can serve as the basis for the usual wear measurements. In any case, the change of the engine is taken into account accordingly in the final evaluation in the point evaluation.

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