Ok... I am about to rip my hair out and need help.
Recently my 17,000 mile '93 k75s had the input shaft on the gear box replaced among other things. Previous repairs for notchy shifting were attempted to be fixed by TransAm BMW in Lititz, PA. Both repairs replaced some of the same parts at 6k and 9.4k. Shift drum, etc. This time, the input shaft was worn and the expected culprit was misalignment of the transmission to the engine....
On counsel from Bob's BMW I purchased a second hand intermediate housing which was measured professionally as straight - I was told a small percentage of the K housing were poorly machined and I wanted to eliminate this variable which I did. I did all the install work myself. However, the gearbox was done at Bob's after I took it out to the tune of $960.
Now I am back to notchy shifting after 1600 miles and with the bike when in neutral with the clutch out it sounds like it did before - typical "I need my splines lubed" clatter which considering I used the right lube (Starbaurags PTSM) and it was done it should be I should not have that trouble.
But there is a bigger problem...
Here is the scenario:
1. When downshifting under power to pass someone it seems to be fine
2. When downshifting under trailing throttle - unless I blip the throttle - it acts like it is locked in gear. This happens in 3rd, 4th and 5th gear almost every time unless the RPMs drop below 2k. It doesn't do it every time but is growing more and more frequent.
3. The bike shifts up and down through all gears fine in neutral with the engine running and the clutch in.
Clutch adjustment is to factory spec for cable length at the clutch arm and lever free play is correct.
When I replaced the gear box I did not replace the entire clutch, I replaced the clutch disk only. Is there any reason that the cover, spring and pressure plate would make this happen? (The cover and pressure plate were all in excellent condition.) Is there anything else that could cause the troubles?
What could possibly be the problem... as in my eyes the only thing that could cause this is the clutch.
I am at a loss.
