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Author Topic: Emergency shifting tool  (Read 2524 times)

Offline Barry

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Emergency shifting tool
« on: July 18, 2012, 04:43:16 AM »
There has been some discussion on the Airheads list recently about the problem of pawl spring breakage in the gearbox.  When this spring breaks and it has happened to a few unlucky people you are stuck in whatever gear happens to be selected and that could be neutral which would certainly be a problem but 1st or 5th would be very unpractical too.  When the spring breaks a pawl arm falls down preventing the gear lever movement from being transmitted to the shift mechanism. A tool has now been devised to temporarily lift the pawl back up so you can operate the gear lever and change into 3rd which is considered to be the most practical gear in a get you home  scenario.

Snowbum has now published this very useful information on his website.

http://bmwmotorcycletech.info/emergency-shifting-tool.htm
« Last Edit: July 18, 2012, 05:02:02 AM by bhodgson »
Barry Cheshire, England 79 R45

Offline Julio A.

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Re: Emergency shifting tool
« Reply #1 on: July 18, 2012, 06:18:43 AM »
Did snowbum just put a rod through his transmission oil filler plug or is that another part?
Julio Alarcon
1981 R65
1976 R90/6
2001 R1150 GS/ADV
2015 TR650

Offline montmil

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Re: Emergency shifting tool
« Reply #2 on: July 18, 2012, 08:57:06 AM »
The modified Al Vangura-designed tool in the photos is by Bob Sipp; as are the photos. Bob da Snowbum did not say he made on for himself. Bet he already has one.

The drilled-out filler plug and knurled knob are nice touches on the Sipp tool. I need another small project. ;)
Monte Miller
Denton, TEXAS
1978 BMW R100S
1981 BMW R65
1983 BMW R65
1995 Triumph Trophy
1986 VW Cabriolet

tvrla

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Re: Emergency shifting tool
« Reply #3 on: July 18, 2012, 11:52:36 AM »
Thanks for that Barry!

You know, that got me thinking about the 'improved' version.  ;)

It may be possible to engineer it to operate via the clutch cable for normal shifting.

Offline Barry

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Re: Emergency shifting tool
« Reply #4 on: July 18, 2012, 12:13:43 PM »
Quote
It may be possible to engineer it to operate via the clutch cable for normal shifting.  


It's an interesting proposition. Would you have to take the gearbox end cover off to engineer it accurately ? I've never needed to open up an Airhead gearbox so I'm no expert but looking at the published pictures of the tool in use it occurred to me that if a a suitably positioned hole was machined in the gearbox end cover then a much simpler design of tool could be used and the hole wouldn't look too out of place if threaded to take a standard. level/filler plug.

On the other hand it might just be easier to do something about preventing the spring breaking. The other bit of info that surfaces in this pawl spring debate is why it breaks in the first place. There is a suggestion that the pawl boss which supports the spring may be slightly too large in diameter causing the spring to bind when it is under tension. As far as I can make out the springs is #7 and pawl #8 in this diagram.
« Last Edit: July 18, 2012, 12:32:40 PM by bhodgson »
Barry Cheshire, England 79 R45

Offline k_enn

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Re: Emergency shifting tool
« Reply #5 on: July 18, 2012, 12:38:29 PM »
I think I'll just call a tow.

k_enn
k_enn
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Offline donbmw

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Re: Emergency shifting tool
« Reply #6 on: July 18, 2012, 05:18:00 PM »
The one time that I had the shift spring brake I was down shifting into 3rd gear. Luckly i was just down the street from home. I had a buddy that his broke in 1st gear and rode home about 200 miles like that. This tool would be nice to have so you could at least get in 3rd gear to get you home. Your stops and start would not be to bad in 3rd.

I would use the tool to get in a better gear for any long distance travel and put the filler plug back in and not have this installed while moving.
1975 R90/6, 1980 R65, 1982 R65, 2015 Ural Patrol & 1959 Triumph TR3

Offline montmil

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Re: Emergency shifting tool
« Reply #7 on: July 18, 2012, 06:37:54 PM »
Big buzz about this "tool" on the Airlist.

After posting drawings and photos, Robert Fleischer, aka The Snowbum, said he will offer no further details nor commentary.  
Monte Miller
Denton, TEXAS
1978 BMW R100S
1981 BMW R65
1983 BMW R65
1995 Triumph Trophy
1986 VW Cabriolet

tvrla

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Re: Emergency shifting tool
« Reply #8 on: July 19, 2012, 12:40:30 AM »
I've never had one break, but ride enough that it's possible it'll happen at some point. I've heard that the early five speeds (74-5) had to large of a boss and the spring would bind. But our R65s are newer and out of that range.

I was thinking like this:

Use a bolt with a welded-on arm instead of a drilled oil fill plug. Drill a hole through the bolt and either mount a seal or a felt inside to keep the oil in.

Bend up the steel as shown inside the transmission. But once it passes through the bolt, bend at right angles.

Attach a spring to keep it disingaged.

Attach a cable from the bolt's arm to the rod, then to the clutch arm at the back of the transmission. Make it easy to attach, and then when the clutch is pulled in, it also releases the 'pall activator'.

That way you'd be able to shift normally.

That's an interesting idea to put a hole in the back cover. I even thought  of running a cable or rod up through the top of the transmission. But it seems like the simplest solution is to do what I've just laid out. It would still be small enough to take up very little room, and could allow the bike to be ridden many thousands of miles normally until the right time to fix it properly, and would eliminate the need to slip the clutch through towns or run down the highway in third.

Even though I've fixed something like ten or twenty of these transmissions, I don't totally understand them. Thinking on this more, it seems the pall needs to be in contact with the pins all the time and has a spring because the shifter moves back and forth. It may be possible that a spring type mechanism is all that's needed on the outside of the transmission (with our rod solution) to provide constant tension on the pall arm. That would be a much easier solution!
« Last Edit: July 19, 2012, 01:14:17 AM by tvrla »

Offline Barry

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Re: Emergency shifting tool
« Reply #9 on: July 19, 2012, 04:19:28 AM »
Quote
... It may be possible that a spring type mechanism is all that's needed on the outside of the transmission (with our rod solution) to provide constant tension on the pall arm. That would be a much easier solution!  

That's how I read it.



I knew that Snowbum was only publishing the info and did not invent the tool. What surprised me is that the tool was developed 13 or 14 years ago and we only just heard about it !
Barry Cheshire, England 79 R45

Offline Air4Life

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Re: Emergency shifting tool
« Reply #10 on: July 19, 2012, 05:24:52 AM »
I get the impression that there is very little chance for the broken piece('s) that remain inside to cause further damage.  Is it the fact that gravity and it being bathed in gear oil keeping it out of the way of damaging the rest of the moving parts?  Maybe a stronger magnetic drain plug would be helpful here...

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Offline Barry

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Re: Emergency shifting tool
« Reply #11 on: July 19, 2012, 06:21:13 AM »
That's a good point.  I haven't seen a broken spring but hopefully it's the coiled part that breaks and both pieces stay put on the boss.
Barry Cheshire, England 79 R45

Bob_W

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Re: Emergency shifting tool
« Reply #12 on: July 19, 2012, 07:30:45 AM »
Don't trust immunity in newer transmissions-it happened to me on an '83. Left me two up in Highlands with 4th and 5th. Careful planning for only downhill stops enabled me to get back to Atlanta.
There was an update to the shifting assembly which was supposed to help, but I do not remember the details.
Bob

tvrla

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Re: Emergency shifting tool
« Reply #13 on: July 19, 2012, 10:08:56 AM »
Any spring can break, so don't think the newer style is immune to this problem. When the spring breaks, I believe the bit that breaks off just falls to the bottom of the transmission, the rest stays where it is. No way for it to get tangled in the gears.

I've got a few transmissions in pieces around here, I think I'll look into this.

Offline R65LS

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Re: Emergency shifting tool
« Reply #14 on: July 20, 2012, 11:04:00 PM »

 as a very lucky fellow who has had this spring break 4 times on my '82 R65LS, I am all ears about "why" this happens.  The dealer sure doesn't ......

 mine has broken about every 20,000 miles ..... fortunately I was close to home each time.  Most recently was just last August.

 ACTUALLY, make that 5 breakages.  The 3rd time it broke the dealer fixed it.  The morning I picked it up, the mechanic himself rode the bike from the shop alley to the parking lot in front .... and the new spring broke right there before he hopped off.

Cheers,

Carl
« Last Edit: July 20, 2012, 11:05:01 PM by r65LSrider »