Hi Justin I think it may possibly be either: The first clutch plate you put on MUST be the one that has a larger centre diameter so it does not cover the small spring washer. The other thing may be that the total thickness of the clutch plates exceeds the recommended maximum tolerance. I really hope it is as simple as one of those two things. Please let me know how you get on and I will keep thinking about your question and let you know if I think of something else. Cheers Paul ( Nuffy)

What I am talking about is most clearly explained at 1:10.15 in the video.

Sorry i start explaining it at 40:53 😀

Sorry, I just saw your comment. During Covid I paid around $800 for the second hand gearbox and clutch including freight. It was from a low mileage bike. Hope this helps.

Hi Manuel It was very expensive and difficult at the time to get my hands on parts. Also, the 1300 gearbox has been modified slightly as the earlier model is known to jump out of gear down low once there is a certain amount of ware. I managed to get the 1300 gearbox locally in Australia along with a few other parts from a wreckers in less than a week so went with that option. I still have the old gearbox sitting in my shed and offered it up for free on an Australian Facebook page for anyone who wanted it for parts or to replace the shift fork themselves. I sent some parts from the clutch basket to a guy in the UK as he was struggling to get his hands on the parts. I sold the BMW and I am now on a 2021 Ducati Multistrada 950s which I may start doing a few travel videos on. I am back working on the XJ650 project after having put it on hold for a very long time due to some other more pressing tasks. Stay safe my friend and thank you for the kind words and especially for taking the time to reach out with your message. Hard to believe how many people have watched that video and the number of positive comments received. Cheers Paul (Nuffy)

Massive oversight my friend!!!! Sorry about that. You are the first to mention it. I have no idea why I didn’t show that part except perhaps I was just too excited about getting it on the road and riding. Sorry mate, not intentional.

Hi, not sure where to get these but I may still have them from my original clutch pack. Where in the world are you?

@@nuffysbuilds3750 In the U.K. but happy to pay postage as they are rare. Guessing you’re in Australia or nearby.

@@robplazzman6049 Hi Rob, I will have a look this week and see what I can find mate.

@@robplazzman6049 yes, Australia

@@nuffysbuilds3750 👍🏻

Have you locked the starter gear?

Oil pump chain?

@@nuffysbuilds3750 I was able to get it to cooperate eventually, thank you!

Very good points Edwin. Thanks for watching, and particularly for taking the time to point out these important aspects. I have pinned your comments so they will show at the top of the comments section for others to see more easily. Stay safe, have fun and thanks again for taking the time to share your experience.

Hey Cobra, thanks for watching and a huge thanks for taking the time to leave a comment, I really appreciate it. I’ve just started back working on the cafe racer after spending 8 months tracking some parts and doing two other builds…. Stay tuned this might be my last build on KZfaq but hopefully the most interesting final product. Cheers Nuffy ( Paul )

@@nuffysbuilds3750 yh mate.. all the best for the build... appreciate your work man.. and thanks for entertaining us mate🖤

Thanks for watching and for leaving a comment I really appreciate it. Ride safe, have fun mate.👍

Hey Drone Pilot, glad you liked the video. Thank you for taking the time to watch and especially for taking the time to comment. Ride often and be safe out there. Cheers Nuffy

🤣🤣🤣🤣🤣 love the comment mate. That little air conditioning unit is about 20 years old and I literally clean it outside with a hose once a year due to the dust from the shop…. I can’t kill it. Thanks for watching, and a big thank you for taking the time to comment. Cheers Nuffy

Thank you so much, I really appreciate the feedback… especially from someone who has some seriously good content!!!!! Cheers brother 👍🏻

@@nuffysbuilds3750 👊🍻🤘

Hi, I don’t have the answer sorry. I would suggest that you try measuring the new clutch plates when they are stacked together and also measure the old clutch plates when they are stacked together first. Try and find out what they should measure before you change them. A common issue can be the hydraulic slave cylinder. The oil gets dirty and they do need to be cleaned out and hydraulic fluid changed….. Do not use brake fluid. I believe the two washers / spring washer I mentioned in mine were a change that was made to help with the issue of the clutch plates sticking together which I think was mainly due to the poor oil flow through the clutch plates. Take your time, take lots of photos as you go and please let me know how you get on. All the best mate. Cheers Nuffy

That washer is a modification to un-stuck the 1st plate. This supose to cancel the hard clunk when shifting from neutral to 1st gear. Mine hase it, does now work, lol.

@@edwinderegt6715 Hi Edwin, yes you are correct…🤣🤣🤣 Thank you for watching and taking the time to comment. Next time you are riding, try lifting the gear lever slightly before you pull the clutch and shift gear. I think you will notice a smoother gear change. 👍👍

Ratchet spanned and a steel tube for additional leverage…. They were tough. Sorry for the late reply Thanks for watching, I really appreciate it.

@@nuffysbuilds3750 Hey, no problem. Managed to get them loose by locking de rearwheel with a piece of wood :p

Soy for the late reply, and thanks for your comment. I’ve only owned this one and not sure I would be rushing out to buy another one unless it was new. I’m currently looking at a lot of bikes on the second hand market and I’m leaning towards the Yamaha MT10 or something from Kawasaki. BMW parts are expensive and often more difficult to get hold of - for me at least… The BMW engines seem to do really well for longevity with quite a few of the K1200’s exceeding 500,000 klm. Happy Hunting, all the best. Thanks again for watching and I really appreciate you taking the time to comment.

Hi there, I’m in Australia so unfortunately I’m not able to help. I suggest you try looking for a K1300s Facebook group and see if there is someone local that can help. Alternatively, you will need to find a local bike mechanic. I hope you get it sorted mate. All the best. Nuffy

@@nuffysbuilds3750 I think I found a shop in North Carolina, which is much closer. Thank you for your quick response and your awesome video!

@@gamerski2134 let me know how you get on and send a photo of you and your bike when you get back riding. Thanks for watching and I really appreciate your positive comment. Stay safe friend Cheers Nuffy

The real problem is that a lot of parts can are not available, you can buy only compleet set of gears from BMW. R&D motorsport Clearewater did weld the dogs and theath of my gearbox and machined them after. After 3 gearboxes, this was the fix! With sending costs from europe, it was close to the costs of a new gearbox. But now I have modifyd parts, runs better than OEM. Like I sayd, 3rd time it broke down on me in OEM spec. It hase never run as good as now.

Hello, Thank you for watching and for taking the time to comment, I really appreciate it. Part of the reason was due to the cost and also at the time during Covid, it was difficult and slow to get the new parts. Also, the 1300s gearbox has squarer dogs. These are the parts between the gears that help change between gears. This was a significant improvement from the 1200s gearbox as one of the issues with the 1200s gearbox is it sometimes would jump out of gear as these parts wore. Have fun, be safe and a big hello from Australia. 👍

Used K1300 have same problems. I had a brand new one... Also they hard to find.

🤣🤣🤣🤣 yip, blame me mate, I have big shoulders. All the best, keep me posted and make sure you send me some before and after pictures so I can show some photos on my channel. The fact that you are willing to try, tells me you will succeed. Cheers Nuffy Email: [email protected]

@@nuffysbuilds3750 Will do. I’ve got to put a new clutch in my Speed Triple first, then find a K1300. I’m in France - nothing is simple here and everything costs an arm and a leg!

Hi Mehmet, sorry for not replying sooner. In my opinion, the biggest issues with these bikes are the electronics. Electrical or computer issues can be difficult to diagnose on older bikes, and expensive. Mechanically they are excellent. Most problems can be fixed at a reasonable cost with some general tools and basic mechanical skills. In most cases, you can buy a very capable bike for not too much money. It is the problem that many of us face, we don’t want to spend a large amount of money buying a new trouble free bike, so we have to compromise and get the best value for our money……. I think the K1200 is a great place to start looking. All the best my friend, thank you for taking the time to leave a comment.

@@nuffysbuilds3750 thank you so much for your reply. I guess I will get a 2008 model K 1200 S which might be better ?

Cheers Carlos, hope you are getting out for a ride this weekend mate.

Hi Simon, it was during Covid so I made a clutch holding tool out of 4mm plate steel. You can buy them online. If you have a welder and a bit of flat plate and 10mm x 10mm bar stock you can make it…. But a clutch holding tool is what you are after. Hope that helps. Let me know if you need some photos of the tool and I will email them to you mate. All the best Cheers Nuffy

@@nuffysbuilds3750 Thanx very much for that. I'll most likely buy one online as I've never tried welding and don't own a welder. My nephew may well do. If he has we could give it a go.

Did the first fibre plate you put on have a slightly larger internal diameter so it sits outside of the very thin conical washer?

The central piece on slave cilinder needs to flat, not round. Did you check? It can invert.

@edwinderegt6715 I was very careful to put back together the same as when I took it apart and checking with the manual. It was much better to ride after the repairs. I sold this bike last October and I have been building a couple of new projects. Soon I will buy a KTM 1290s for adventure riding. 👍🏻

Hi Thomas, My understanding is they go all the way in as you have done. My immediate thought is that your clutch pack is thicker than the recommended maximum. See if you can find the recommended thickness of the fibre plates and metal plates. The next thing I am thinking, is if you have the angled washer at the back that reduces the friction (thin conical washer) Have you rotated the last fibre plate one step Have you checked your clutch oil level to make sure you are getting full pressure I will watch the video again myself and see if I can think of anything else. Happy to help you work through this. Keep me posted on how you go. Where are you in the world? I’m in Australia. Cheers Nuffy (Paul)

One of the fibre clutch plates has a slightly larger inner diameter. This needs to be the first plate that goes on, it should allow the thin conical spring washer to sit inside. If you don’t have this correct then the first fibre plate will be sitting on top of the washer

Try tightening the bolts to 8nm, it should hold the large conical washer firmly but should not deform it.

Thank you so much for watching and taking the time to comment, I really appreciate it. grazie per la visione e il tempo dedicato a commentare. Lo apprezzo molto. stai al sicuro, divertiti. Regards Nuffy ( Paul )

Hi Kiryani, thanks for watching and I really appreciate you taking the time to comment. My K1200s is a 2007, the 1300 gearbox came out of a 2009 K1300s. You MUST keep the original gearbox, because you will need the gear indicator piece off the original gearbox so the electrical plug is compatible. Very straight forward job to change. The 1300 gearbox is definitely a bit clunky compared to the 1200 because it is designed to have the quick shift setup. You just need to change gears quicker and it is best to preload the gear selector and just tap the clutch. Very smooth gear changes once you get used to the slight difference. All the best, and feel free to reach out if you have any questions at all. Thanks again Nuffy (Paul)

@@nuffysbuilds3750 Thank you for your quick answer and the details. I wasn't able to find a k1300s gearbox so I got one from a k1200s with 20,000 miles on it. Hopefully it will last a little bit until I find a better replacement. Great videos!

@@kriyani I think you will find the 1200s gearbox smoother and more enjoyable. Perhaps check the shift forks for ware before you put it into the bike. It should only take 10 mins to do the check, at such low mileage, I expect it will be great. All the best, stay safe, have fun and thanks again for checking out my channel it really is appreciated.

@@nuffysbuilds3750 thanks for the advice! The best for you as well. Keep up the good work!

@@nuffysbuilds3750 quick question. what is the size of the socket you need to remove the clutch hub? Can't find it in the repair manual.

Thanks for watching 👍

Thanks for watching, and I appreciate you leaving a comment.

Cheers brother 👍

Hey Freddy, thanks for taking the time to watch and comment.I will be watching your video on the electrical a few more times very soon. I hope you and your family are safe and well and I trust you are finding time to work on your own projects mate. All the very best my friend 😎🏍👍

You’re not wrong mate… out with the wood saw 😂😂 thanks for the comment, hope you are safe and well dude.

Hi David, thanks so much for watching and I really appreciate your comments mate. All the best with repairing your K1200S… I also changed the cam chain tensioner to a manual one…. Very easy and well worth it too. Have fun, be safe and thanks again for watching and commenting !!

@@nuffysbuilds3750 mech chain tensioner? Please...tell me more. Thank you.

I might do a short video to explain more clearly. Very easy job to do, and it eliminates the typical rattling noise you get with cold startups. It cost me about $70 Australian for the part and takes less than 1 hour to do. Half the time is spent removing and reinstalling the fairing on the right side. I think it is well worth it.

@@nuffysbuilds3750 There is SOooo much information about this clutch issue on K1200s/K1300s'. It is somewhat difficult to decipher it all. I just need to use the KISS method of sorting it all out down to the basics of what I need todo. I've had that notorious rattle since the Bike was new but just @ idle. BMW, just couldn't/wouldn't hear it...however, clutch lasted 60K. Thank you Nuffy

Thanks for watching. Stay safe and enjoy the K1200R. 🏍👍🏻

😂😂yeah, I have the same concerns about having parts left over too…. After a few hundred kilometres of riding my anxiety decreases….. 😂👍

Thanks, I have been enjoying a few of your videos also. I really enjoyed the small infill panel video you made using the shaping tools. You make it easy dude. Keep up the great videos, and thank you for subscribing. I look forward to binging more of your videos this week while I am travelling for work. 🏍👍🇦🇺

Thanks mate, yeah it has been a while.... I forgot to mention that I needed to buy a new computer as well. Hope all is well, looking forward to the red rocket (VFR) video series you have recently started.

@@nuffysbuilds3750 Thanks, hopefully that won't stall out. I really want to ride that one

Hi Mac Sorry for the late reply. I ordered an online version. It was not the most user friendly manual, but it did allow me to zoom in on things. I will have a look on my laptop and get back to you on which version it was if I am able to. All the best with your bike mate. Stay safe, have fun. Thanks for watching my videos and commenting, I really appreciate it. Hopefully I will be getting back onto my own projects this week and will get back to uploading more content. Cheers Nuffy

Hallo,I’m ready to buy a k1200s,can you give me some advice ? For example ,what parts need to be looked at carefully,which year is the better,and the number of the kilometers,what parts are more likely to break, I look forward to hearing from you

Hi Tomas, thanks for checking out my videos, and I appreciate the comment. Yeah, I’m all about comfort, followed by safety…. 😜 Have a fantastic week mate. 🏍👍🇦🇺

Hi Michael, thanks for checking it out, and I really appreciate your comments 👍

Hi Lucas, where in the world are you?

Hi Tim, no I have just been working on a vapour blasting cabinet and some other projects in preparation of tearing the bike down and using the vapour blaster to clean everything as I go. Apologies for the lack of uploads….. stay tuned mate 👍

2007 K1200s with upgrade to K1300s gearbox. Thanks for watching, and I really appreciate you taking the time to comment mate. 👍🏍

The speed rules are there for everyone’s safety, I totally agree mate. The camera being low down, certainly makes it look faster than it is. Thanks for watching, and appreciate your comments. 🏍👍