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I'd like the beer - but hope I'm wrong. Bikerfish has the best sound description of stripped clutch spline.

I'm not sure I buy that "dry out" concept. Just because it has rarely been hot shouldn't reduce a seal's life, it should increase it. What gaskets would "dry out"?

I think it is pretty much an...

The suddenness of the problem probably means something broke - not a gradual oil seal leaking stuff onto the clutch. Stripped transmission input spline?

Maybe something has happened to the spring in the driveline damper (I assume R1100 has one like the older R bikes).

Find another similar bike and put them both in 1st gear with the engine off on...

[QUOTE=boofer]Secret meathod for retreaving out of reach parts: turning etc"

But if you use this method - be sure to connect the welder ground to the appropriate casting. You don't want to run...

I now realize you are dealing with the rear axle drain plug at the bottom of the inaccesible well. Try the magnet trick described above, but if that isn't enough-

Degrease & dry the pieces & use...

Obviously it is pliers/visegrip time. Have you stripped the internal hex socket?

The plug should come out a little easier if the crankcase is hot. You might even quickly hold an ice cube against...

As much as I hate dealing with Whitworth fasteners, I have to admire them because the thread form had a radius in the root making for better fatigue properties.

You have to be careful with metric fasteners tapped into soft materials like aluminum. The metric series don't have a coarse and fine thread series like the inch fasteners do.

The old unwritten...

I bent one flange of both front and back wheels on my R1100RT hitting a pothole. The tires still ran true, but the rim deformations were about 3/16 inch. I straightened them in a big vise using...

Maybe it is getting to be time for a sub group to chip together, buy this turkey, and reverse engineer it to find out what goes wrong with these hideously expen$ive part$.

Any mad organizers out...

As a mech engr, I suspect the spline life problems are due to 1) radial misalignments OR 2) radial loading.

Misalignments could be caused by a machining error.

Radial loading would be caused...

Nope - the smaller wheel would be better for starting. I doubt you would be able to fweel the difference though.

Remember you don't get to ever change one gear. There is always the one that...

Look hard at the excessive fuel consumption. I can't imagine you driving that hard to justify such low fuel economy. Running that much excess gas thru the engine will keep washing the cylinder...

Remember that automotive alternators run at pretty high RPMs, hence they get a lot of output even at idle..

As the operating RPM goes down, the strength of the rotor magnetic field has to go up....

I need that name too. Got both front and rear rims on a pothole on my 2000RT.
Bent the flange about 3/16 inch out on one side of both rims. Forunately I have no radial runout, and the wheel held...

I completely agree with Roy. Maybe monitor the bolts some to make sure they don't loosen. Of course we have the wheels off to change tires anyway.

Bolt tensions will be very inconsistent...

I understand the R11XX ABS startup (switch-on) processor logic includes a check for marginal battery voltage. Mine sure behaves that way. I have a non-OEM battery that is sometimes marginal...

Sorry to be so pessimistic, but to this mech engr (retired) this is a classic fatigue failure. Probably the part is underdesigned. The NTSB may even be interested if there are many others.
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Chargers may be RATED for 2 or 3 Amps but are they delivering that much current? I doubt it. If nothing else you can add a series resistor to one of the leads to cut down the continuous charging...

When I last measured it, my 2000 R1100 RT drew about 30 milliamps with everything shut off. This means about 0.7 AH per day is taken out of the 18 AH battery. It would seem like the battery would...

My 2000 R1100 RT with 10K miles on it, with full bags and backrest, with one 225 lb rider on a 3400 mile trip from and back to Minnesota averaged 51 mpg. Mileage improved slightly with altitude to...

Another weird point the EE friend raised - The open circuit output voltage of a lead acid cell rises as they become colder. Hot battery = lower O. C. voltage. That's why voltage regulators have to...

An engineer-friend from Thermo-King was the EE in charge of their truck trailer refrigeration engine electrical systems. He always talked about internal corrosion of lead-acid batteries (which is...

Be sure you clean off the white paint with rubbing compound before you decide if you have to paint over anything. It is surprising how effective this treatment can be.

Can't help on the H lock. ...