ChangingaMainSealandClutchSlaveCylinder

BroughttoyoubytheridersinCentralTexas ByKennyCrawford(a.k.a.BlauBeeMr)

Ifyouhaveoildropsforming ordroppingfromthe transmissionhousing....you needtoattackandreplacethe mainsealand,perhaps,the clutchslavecylinder!

Thisdocumentisnotintendedtobeallinclusiveonhowonegetstoandchangesamain engineoutputdriveshaftsealandclutchcylinderonaBMWK1200LT.Whereavailable,I amincludinglinkstowebsitesthatwillhelpyouinyourefforts.Ifotherridersidentify criticaldeficienciesinthetextofthisdocument,pleaseprovideyourcomment(s)asan addendumforinclusionorpostittotheBMWLTForumforotherstoseeanduse.This documentusestheBMWRepairManual(BRM)andClymersManual(CM)astheprimary sourcesofreferenceandreflectstheappropriatepage(s)ineachmanualaccordingly.

Arrangementofdocument:We attemptedtocaptureeachstepwith aphotographintheprocessofour TechSession.Wherephotographs werenttaken,Iamprovidingthe appropriatesteporprocessas indicatedintheBRM/CMasa reference. Note:TheBMWRepairmanuallink providedinthepreviouspageisan excellentonlinereferencesource.I receivedtheCDwhenIpurchased thebikefromthepreviousowner CM(onleft)andtheBRMCDandprintout(onright) anddecidedtogooldschooland printedoutall452pages(double sided)andputtheminabinderforquickandeasyreferenceandnote taking/highlighting..ifyoueverhavetodothisjob(oranyothermaintenance),itllpay foritselfmanytimesover.IkeeptheCDtuckedawayinthepocketofthebindertoprint offpagesIneedtoreplaceorwanttouseasaquickreference. TheCMiswelllaidoutand,forthemostpart,alignswiththeBRM.Belowarethe highlightedchaptersthatpertain(onesyouwilluse)inthisproject: 1. GENERALINFORMATION 2. TROUBLESHOOTING 3. LUBRICATION,MAINTENANCEANDTUNEUP 4. ENGINE 5. CLUTCH 6. TRANMISSIONANDSHIFTMECHANISM 7. FUELANDEXHAUSTSYSTEMS 8. ENGINEELECTRICALSYSTEM 9. BODYELECTRICALSYSTEM 10. COOLINGANDLUBRICATIONSYSTEMS 11. WHEELSANDTIRES 12. FRONTSUSPENTIONANDSTEERING 13. REARSUSPENSIONANDFINALDRIVE 14. ANTILOCKBRAKESYSTEMABSII 15. INTEGRALABS 16. BODYANDFRAME(RS&GT) 17. BODYANDFRAME(LT) 18. COLORWIRINGDIAGRAMS(theseareexcellentsourcesfortrackingthewiresinyour harness!)

1. Orderingandorganizingfortheproject. 1.1. Thefirststepistomakesureyouproperlyidentifyallthecomponentsandparts youneedtoorderbeforestartingtheproject.IhadalittlehelpfromHoss (shoswell)andBrian(hallzee)inacquiringthelistofrequiredpartsastheyhad beeninthispredicamentpriortome.HereisthelistIcreatedinExcelandshared withandpurchasedthepartsfromBentonvilleBMW.Youwillnote,Ielectedtonot

purchasetheOutputCylinder(a.k.a.ClutchSlaveCylinder)sinceanewonewasless expensivefromBeemerBoneyard.Inadditiontotheslavecylinder,Ialso purchasedtheComplete12/24KMileSuperMaintenanceKitWithEngineOil (Synth)&Trans/FinalDriveOil(Synth)becauseIwantedtowrapthebigservice intothejobsincethefluidswouldbedrainedandthefueltankwascomingoff anyway. 1.2. SeeAnnexAfortheBMWPartsFichedocuments. 1.2.1. Inessence,IprintedouteachpageasapartsreferencewhenIbeganthe repairsandtoensureIhadeverythingIneededonhandbeforebeginningthe project.HereareafewexamplesofwhatitlookslikeonceIreceivedtheparts andarrangedthemaccordingly(yes,itisalittleOCD):

12/24KServiceKit

ClutchParts

1.2.2. Hereisthe$22partthatcauseseveryonesomuchtroubleandexpense

1.2.3. HereistheclutchslavecylinderfromBeemerBoneyard:

1.2.4. Iorganizedallthepartssimilarlyinbaggieswithaprintoutofthefiche,the part,andanenvelopecontainingthesmallerparts(washers,gasket(s),etc.).

2. SpecialTools..theCMhasseveralrecommendationsforhowtomakeyourownspecial tools.Inadditiontothosefoundinthemanual,andwiththehelpofDon(1dbweldor),I madeaclutchcenterguide,sealdrive,andthetransmissionrubberbushingtemplates (seeAnnexBforthespecifications/drawings).IfyouhaveyourveryownManCave likeChanningdoes.youllhavenoproblemtacklingthisprojectandmodifyingthe toolsyoullneedtogetthejobdone.Intheprocessofdoingthisproject,Channingdid havetosacrificeandmodifyafewofhistools..

Wehadtocutdowntheshortsideofahexwrenchtobeabletoloosen/removetheheadscrewandspeed sensorfromtheleftsideofthetransmissionhousing.

Channinggrindedthebacksideofa15mmwrenchtobeabletoaccess....andturntheenginetemperature sensoronthelowerbackleftoftheengineblock.

2.1. Thebiggestadvantageofhavingabikeliftisthefactitsavesyourknees,back,and allowsyoutokeepthebikestableata decentworkingheightwhileyousitona rollerstool. 2.2. Steponewastakingoffallthe Tupperware.Onceyouhavedonethis onceortwice,ittakesabout11.5hours. Rememberingwhereallthesmall, medium,andlargetorxscrewsgois alwaysafuntask.Justremember,the largescrewsmostcommonlygothrough twopiecesofplasticorintoawellnut.
Thefrontfairing,trunk,andsaddlebagsstayed onthebikeforthisjob.Here'sChanningandI thenightbeforetheTechSessiondiscussingthe planforthelongdayahead.

2.3. Wealsotookthefrontseatandfueltankofftoeaseaccessandchangeouttheair andfuelfiltersaspartofthe12/24Kservice.Justthink,ifyoutookthistothe dealer,youdpayforallthelaborinremovingtheTupperwareandfueltank.its trulynotthathard!Note:wealsounscrewedthelicenseplateholderatthispoint.

2.4. Hereitis,prepdandreadyforthenextdayswork!Dontforgettotakeoutthe battery!Makesureyouputthebikeinto5thgearbeforeyoubegintheprocess!

IsuredohopethenextgenerationLTdoesn'thave New(top)andOld(bottom)airfilters.Removea thismuchworkrequiredtochangeoutfiltersor fewscrews,removetheplasticcover,pulltab,and accessrelays! replace....easy!

3. Thestartofanew(LONG)day!Wetookourtime,wentbythebook(s)andthisjobtook from7AMto~11PM. 3.1. Thefirstthingthatcameoff,at7AM,wastheexhaust!Beverycarefulwhen removingthesensorfromtheexhaustpipe.Iputitintoalabeledplasticbaggie andplaceditinaplasticbin.

3.2. By7:30allthefluidsweredrained..

3.3. andfolksstartedshowingup(withcoffeeanddonuts)readytolendahand, providesomeexpertise,andlearnafewthings.!

3.4. .thisishowfarweneedtogotoreplacethemainseal..

4. RemovetheRearWheel(BRM36.8/CM359): 4.1. Useanenginehoist(orotherweightrateditem)andnylonwebbing(weused 750lbstrengthnylonwebbingdoubledover)andconnect/wrapitaroundthe framewherethehoistwillnotcomeincontactwiththetrunk.

4.2. Thoroughlycleanthefinaldrivefromalldebris.Removethefillisterheadscrewto disconnectthespeedometercablefromthefinaldrive.Wedidnotdisconnectthe cablefromthebikeontheotherend.Oncetherearbrakecaliperisremoved,you canhangthespeedometercableoverthebrakeline.

4.3. Usingalonghandledratchethandleorbreakerbar,loosenthefourouterboltsthen thecenterbolt.Usingthehoist,jackuptherearofthebike~34orjustenough tobeabletoslidethereartireoutonceyouunboltthefivewheelboltsandthe shim(ontheinsideoftherim).Removethefivebolts,tire,andshimtakethetime tocleanthesepartsandthenplacetheboltsandshiminalabeledbaggie.

5. FinalDriveRemoval.(BRM33.7/CM415) 5.1. Removetherearbrakecaliperandhangitwithziptiestotherearofthebikeframe outofthewayoftheworkyouwilldowhentakingoffthefinaldrive,driveshaft, andswingarm.

5.2. Loosentheclampandremovethebootandloosenthetorquelinknutandbolt.

Loosenthisbolt. 5.3. Heatbothsidesofthethefixedbearingjournalwithaheatgun. Heatw/heatgun.

5.4. Thenextspecialtoolyouneedisa30mmtorqueadapter/sockettoremovethefree bearingjournal(seeCM415andfig7on416forfabricationinstructions).

Useasecondpairofhandswhenremovingthefinaldrive.Ifyouareworkingalone, youmaywanttouseascissorjackandusewoodontoptosupporttheweightof thefinaldrive.Oncetheboltisheatedto~120o,removethefreeandfixedbearing journalsandboltfrombothsidesandcleanonceremovedforlaterinstallation.(CM 421)

5.5. Pullthefinaldrivestraightbackfromtheswingarm.Lookinsidethefinaldrive reardriveshafthousingforanypoolingofoil.ifnone,youregoodtogo!

6. SwingArmRemoval(BRM33.20/CM445) 6.1. Withthefootrestsalreadyoff,rightfootpegandbrakelinetieduptopreventkinking orbreaking(BRM46.22/CM545/546),accessandunboltthetwoHexboltsholding thecrosstube(CM558559),removethecrosstube,andsetitasidewiththebolts inaplasticbaggietokeepthingsorderlyandwiththeirrespectiveprimaryparts..

6.2. Loosentheuppershockabsorberbolt,removethelowershockabsorberboltto checkforplayintheswingarm. 6.3. Grabtheswingarmandcheckforplay(sidetoside.anyplayrequires replacementofbearings).Theswingarmshouldmovefreelyupanddown.Once checked,replacethelowershockabsorberbolttoholdtheswingarminplace.

6.4. Toremovetheswingarm,youwillneeda30mmtorqueadapter(CM445)and 12mmHexsocket.Theonepicturedbelowhasabearinginsertthatwillaccepta long12mmHexwrenchtoallowyoutomakeadjustment(torque)asrequired whenyoureinstalltheboltsoryoucanmanufactureoneasperCM445fig143. Removetheretainingclipsfromtheleftandrightsidesofthethreadedrings.

6.5. Removethelowernutandboltsecuringtheshockabsorber.Tietheshock absorberuptokeepitoutofthewayfortheremainderoftheprocess.

6.6. Oncetheboltsareremoved,pulltheswingarmstraightbackoffthefrontdrive shaft(therubberbootwillcomeofftoo).SeeCM447449forreinstallation.

6.7. Inspectthetransmissionoutputdriveshaftforleaks.Cleantheswingarmbearings thoroughlyandrepackthemwithOptimolygrease/lube. 6.8. Removingthefrontdriveshaft(BRM33.22/CM449)requirestheuseofatwojaw slidehammeroraprytool.Weusedaprytoolandaccessedtheshaftknuckles throughthebearingholeintheframeforleverage.CAUTION:Useathickrag, rubbermat,orpieceofthinwoodtopreventdamagetothethreads.weuseda sweatshirtmaterialasseeninthepicturesbelow.

7. Removalofslavecylinder(BRM21.13/CM178/179).Thiswasoneoftheculpritsin theclutchhousing.badcylinderandseals.Iorderedminefrombeemerboneyard.com. Whenyoudisconnectthebanjoboltfromthetopofthecylinder,itwillleakalloverthe placeunlessyoucontainit.weusedaziplockbaggieandaziptienotetheDOT4 fluidalreadyinthebaggie!Disconnectthebleedlinefromthetopofthecylinderas well.

7.1. Loosenthethreeboltsoneturnatatimeeachtoensurethecylindercomeout straight.Bepatientanddothisrighttopreventfurtherdamagetothecylinder housingwalls!Makesurethegasketiffullyremovedfromthefacingofthetranny.

7.2. Removethepushrodbypullingstraightoutofthetransmissionhousing.Clean thoroughlyandplaceinsidealargecleanplasticcontainer(IusedaRubbermaidto preventsandordebrisfromgettingonpartslikethis).Putacleanragintheholeto protecttheinsideofthetransmission.Note:theshortendofthepushrodisthe slavecylindersideoftherod.longendtowardengine.ReinstallationCM178179).

8. PreparingtoremovetheTransmission(BRM23.1023.11/CM184188). 8.1. Removetheskidplateandsidestand.

8.2. Disconnectthesidestandsensor.

8.3. Removethegearindicatorswitch(totheupperleftoftheclutchslavecylinder).

8.4. Removalofthespeedsensorfromtheupperrightsideofthetransmissionrequired theslightmodification(sacrifice)ofaHexwrenchbycuttingtheshortendoffa littlesoitwouldfitintotheboltundertheframe.

8.5. EnjoyedalittleTexasBMWCommunityFellowshipduringthesession!

8.6. BEFOREremovetheenginemountingboltssotoallowyoutojackuptheframeand tiltthemotor,ensureyouhaveabraceinplacetosupportthefullweightofthe engineandyoucanaccess/removethetransmission.

Notethecleanraginside theslavecylinderhole.

8.7. Toremovethetransmission,youhavetoaccesstheenginemountingHexboltand accompanyingnutoneithersideofthetransmissionmounts.Wehadtodetach

(butnotremove)thebatteryboxontheleftsideofthebike(insidetheframe).(CM 185186figs8&9)

8.8. Hereisapictureoftheboltaccessholeandboltduringremoval.

8.9. Atthispoint,Iwaswonderingifitwouldallgobacktogetherthewayitwas supposedtoandnothaveanysparenutsandbolts!

8.10. Accessandloosenthefront(L&R)enginemountingboltsenoughtoallowthe enginetotiltwhenraisingtheframewiththelift(redbarwithchainhookedto yellow5Kstrapinphotoabove).Idontrecallwhywedidntuseahexsocketwith aratchetextensionbutthecresentandhexwrenchedworkedforus.

8.11. Wealsodidthefollowingpriortotiltingtheengine(raisingtherearofthe bikewiththelift): 8.11.1. Disconnecttheradiatoratitsupperpivotpointstopreventanybendingor kinksfromoccurringwhentiltingtheengine(wehaddrainedtheradiatorfluid inthefirststagesoftheprocess).Therearesmallclipsbehindtherubber grommets.Usingaflattipscrewdriver,pushtheseoffwhilebeingcarefulto notlosethemintheprocess!Iftheydontcomeoffeasily,useadroportwoof water/dishsoapsolutiontomakeremoval/installationeasier.

8.11.2. Disconnectthestartercableontopofthestarter(thisisatightfitforyour hands!). 8.11.3. Disconnectthealternatorcableandelectricalconnector(thisisanothertight fitforyourhands!). 8.11.4. RemovetheReverseAidLink(ontheleftsideofthetransmissionleadingto thestarter).

9. RemovingtheTransmission. 9.1. Channingprovidedhismanlyairsockettospeedtheprocessofremovingeach boltandrepeatedituntilcomplete!Oncetheywereloose,somerequiredustouse aballendhexwrenchbecausetherewasntenoughspacefortheairwrenchto reachthetoprightbolt(picturedontheright).

9.2. Therearesevenhexboltsconnectingthetransmissiontotheintermediatehousing. Wefabricatedaboltholderoutofapieceofcardboardandlabeledeachbolt accordingtotheirpositiononthetransmissionasweremovedeachbolt.

9.3. Oncetheboltswereloosenedandthebottomonesremoved,itwasclearlyevidentI hadasignificantamountofoilaccumulatedintheintermediatehousingasis evidentinthepicturesbelow(sorryforthelackoffocusinsomeofthepictures)!

Asteadystreamof oilpouredoutof thebottomofthe seambetweenthe intermediate housingand transmission! Thiswouldhave beenfineifitwas supposedtobea wetclutch!

9.4. Afteryouremoveallthebolts,slightlytaparoundthetransmissionwitharubber malletandbringthetransmissiongingerlydowntothebikeliftwithsomeoneon theothersideofthebike(dontattempttodothisbyyourselfifyoucanhelpit.its notaneasytaskasthetolerancebetweentheframeandtransmissionisvery tight!).Notetheoilatthebottomoftheintermediatehousinginthetworight pictures!

10. ReplacingtheTransmissioninputshaftseal(BRM/CM201202). 10.1. Noticetheinputshaftsealisrecessedintothehousing.Takeamicrometeror otheraccuratedepthgaugingdevice(ifthereissuchathing)andmakeseveral measurementsaroundtheedgeoftheseal(rightpicture)andnotetheaverage depthastherequireddepthforyourreplacementseal(minewas5.12mm).

10.2. Removingthesealwasaharrowingprocess.Weelectedtonotdissectthe trannytoremovetheseal.Thisrequiredsomeverysteadyhandswithadrill,bit, andaheavydutyrazorblade.Weusedtherazorbladetoprotectthesplinesofthe inputshaftwhendrillingintotheseal.IfIwastodothisalloveragain,Idfollow theinstructionsintheCMandsplitthetransmissionjustsoIcouldlookinsideand makesureIdidnthaveanyproblemscreepinguponmeinthefuture.Oncewe hadtwoholesdrilled,wescrewedtwo3screwsintothesealandbegantoprythe sealfromthetransmission.Onceremoved,Ithoroughlycleanedtheoilresidue fromthetransmissionuntilitsparkled!

10.3.

Ok.maybenotsparkling.butitismuchcleanerthanitwas!

10.4. ResettingthenewsealrequiredasealsettoolfabricatedbyDonBrown (1dbweldor).YoucandothesamethingwithasealdriversetfromHarborFreight oryoursocketset.Welubricatedtheedgeofthesealandgentlytappedituntilit reachedthe5.12mmdepthofthepreviousseal.

11. Removingtheclutch.(BRM21.1/CM164168(Ch5) 11.1. Thefirststepisremovingthesixretaininghexboltsintheclutchhousing cover(threepictured)andslidetheoldclutchhousingcoveroff.Youwillneedto fabricateabartopreventtheplate fromturningwhileyouaretryingto unboltthem(seeCM167fig7).You mustunboltinacrisscrosspattern toensureitiscomingoffstraight.

11.2. Thiswillfurtherexposeyourclutchplate,pressureplate,(cover,clutchplate, andpressureplateinleftpicture)diaphragmspring,andspacerring(stillin intermediatehousinginrightpicture).Notetheobviouspresenceofoilthroughout! Atthispointyoucanprobablydeterminehowsoakedinoilyourclutchis.I determinedthatbeforebeginningtheprocesssincetheclutchwasslippingin35th gears. cover,clutchplate,pressureplate

11.3. Slidethediaphragmspringandspacerringofftoaccesstheclutchnut,o ring,andclutchhousinginordertoreachthe$22sealthatcausedyoutodoallthis worksofar! diaphragmspring

clutchhousing
"#$%&'$()!*%'#+(! 11.4. Unscrewthelargeclutchnutwhichisretainingtheclutchhousingandkeep thisasasouvenir(Iusedsteelwireandtwistedthewiretoholdthenuttotheframe ! bymygoodluckbellontherightrear ofthebikeunderthe saddlebag.kindofabeenthere donethatmomento)!Youwillneed tofabricateaclutchhousing holder(seeBRM21.6/CM167fig 8)toturnthe30mmnut.Oncethe nutisremoved,pullthe compressionring,oringoffthe outputshaft.

11.5. Toproperlyremovetheclutch housingyougrabtheholesandpushpull thehousingbackandforthtounseatand pulltheoringfromtheoutputshaftor cutitwithanExacto/razorbladesince yourenotgoingtouseitagain!Youwill alsoremoveanddiscardthethrust washer.Youcanreuseyourclutch housingafteryouthoroughlycleanit! 11.6. Hereitis..the$22partthatcausedallmyproblems..fivehoursintothe project!Notetheamountofoilaroundtheintermediatehousingandevidentatthe seal.

Oil Oil Oil Oil

Oil Oil Oil

11.7. Wedidnotremovetheintermediatehousingbecausetheboltswere extremelytightandIdidntwanttobreakoneoffintheengine.ifIeverhavetodo thisagain,Iwouldfigureouthowtoremovethemandtaketheextratimeto removethehousing,cleanitallup,andtorqueitbacktospecification.RefertoCM 130131toremovetheMainOilSeal.WeusedasealremovaltoolfromHarbor Freight(forremoval)andapersonallyfabricated(andmachined)bearingdriver (toinstallthenewsealfarrighttoolinrightpicture).

11.8. Afewbangswitharubbermalletagainstthehandleofthesealremovaltool andweeventuallyworkedthealuminumsealoutofthehousing.

11.9. Onceyouremovetheoldseal,youneedtopreparethenewTeflonsealby lubricatingtheouterpartofthesealwithengineoiltoeaseininstallation.Position thenewsealintheholeanduseyourpersonalizedbearingdrivertoinstallthenew seal.

11.10. PlacethenewTeflonsealintothehole(left)anddriveitinflushwiththeface ofthehousing(center).Checkthesealtomakesureitisproperlyseatedandnot marredordamaged,ifitis.youneedtobuyanewoneorallyourworkwillbefor naught.CLEANEVERYTHINGTHOROUGHLYweusedbrakecleanerand thoroughlydriedalltheinternalcomponents,nooks,andcranniestoensureno residualfluidsremained.

12. Drillingweepholes(youwontfindthisintheBMWRepairManualorClymers).Plenty oflinksareontheforumdiscussinghowtodothis. 12.1. Intermediatehousingweephole.Usingmycalibratedeyeballs,Idetermined thelowestcenterpointoftheintermediatehousinganddrilledasmallholethrough thehousing.

12.2. SlaveCylinderweephole.Tomakesuretheholefortheslavecylinderwasin therightspot,Imeasuredwithamicrometer(lengthofslavecylinder,depthof cylinderhole(34.82mm),andthespotwhereIwasgoingtodrillonthebottomside oftheslavecylinderhousingoutsidethetransmissionhousing(32.06mm)).

12.3. Beextremelycarefuldrillingyourweephole,useagoodqualitydrillbit, placeathickragontheinsideoftheslavecylinderhole,andtakeyourtime!I decidedtodrilltheholeataslightangle(610degrees)towardthefrontofthe transmissiontoallowanyaccumulatingoiltoexitasfarforwardaspossible.

13. Reinstallingnewclutch(BRM21.721.8/CM168173). 13.1. Cleananddrytheclutchhousing(weusedbrakecleaner,ascouringpad,and rags)andrelubricatethesplinesusingoptimolylubebeforeinstallation.Once complete,slidethethrustwasher(youcanreusetheoldone)andclutchhousing ontotheengineoutputshaft.

13.2. Beforeinstallingtheneworing,newthrustring,andthenewclutchnut, makesuretheoutputshaftthreadsarecleanandfreeofanylubricantoroilsoryou willnotachievethepropertorquespecifications.andfingertightentheclutchnut ontotheoutputshaft.Installtheclutchhousingholderyoufabricatedwithtwo boltsfromtheclutchcovermountsoallowyoutotightentheclutchnuttothe requiredspecifications.Usingaclickertypetorquewrench,tightentheclutchnut to140Nm(103ftlbs)andthencompletelyloosentheclutchnut(inessenceyou juststretchedthenut)andthenretightentheclutchnutto50Nm(37ftlbs). NewORing Newthrustring

Newclutchnut

housingholder

13.3. Toachievethepropertorqueontheclutchnut,youneedtouseatorque anglemeter(CM169fig18).Connectthetorquemetertoa30mmsocketand breakerbarandtightentheclutchnutanadditional60degreesbeyondthe50Nm (37ftlbs).

13.4. Lightlylubricatethethreepinsontheclutchcover,placeitwiththepinsup, andassemblethethreeremainingpartsofyournewclutch: 13.4.1. clutchcover(bottom) 13.4.2. clutchplate(middle)lubricatetheclutchplatesplineswithoptimoly (ensurenolubricantgetsonthefrictionplate!) 13.4.3. pressureplate(top)lubricatetheraisedtabsofthepressureplatewith optimoly. 13.4.4. diaphragmspring(inhand)lubricatethespringsouterrearedge(closest totheenginewhenmounted)withoptimoly 13.4.5. spacerring lightlylubricatewithoptimoly

clean/dirt&oilfreeworkspace 13.5. Slideaclutchcenteringguide(DonBrown1dbweldermadethisoneand loanedittome)throughthefrontoftheclutchplate.Lifttheassembledclutch usingthecenteringguide,whilekeepingittightlytogether,andguideitontothe outputshaftandclutchhousing.

13.6. Tightenthesixhexboltsontheclutchcovealittleatatime(12turnsatime) inacrisscrosspatternuntilhandtight.Turnthecenteringguideasyougoto ensureitcanturneasilyandtheclutchdoesntbind.Torqueto18Nm(13ftlbs).

13.7. Reinstallingthetransmission(BRM23.3723.38/CM188191). 13.7.1. Thisprocessisthereverseoftheremoval.Thisiswherestep2.4(puttingthe bikeinto5thgearbeforestartingtheprocess)comesintoplay!Themajor differenceisthedifficultyyouarecertaintoendureasyoutrytofit/guidethe transmissionbackontotheintermediatehousinggiventhetighttolerancesof theframe.Lightlylubricatetheinputshaftsplineswithoptimolyandalignthe inputshaftwiththeclutchplatesplines.Pushthetransmissionontotheguide pinsontheintermediatehousingallthewayforwarduntilitisfullyincontact withthefaceoftheintermediatehousing.

13.7.2. Dontforgettoreinstallthereverseaidlink(CM186,fig5item#10)witha transmissionmountingboltintherightlocation.Installtheallofthe transmissionmountingbolts(fromstep9.2).Removethetwoguidebolts/pins usedtoaidinmountingthetransmissionandreplacewiththelasttwo mountingbolts.Torqueboltsto24Nm(18ftlbs).

13.7.3. Installclutchpushrodandslavecylinderandtorqueto9Nm(80inlbs)and reinstallthegearindicatorswitch.

13.7.4. Lowertheframeandreattachthestarterandalternatortothewiring harness.Continuetocarefullylowertheframeandalignthetransmission mountingboltholesandinstalltheboltfromtherightsideofthebike.ifit doesntfit,itsnotaligned.DONOTFORCEIT!!Onceyoufullyinsertthebolt, threadthenutontheleftsideandtightento70Nm(52ftlbs). 13.7.5. Tightentheleftandrightsideenginemountingboltsandtightatfirstand thenfullytowquethemto41Nm(30ftlbs). 13.7.6. InstalltheengineguardapplyLoctite242tothe8mmboltsandtightento21 Nm(15.5ftlbs).Applyloctite242andtightenthe10mmboltsto41Nm(30ft lbs).

13.7.7. InstallthecenterstandpivotboltswithLoctite242andtightento41Nm(30 ftlbs) 14. Installationoftheremainingitemsisthereverseofremoval.Alltorquespecifications areindicatedattheendoftherespectiveBRMorCMchapters. 15. Refillingfluidlevels. 15.1. Refillthetransmissionwiththeappropriatetypeandquantityofgearoilin thetransmission. 15.2. Reconnecttheradiatortothemountingpointsandrefilltheradiatorand overflowbottle.

Thiswaskindofanabruptendingtoaratherlengthydocument.Thisprojecttook14solid hoursofefforttocomplete(allthewaytogettingtherearwheelreinstalled)andwe deliberatelytookourtimetoensurewediditright.Ifyoueverdecidetotakethistask uponyourselforaspartofalocal/regionalTechSession,besuretoresearchtheBMW RepairManualandClymersManualandorder/acquireyourrequiredpartsbeforeyou begin.itwillsaveyoutimeandyoullgointotheprocesswithagoodideaoftheorderin whichyoumustattackthebeast! Withouttheadviceofmembersofthisforum,Iwouldnthavehadthenadstoevenattempt thisprojectmyself.thankstoallwhoprovidedtheirsageadviceandwisdomalongthe way! Lastly,havingtherighttoolsandsupportisextremelyimportant.Idliketoextendspecial andsincerethankstoEric(EricSuz),Allen(astuber),PastorJack(ccpastorjack),DonBrown (1dbweldor),Steve(katnapinn),andChanning(cfell)andhismancavewhoallwere certainlylifesavers!Thankstoeachofyou! GOODLUCK! Kennya.k.a.BlauBeeMr

15.3. 15.4.

Refilltheenginecrankcaseoiltotheappropriatelevel. RefilltheFinalDriveoiltotheappropriatelevel.