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Removing Gearbox Place the MC on auxiliary stand BMW tool # 90 88 6 00 1 550 • Remove the seat. • Remove the left & right air duct trim panels. Remove the fuel tank. Removing the fuel tank: Caution: Fuel is highly flammable and also represents a health risk. Use reasonable safety precautions. Use special tool 90 88 6 13 3 010 to clamp both fuel lines prior to detaching them. Disconnect the vent and drain lines. Disconnect the fuel pump connector. Remove rear wheel/Rear drive/swing arm, Disconnect the negative terminal first, then the positive terminal. When installing reverse the connection order. Place gearbox face down on work bench, heat to 100° C with hot air around bearing area in the housing. • Hear around the two (arrows above) locating pins. • Use a flat end pin punch and tap the locating pin into the cover while hot. The housing will raise while tapping on the locating pins, • Tap the housing with a dead blow hammer an remove housing. Remove circlip (60) and sliding gearwheel for fifth gear (61). • Turn output shaft (50) and clamp into the vise with soft jaws. • Use universal puller, BMW No. 90 88 6 00 7 500, to pull off deep-groove ball bearing (45). Assembly starts at the shift gear-wheel for 4th gear. Before assembly, oil all running surfaces lightly with gear oil. To check and adjust the fully-compressed length, measure deviation from zero as described below and adjust with a shim washer. Before each measuring step, even if the shaft is not to be installed, make sure that the deep-groove ball bearing is fully compressed. • Pull off input side deep-groove ball bearing with universal puller, BMW No. 88 88 6 00 7 500. • Insert zero gauge, BMW No. 90 88 6 23 4 763, in to measuring stand, BMW No. 90 88 6 23 4 761, Secure dial gauge, BMW No. 90 88 623 4 762, in rear.
Tags : deep groove ball bearing, gearbox repair, soft jaws, groove ball, dial gauge, bmw r 1200 c, bmw r 1200, output shaft, work bench, shift gear, r 1200 c, drain lines, circlip, negative terminal, swing arm
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