Preparatory work
- Remove fairing and engine spoiler.
- Remove the battery.
- Slacken exhaust system.
- Remove the inductive sensor on the rear wheel.
- Remove the rear wheel brake caliper, fasten to the rear frame with the inductive sensor using a cable tie.
- Remove rear wheel.
- Remove rear wheel drive unit.
- Remove the swinging arm.
- Remove cross tube.
- Remove clutch slave cylinder.
- Withdraw clutch pushrod.
- Remove reverser switch.
- Disconnect leads to starter and gearbox.
- Remove the gearbox.
Removing clutch
Remove the six retaining screws (7).
Remove clutch housing cover (6), clutch plate (5), thrust plate (4), diaphragm spring (3) and wire ring (2) from the clutch housing (1).
Removing clutch housing
- Secure the holder, BMW No. 11 2 821, as illustrated.
- Unscrew hex nut (5).
- Remove thrust ring (4).
- Move clutch housing (2) backwards and forwards until the O-ring (3) is visible.
- Remove the O-ring (3).
- Pull off the clutch housing (2).
- Remove thrust washer (1).
Installing clutch housing
- Lightly oil the internal spline (2).
- Install thrust washer (1) between output shaft and intermediate flange; apply a blob of grease to hold the thrust washer in place, if necessary.
- Fit the clutch housing (2).
- Fit the mounting fixture, BMW No. 11 2 821, on the clutch housing at the position illustrated.
Caution: Fit new nuts (5).
- Fit a new O-ring (3) and thrust ring (4).
- Tighten nut (5) with the collar facing outwards (140 Nm).
- Loosen nut and retighten (50 Nm).
- Tighten nut with angle of rotation indicator, BMW No. 112500.
- Remove the retaining fixture, BMW No. 112821.
Tightening torque:
- 1. Clutch housing nut — 140 Nm
- 2. Slacken
- 3. Retighten to — 50 Nm
- 4. Wrench angle — 60°
Installing clutch
Caution: Always use new screws.
- Grease all lubrication points with Optimoly MP 3.
Lubrication points:
- Splines on clutch plate and input shaft.
- Diaphragm spring contact surface on clutch housing.
- Diaphragm spring contact surface on pressure plate.
Caution: Offset colour markings for residual imbalance by 120°: yellow on clutch housing (1), white on thrust plate (4) and clutch housing cover (6).
- Insert wire ring (2) into clutch housing (1).
- Insert diaphragm spring (3) with curvature towards the thrust plate (4) into the clutch housing (1).
- Insert thrust plate (4), clutch plate (5) and clutch housing cover (6) into the clutch housing (1).
- Tighten screws (7) to hold clutch in position.
- Centre clutch plate (5) with centring mandrel, BMW No. 21 2 673, and centring bar, BMW No. 21 2 672.
- Tighten screws (7) in succession, in diagonally opposite sequence.
Tightening torque:
- Housing cover to clutch housing — 18 Nm