Coution: Disconnect the negative cable from the battery first, followed by the positive cable.
- Disconnect the battery.
- Remove the left and right fairing side sections.
- Remove actuating control for reverser.
- Remove engine spoiler.
- Remove left and right skirt brackets.
- Remove tank cover with the control unit for the radio.
- Remove fuel tank.
- Remove the intake air pipe.
- Remove the left and right air outlet ducts from the radiators.
- Press left and right radiators with fans out of their holders.
- Remove fuel injection rail.
- Remove throttle-valve rail with air filter box.
- Disconnect fuel lines from engine.
- Disconnect hose (arrow) for crankcase breather.
- Remove front left footrest plate.
- Remove front right footrest plate.
- Remove left and right rear footrest plates.
- Remove left and right battery covers.
- Disconnect plugs for oxygen sensor, side-stand switch, coolant-temperature sensor and gear indicator behind left-hand battery cover.
- Disconnect primary lead from ignition coil.
- Remove exhaust system.
- Fit lifting gear, BMW # 00 1 510.
- Remove rear wheel.
- Remove inductive sensor from rear wheel drive.
- Remove the rear wheel brake caliper, fasten to the rear frame with the inductive sensor using a cable tie.
Warning: Note high release torques.
- Remove rear wheel drive unit.
- Remove swinging arm.
- Remove front drive shaft.
- Disengage gearshift linkage at ball joint (2).
- Remove transverse tube.
- Remove actuating unit for reverser, complete with switch unit.
- If the gearbox is to be fully disassembled, remove the main (centre) stand.
- Cut through the cable strap (arrow) and remove the cable for the side-stand switch.
Caution: The two Torx screws securing the left rubber mount (1) are each marked by a spot of paint: do not slacken these screws.
- Disconnect plug for speed sensor (5) of reverser at right-hand skirt bracket.
- Remove nuts securing cross member to engine at left and right.
- Remove the clutch slave cylinder (8).
- Remove clutch release rod (7) from the gearbox.
- Secure front wheel in position.
- Use workshop crane, BMW # 46 5 640, to raise rear of frame high enough to take weight off gearbox mounts.
- Remove gearbox mounting bolt (6).
Caution: When raising the frame, make sure that there is adequate clearance between the gearbox and the frame on the right and between the upper transverse tube and the generator: always take care not to scratch the surfaces.
- Use workshop crane, BMW # 46 5 640, to raise frame until gearbox and starter motor are accessible.
Note: Disconnect the power cable for the starter motor from the positive terminal on the rear frame.
- Disconnect cables for generator and starter motor (4).
- Compress spring and remove gear indicator switch (9).
Note: If not removed, the main (centre) stand must be retracted to permit removal of the gearbox.
Screw (1) is secured with Loctite 243.
- Remove seven screws (1) securing gearbox to intermediate flange.
- Remove link for reverser (2).
- Pull gearbox out of intermediate flange until stub of input shaft is clear and remove gearbox complete with starter motor.
- If gearbox is to be fully disassembled, remove screw (3) securing starter motor and remove starter motor.