
Note: Always install new engine-side and gearbox-side sealing rings for starter motor.
Use one hand to press the starter motor profiled sealing ring on the gearbox side into its groove.
- Install sealing rings.
- Introduce starter motor (5) into bore in crankcase.
Note: If not removed, the main (centre) stand must be retracted to permit installation of the gearbox.

- Secure guide pins, BMW No. 23 1 820, to intermediate flange.
- Apply a coat of Optimoly MP 3 to the splines of the gearbox input shaft.
- Slide gearbox over guide pins, BMW No. 23 1 820, and into position on sleeves of intermediate flange.
Caution: Make sure that pinion of starter motor is correctly meshed with reverser.
- Remove guides, BMW No. 23 1 820.

Note: Apply Loctite 243 to threads of screw (3).
- Position link (4) for reverser against gearbox housing.
- Install screw (3) with threads coated with Loctite 243.
- Tighten all seven screws securing gearbox to intermediate flange.
Caution: To prevent the clutch slave cylinder from tilting, tighten three securing screws alternately and uniformly.
- Install clutch release rod.
- Clean mating surfaces on the gearbox housing and clutch slave cylinder, use new paper gasket.
- Install the clutch slave cylinder.
- Lower frame until cables can be connected to starter motor and generator and reconnect cables.
- Connect power cable for starter motor to terminal on rear frame, use cable ties to secure cables.
- Fully lower the frame.
- Insert gearbox mounting bolt (6) and tighten.
- Insert clutch release rod (7) into gearbox, noting correct installed position.
- Connect selector lever (2) to gearshift linkage.
- If necessary, install screws (1) securing bearing mount to main stand.
- Secure cable for side stand switch to gearbox with cable tie (arrow).
Caution: The alignment of the left-hand rubber mounts relative to the frame is preset at the factory; do not slacken the securing screws.
The rubber mounts do not have to be re-aligned unless the left-hand rubber mount has been replaced.
Note: When lowering the frame, make sure that clearance is adequate on the right between frame and gearbox: do not scratch the surfaces.
- Secure the left/right engine mountings to the cross-member.
- Fully lower the frame.
- Remove workshop crane, BMW No. 46 5 640.
- Install skirt brackets.
- Connect plugs for oxygen sensor, side-stand switch, and coolant-temperature sensor.
- Install actuating unit for reverser, complete with switch unit.
- Install radiators with fans left and right in holders.
- Reconnect plugs and cables for engine and gearbox.
- Install transverse tube.
- Install front drive shaft.
- Install swinging arm.
- Install rear wheel drive.
- Install brake caliper.
- Install inductive sensor for rear wheel drive.
- Install rear wheel.
- Install exhaust system.
- Install left and right battery covers.
- Install left and right rear footrest plates.
- Fill gearbox with oil to correct level.
- Install left and right front footrest plates.
- Install throttle-valve rail with air filter box.
- Install fuel injection rail.
- Install the intake air pipe.
- Install the fuel tank.
- Install tank cover with the control unit for the radio.
- Remove lifting gear, BMW No. 00 1 510.
- Install engine spoiler.
- Install actuating control for reverser.
- Install left and right fairing side sections.
Caution: Connect the positive battery terminal first, then the negative terminal.
- Install the battery.
Quantities:
- Initial filling — approx. 0.6...0.75 (1.06...1.32 Imp. pint/0.63...0.79 US quarts)
- Oil changes — top up oil to bottom of filler neck
Tightening torques:
- Oil drain plug — 55 Nm
- Oil filler/level check plug — 23 Nm
- Selector lever to selector shaft — 9 Nm
- Reverser shift lever to gearbox — 9 Nm
- Gearbox to intermediate flange M8 — 24 Nm
- Link, reverser actuator to intermediate flange M8 (clean thread and Loctite 243) — 24 Nm
- Starter motor to gearbox — 6 Nm
- Gearbox to frame — 70 Nm
- Pinch bolts, rubber mounts — 9 Nm
- Speed sensor for reverser — 6 Nm
- Slave cylinder to intermediate flange — 9 Nm
- Cross-members to engine — 41 Nm
- Pivot mount to gearbox — 41 Nm
- Actuating control, reverser (clean thread and Loctite 243) — 6 Nm
- Footrest plate to frame — 21 Nm
- Cover plate, reverser, to gearbox (clean thread and Loctite 243) — 10 Nm
- Cover of reverser to gearbox — 10 Nm