Removing clutch
Removing clutch from vehicle
Remove the sump guard.
Secure stand, BMW No. 00 1 520, to motorcycle with overlength bushes and screws, BMW No. 001527.
Note:
- Mount a washer on the screw on the right as viewed in the forward direction of travel.
- Depth of thread in tapped bore has been reduced!
Remove the seat.
Remove side panel.
Remove fuel tank fastener.
Caution: Fuel is flammable and a hazard to health. Observe relevant safety regulations.
Seal the fuel feed and return lines with hose clips, BMW No. 13 3 010, and disconnect.
Disconnet breather lines.
Disconnect plug of fuel pump unit.
Remove fuel tank.
Remove the battery.
Caution! Disconnect the negative battery terminal first, then the positive terminal. Connect the positive battery terminal first, then the negative terminal.
Unscrew rear battery mount.
Disconnect the air temperature sensor plug.
Disconnect the diagnostic plug.
Remove air filter cover.
Remove the air filter.
Remove the intake air pipe.
Unfasten air filter box at front and rear.
Disconnect plug/oxygen sensor and remove cable.
Disconnect hose clamps/throttle stub pipes and push the stubs into the air filter box.
Disconnect plugs of injection valves.
Remove holders of injection valves.
Remove injection valves from throttle stub pipes.
Loosen the fasteners securing the right and left footrest plates.
Remove top screws on left and right.
Note: When installing the footrest plates, use the long screws on the right and the short screws on the left.
Remove rear-frame fasteners on left and right at front, but only loosen strut fasteners.
Remove rear silencer.
Remove front silencer.
Remove starter motor cover and disconnect cable to power socket.
Disconnect cables from starter motor.
Remove the starter motor.
Disconnect cable from oil pressure switch.
Disconnect plug of side-stand switch.
Disconnect plug of gear indicator.
Remove the fastener securing the rear spring strut at the bottom.
Remove hydraulic spring adjuster.
Disconnect plug of brake light switch and remove cable.
Remove brake master cylinder and guard from footrest plate.
Remove rear brake fluid reservoir from its holder.
Remove brake line from rear frame.
Remove brake line from swinging arm.
[ABS] Disconnect the plug of the rear ABS sensor.
[ABS] Remove the rear ABS sensor.
Remove rear brake caliper.
Use cable ties to secure the brake caliper to the rear frame.
Remove the clutch bleeding/filler adapter from the rear frame.
Tilt the rear frame up and secure it in this position with a strap attached to the handlebar.
Remove cable ties/wiring harness from air filter box.
Use hose clip pliers, BMW No. 175500, to disconnect hose from rotary breather from air-filter box.
Remove air filter box.
Remove the fuel distributor.
Remove clutch slave cylinder.
Remove the gearbox.
Always use oiled guide pins, BMW No. 23 1 820, when removing or installing the gearbox.
Remove the rear wheel, rear wheel drive and swinging arm together with the gearbox.
Caution! Take care to keep the gearbox at its installed height until the full length of the clutch actuating rod is visible, as otherwise the rod can be bent.
Removing clutch from engine
Lock the clutch housing with special tool, BMW No. 11 5 640.
Remove the clutch.
Installing clutch
Installing clutch in engine
Install clutch housing with crankshaft pin (2) located in bore (1).
Install locking device, BMW No. 11 5 640, to lock clutch housing.
Caution! Always use new screws for housing and cover.
Insert all screws by hand and tighten.
Tightening torque:
- Clutch housing to crankshaft (screw threads lightly oiled)
- Initial torque — 40 Nm
- Tightening angle — 32°
Install clutch.
Caution! Make sure that colour marks on the clutch housing, thrust plate and housing cover are offset 120°.
Secure the clutch with the retaining screws.
Center the clutch plate with centering pin, BMW No. 21 2 673.
Tighten retaining screws in diagonally opposite sequence.
Lubrication points:
- Splines on clutch plate and gearbox input shaft.
- Diaphragm spring contact surface on clutch housing.
- Diaphragm spring contact surface on pressure plate — Optimoly MP3 paste
Tightening torque: Housing cover to flywheel — 12 Nm
Installing clutch in vehicle
Installation is the reverse of the removal procedure.
Note: When installing, fit a new seal on the clutch slave cylinder.