BMW Motorcycle (R1100RT, R1100RS, R850/1100GS, R850/1100R). Manual - part 26

23.8

23.9

Removing and installing clutch 
bear-ing/thrust rod/release lever

•

Unfasten and remove brake caliper.

•

[ABS]/[GS/R/RT] Detach plug connector for 
rear sensor and wire.

•

Remove rear wheel.

•

Remove rear wheel drive assembly/heat pivot pin 
to max. 120 °C /remove.

•

[RT] Remove the footrest plates.

•

Remove swinging arm and drive shaft/heat pivot 
pin to max. 120 °C /remove. 

•

Disconnect clutch cable from release lever.

•

Remove release lever (1).

•

Unscrew clip (2).

•

Remove sleeve and spring (3/4).

•

Remove clutch piston (5).

•

Withdraw clutch thrust rod (6).

Lubricating points (arrow):

.......................................Optimoly MP3 compound

•

Install in the reverse order of work.

L

 Note:

Check/adjust clutch operating clearance.

L

 Note:

Check clutch release bearing at piston (5); make 
sure that it moves freely, is not worn and is ade-
quately greased.

1

3

2

4

5

6

RS230021

23.10

Removing and installing gear shift 
pedal

•

Remove retaining bracket (1) and unfasten ball 
head.

•

Remove retaining screw (2) on gear shift pedal.

X

 Tightening torque:

Gear shift pedal to footrest plate
[RS/GS/R] ................................................... 35 Nm
[RT].............................................................. 18 Nm

Removing gearbox

•

Remove dualseat.

•

[RS/GS/RT] Remove side sections of fairing.

•

[RS] Detach inner cockpit panel at fuel tank.

•

[R] Remove fuel tank cover.

•

Unscrew fuel tank mount.

•

Seal, loosen and pull off fuel feed and return line 
using hose clip, BMW No. 13 0 010.

•

Remove vent pipes.

•

Separate plug for fuel pump.

•

Remove fuel tank.

•

Remove battery.

e

 Caution:

Disconnect the negative battery terminal first, then 
the positive terminal. Connect the positive battery 
terminal first, then the negative terminal.

•

Motorcycles with throttle-cable divider, release 
Bowden-cable divider.

•

Unscrew rear battery mount.

•

Remove plug from air temperature sensor.

•

Remove air cleaner cover.

•

Detach air intake pipe and push it into the air 
cleaner box.

•

Unfasten air cleaner box at front and rear.

•

Remove muffler.

•

Separate connector between neutral switch and 
prop stand switch and detach lead.

•

Remove connector from brake light switch and 
lead.

•

[ABS]/[GS/R/RT] Disconnect the plug for the 
rear sensor line and the wire itself.

•

[ABS] brake master cylinder - detach at footrest 
plate.

2

1

RS230321

23.11

•

Remove brake fluid reservoir from holder.

•

Remove rear brake pipe from holder.

•

Detach retaining clip from ball head/shift linkage 
and remove ball head.

•

Take off the footrest plates.

•

Unfasten rear frame screw connections but only 
loosen front strut mounts.

•

Remove suspension strut.

•

Tilt rear frame upwards and secure with strap.

•

Remove rear brake caliper.

•

Unfasten strut at gearbox housing.

•

Heat rear wheel drive pivot pin to max. 120 °C/
loosen.

•

Remove rear wheel.

•

Remove rear wheel drive unit.

•

Remove swinging arm/heat pivot pin to max. 
120 °C and remove. 

•

Press off drive shaft. 

•

Unfasten fuel line from injector and remove.

•

Remove cable connector/wiring harness from air 
cleaner box.

•

Detach return line/oil trap from air cleaner box.

•

Remove air cleaner box. 

•

Disconnect clutch cable from gearbox.

•

[RS/GS/R] Detach starter motor cover and pull 
off wire to power socket.

•

Detach cable from starter motor.

•

Detach oil pressure sensor cable.

•

Detach side stand switch cable.

•

Detach injector cable

•

Detach throttle angle sensor cable.

•

When removing gearbox, pull it out on guide 
pins, BMW No. 23 1 820.

RS230311

23 1 820

23 1 820

RS230011

23.12

Dismantling/reassembling

•

Drain gearbox oil.

•

Remove clutch thrust rod (1).

•

Secure gearbox with assembly fixture, 
BMW No. 23 1 610, to assembly stand.

•

Remove neutral switch (2).

•

Remove retaining ring (3) from selector drum.

•

Unfasten retaining screw on clutch lever (4).

•

Unfasten hose clip (5).

•

Remove sleeve (6), coil spring (7) and clutch 
piston (8). 

Replacing shaft seal on neutral switch

•

Remove shaft seal using a suitable tool.

•

Using light fingertip pressure, insert the shaft 
seal fully.

Direction of installation:

....................................... spring facing oil chamber

23 1 610

4

6

5

7

8

1

2

3

R230020

23.13

Removing gearbox cover

•

Unfasten screw (1) for idle speed detent and re-
move coil spring (2).

•

Remove retaining screws from gearbox cover.

•

Heat gearbox cover to 100 °C at the bearing 
seats.

•

Place sliding sleeve, BMW No. 23 4 632, on the 
input shaft.

•

Press off gearbox cover evenly.

•

Remove ball (3) from neutral stop.

•

Remove spacers (5)/oil baffle plate (6).

e

 Caution:

Do not accidentally confuse spacers!

23 4 632

4

2

1

3

6

5

j

100

Clean Bearing

RT230032

23.14

Removing selector drum

•

Withdraw selector fork shafts (1) from gearbox 
housing.

•

Turn selector forks outwards.

•

Position pawl (2) opposite recess in selector 
drum.

L

 Note:

Avoid damage to rollers (4) on guide pins of selector 
forks.

•

Withdraw selector drum (3), turning it slightly at 
the same time.

•

Remove selector forks.

1

3

4

2

Clean Bearing

RT230041

23.15

Removing gearbox shafts

•

Remove oil baffle plates (1).

•

[1993 model year] Pull input shaft (2) out of 
gearbox housing.

•

Heat output shaft bearing point to 100 °C

•

[Clean Bearing input shaft] Heat bearing jour-
nals of input shaft and output shaft to 100 °C

•

[Full Clean Bearing kit] Heat all 3 bearing jour-
nals to 100 °C.

•

Place sliding sleeve (3), BMW No. 23 4 622, on 
output shaft..

•

[1993 model year] Pull the idler and output shaft 
(4) out of the gearbox housing together.

•

[from 1994 model year on] Pull the input, idler 
and output shaft out of the gearbox housing to-
gether.

Removing and installing input shaft 
sealing ring at housing end

•

Force shaft seal inwards using drift.

•

Drive in the sealing ring with a drift and guide 
sleeve, BMW No. 23 4 650, and with handle, 
BMW  No. 00 5 500.

2

3

1

j

23 4 622

4

100

Clean Bearing

RT230051

00 5 500

23 4 650

23 4 650

RS230051