BMW Motorcycle (R1100RT, R1100RS, R850/1100GS, R850/1100R). Manual - part 29

23.32

Installing selector forks

L

 Note:

Fit rollers (1) on guide pins and apply some grease 
to the pins.

•

Install selector fork (2) for 5th gear in underside 
of output shaft with short end of guide facing up-
wards.

•

Install selector fork (3) for 1st and 2nd gears with 
central guide in top of output shaft.

•

Install selector fork (4) for 3rd and 4th gears in 
idler shaft with short end of guide pointing down-
wards.

Installing selector drum

•

Swing the selector forks over to the edge of the 
housing.

•

Install selector drum with its recess facing the 
selector shaft pawl (5).

L

 Note:

If necessary, secure needle rollers with grease.

•

Insert selector fork guide pins into selector drum.

•

Install shift fork shafts.

1

5

2

3

4

Clean Bearing

RT230221

23.33

Shimming gearbox shafts

Measuring shaft bearing play

•

Bolt gearbox measuring plate, 
BMW No. 23 4 600, to the sealing face, which 
must be clean.

Tightening torque: ........................................ 9 Nm

•

Using depth gauge, BMW No. 00 2 550, meas-
ure distance between measuring plate and outer 
race of deep-groove ball bearing. 

L

 Note:

Before measuring, strike the shaft in question (out-
put/idler shaft) with a plastic-faced hammer (dead 
action) to force it down onto the base of its 
seat; then measure without delay.

e

 Caution:

Do not strike the seat of a Clean Bearing shaft, as 
otherwise the bearing might no longer be correctly 
seated on the locking ring.

•

Measure distance between measuring plate and 
bearing collar on input shaft.

•

Enter all measurements in a table.

a

see page 23.28

Key to abbreviations used in measurements:
MAb

= Dimension between measuring plate 

and output shaft 

MZw

= Dimension between measuring plate 

and idler shaft 

MAn

= Dimension between measuring plate 

and input shaft

H

= Height of measuring plate

Overall dimensions:
GAb ....................................................... = H — MAb
GZw .......................................................= H — MZw
GAn ....................................................... = H — MAn

00 2 550

23 4 600

RS230240

GAb

GZw

GAn

RS230251

23.34

Measuring gearbox cover

•

Measure dimension between gearbox cover joint 
face and base of bearing seat, taper roller bear-
ing to bearing inner race.

e

 Caution:

Always measure taper roller bearing with oil baffle 
plate removed.
The oil baffle plate is slightly corrugated, which can 
falsify the measurement.

Key to abbreviations used in measurements:
DAb.......................= Cover dimension, output shaft
DZw ......................... = Cover dimension, idler shaft
DAn......................... = Cover dimension, input shaft

•

Enter all measurements in a table

a

see page 23.28.

Clean Bearing

RT230261

DAn

DZw

DAb

RS230270

DAn

DZw

DAb

Clean Bearing

RT230271

23.35

e

 Caution:

To check friction coefficient of taper roller bearings 
on input shaft, only install input shaft in
gearbox.
Bearings must be oiled.

Shimming the gearbox shafts (without Clean Bearing)

Example

Dimensions in millimeters

Output shaft
"Ab"

Idler shaft
"Zw"

Input shaft
"An"

H

60,00 mm
(2.362 in)

60,00 mm
(2.362 in)

60,00 mm
(2.362 in)

–

M (measure!)

= G

D (measure!)

–

G

= clearance without spacers

–

specified end float

0,05 – 0,15 mm
(0.00196...0.0059 in)

0,05 – 0,15 mm
(0.00196...0.0059 in)

+ permitted preload

0,20 mm (0.00787 in)

= thickness of spacers

Shimming the gearbox shafts (with Clean Bearing)

Example

Dimensions in millimeters

Output shaft
"Ab"

Idler shaft
"Zw"

Input shaft
"An"

H

60,00 mm
(2.362 in)

60,00 mm
(2.362 in)

60,00 mm
(2.362 in)

–

M (measure!)

= G

D (measure!)

–

G

= Clearance without shims and 

input-shaft bearing

–

specified end float

0,05 – 0,15 mm
(0.00196...0.0059 in)

0,05 – 0,15 mm
(0.00196...0.0059 in)

0,05 – 0,15 mm
(0.00196...0.0059 in)

= Bearing (input shaft)

and shim thickness

23.36

Removing and installing taper roller 
bearing race

•

Gearbox cover temperature at bearing seat 
100 °C.

•

Depending on tolerance, the bearing shell may 
already slide out of its seat when the housing is 
heated. If necessary, pull bearing race out with 
Kukko counter-support, BMW No. 00 8 562, and 
internal puller,  BMW No. 00 8 561.

•

Remove spacing washers/oil baffle plate.

•

Gearbox cover temperature at bearing seat 
100 °C.

•

Place shims of the calculated thickness in the 
gearbox cover/include the oil retaining plate (1).

•

Using drift, BMW No. 23 4 670, and handle, 
BMW No. 00 5 500, insert the bearing race in the 
gearbox cover while it is still hot.

Checking friction coefficient of input 
shaft taper roller bearing

•

Install gearbox cover

X

 Tightening torque:

Retaining screws.......................................... 10 Nm

•

Using adapter, BMW No. 23 3 670, and friction 
meter, BMW No. 00 2 570, check friction in the 
input shaft taper roller bearing by turning at 
app. 1 revolution per second.

e

 Caution:

To check friction coefficient of taper roller bearing 
on input shaft, only install the input shaft in the gear-
box.
Bearings must be oiled.

Friction value:
Preload 0.2 mm (0.00787 in) = 
friction value 0.5 – 1.0 Nm

00 8 562

00 8 561

j

100

RS230030

00 5 500

23 4 670

1

j

100

RS230032

00 2 570

23 3 670

RS230291

23.37

Installing gearbox cover

•

Slightly grease the shims of the calculated thick-
ness for the idler and output shafts (include oil 
trap plate (1) in the shim thickness) and place 
then flush on the deep-groove ball bearing.

•

Place sliding sleeve (2), BMW No. 23 4 632, on 
the input shaft.

•

Apply a thin coat of Loctite 573 to the housing 
joint face, which must be clean and free from 
grease.

•

Heat the gearbox cover to 100 

o

C.

•

Fit gearbox cover/insert selector shaft and selec-
tor drum in bearings.

•

Preload arm of stop lever spring, attach and 
completely fit gearbox cover.

e

 Caution:

Arm of spring at clutch end of gearbox housing must 
be under preload and must not be dis-placed to-
wards the output end of housing.

•

Tighten down gearbox cover.

•

Insert idle stop (3) (ball and spring) into gearbox.

•

Insert the neutral detent screw with Loctite 243.

X

 Tightening torque::

Retaining screws on gearbox cover  ............ 10 Nm
Neutral detent screw
(clean thread + Loctite 243).......................... 13 Nm

23 4 632

1

3

v

573

v

243

j

100

Clean Bearing

2

RT230281

23.38

Removing and installing input shaft 
seal at housing cover end

•

Drive out shaft sealing ring with punch from the 
inside.

•

Drive in the new sealing ring with a drift and 
sliding sleeve, BMW No. 23 4 630.

23 4 630

RS230290

23.39

Completing assembly of gearbox

•

Install retaining ring (1) in selector drum.

•

Install neutral switch (2).

•

If applicable, install gear display switch

e

 Caution:

Make sure that the O-ring is in good 
condition.

•

Install clutch piston (3), coil spring (4) 
and sleeve (5). 

•

Attach hose clip (6).

•

Install clutch lever (7).

•

Install thrust rod (8).

X

 Tightening torque:

Retaining screw on clutch lever.................... 18 Nm

Lubrication points:
Splines on clutch plate and input shaft
Diaphragm spring contact face at clutch housing
iaphragm spring contact face at driven plate 
Release lever adjusting screw contact face at clutch 
piston.

Lubricant:............................... Optimoly MP3 paste

Oil fill quantity to lower edge of filler screw: 
API GL 5 SAE 90  ...................1.0 l (1.76 Imp. pints)

2

1

7

5

6

4

3

8

RS230300