Trans Removal

[Jovial Henry]

Started the trans removal on my 02rt this morning. 1. Have slave removed but can not get push rod out???? I pulled pretty hard with pliers. 2. Also what is the round black thing just below and to the right of the slave. Gear indicator? and how does it come off. Haynes does not mention it. Still need to remove final drive and swing arm. Waiting on Allen wrenches.

[Boffin]

The black round thing is the gear/neutral switch and can stay where it is.

The pushrod can be a swine to get out - it tends to weld itself to the clutch. I found that using self-grip pliers and rotating it freed it off for removal.

 

Andy

[Jovial Henry]

The neutral switch has wires going to it. Can't remove trans with them there.

[Jovial Henry]

Ground down some locking pliers (vice grips) that were too large to get in there. Still no luck. I can rotate it a few degrees and can pry with a bar and it comes back about an inch then pops back in when I release it.

I assume the clutch release (pressure plate) is now ruined? Will the rod come out the clutch side if I slide the trans straight back???

 

 

[dirtrider]

Afternoon Henry

 

On the wire going to that neutral switch?-- Just follow that wire where it goes through the hole on the side of the trans to it's connector on the L/H side of the bike. Then just unplug it & remove the trans with the switch still attached.

 

On that stuck push rod?-- Those can be a pain to get out. If it won't come out with a good hardy pull with vice grips you can slide the trans back with the push rod still in the input shaft. If it has welded itself to the clutch spring then the trans input shaft should pull off over the push rod (will probably bend the push rod unless you can go straight back with the trans until clear of the push rod).

 

If the push rod is stuck on the felt inside the input shaft then it should come out with little damage as it will be capsulated inside the input shaft & stay there during the removal of the trans.

 

[Jovial Henry]

Thanks Guys!!! That is kind of what I thought. I am thinking the input shaft is going to be shot anyway. Is it real difficult to replace input shaft. Wish I had just sold it for scrap. Lots of very good parts plus have extra seats, exhaust, shocks, etc. etc.

[dirtrider]

Afternoon Henry

 

Installing a new input shaft isn't rocket science but can be a bit of a test the first few times as you won't have the proper tools or shaft measuring fixtures. You will need a gear puller or bearing separator to remove the bearings & will have to cobble together a fixture with indicator to set the shaft heights.

 

If you are going to do your own shaft replacement get a GOOD BMW service manual, then read & understand all that needs to be done. Then research online the different work-around's BMW owners have found & used.