Transmission Install

A Transmission install is actually not difficult.

Step #1 is making sure the swingarm is unmounted from the frame. It can remain connected to the shocks.

I then took caution to protect the frame:

Protection. Notice the rags too:

Time to prep the transmission. It helps if the shifter and the clutch arm are removed. In my case, i removed the shifter but left the clutch arm mounted:

Time to lube the splines. Make sure the splines are clean of dirt and grime. I use a BMW moly grease. It is sticky stuff. :

Keeping the swingarm and rear wheel pulled back, gently lift the transmission into place. It may take a small wiggle here and there to get the splines to mate with the engine.

Make sure the top right bolt of the engine housing aligns properly with the transmission housing as you mate the splines into the clutch:

Time to tighten everything down.
You need a M8 nut and washer for the top right engine stud bolt.
a M8 x 40mm bolt and washer for the top left mount. (Note, i am not installing the BMW airbox. If i was, there is a retaining clip that mounts to the top left bolt along with a washer intended for the airbox).
a M8 X 85mm bolt, washer and nut for the bottom right mount
and a M8 x 40mm bolt and washer for the bottom left mount.
A 6mm hex socket and wrench does the trick along with a 13mm wrench/socket.

Lastly before you mount the swingarm, Make sure you attach the driveshaft boot. Notice the different ends of the boot. The round end is for the transmission, the oval/rectangular end is for the drive shaft.

Next step… aligning and mounting the swing-arm… stay tuned!

Liberty Tools Video

Had a major setback. Pipe broke in the ceiling of my garage. Insurance wants to demolish my entire garage. The plus side is that i can’t wait to redesign my work area. The bad part is that I was making good headway on the bike.
I wish i had this tool shop where i live… but then again, i’d need a bigger garage.

Starter upgrade

A while back we ordered a new starter from Euro Moto Electrics.
It weighs half as much as the original BOSCH starter. About 6lbs lighter to be exact.

As a result, it doesn’t require the rear mounting bracket the heavy Bosch starters need (#2 in Photo).
The starter itself has threads where it connects near the flywheel so no need for the original nuts. You simply install the bolts from the flywheel side, and tighten the starter to the engine housing.
I plan on keeping the extra plastic cover and wire ring that holds it in place (#10 and #11). It will help keep some of the clutch dust contained.