Gonna pull transmission

[jagarra]

Started work on my bike today, even though I am converting to dual disc I thought would do some maintenance on the rear of the bike first. After I pull the tranny and grease the input shaft, should I do any other items while it is out, like pull swing arm and service anything back on the end of the bike.
I am really leaning on replacing the shocks with a new set of Ikons, saw the deal on e-bay, but I am going with a direct factory order with all the bells and whistles.

[ME 109]

When was the rear main seal last done? Oil pump cover o ring, how old is the clutch friction disc, tranny input shaft seal....
It's a matter of pulling things apart and seeing what is needed. Oil weeps are the best clue.
Of course none of the above can be addressed, without consequence for however long.

I can almost see the little Ikon factory from my home. It's a 5 minute drive. Did you order the 7610 with 4 position rebound damping? Ikon can also substitute shock springs for heavier or lighter, depending.
My 7610 shocks are very good and have a working range from a light rider, to two up loaded for touring.

[jagarra]

On the items you listed I have no idea. I haven't had the bike more than a few years, no telling what was done prior to that. Ran into an issue, had the tranny sliding out but the clutch arm is in the way, hitting the frame. For the life of me I don't see how to pull the pivot pin in there. I can spin it, but I don't see what in the hell holds it in place.

I ordered the shocks today, with the adjustable damping and the /6 covers. Even told them my weight so they would supply correct springs. 2-3 weeks delivery. Just a breath under $500 with shipping and such.

[Rob]

There is an 'e' clip on the shaft. Just inboard one on the bosses. Watch it when it comes out, it will fly!

You will probably have to drop the swingarm to allow the box to move rearward enough to clear.

[Rob]

[ME 109]

Just a breath under $500 with shipping and such.

That's ok. I paid $440 for mine, direct from Ikon.
You'll like the shocks, they work very well and can handle a ton of hard work.

[jagarra]

Thanks Rob,

Tranny sitting on bench now. My clip may have been an original, had a turned up lip on it so it could be grabbed easier. First inspection before cleaning looks like no leaks on input shaft, dry, just lots of clutch dust. Taking a scribe to the splines, no step where it goes from riding on the clutch to the seal. Original tranny, clock says 111k miles on it.

May pull clutch/pressure plate to see what's underneath. Looks like it is held on with allen head. Never been into one of these bikes before. My manual is for a factory trained mechanic, so it leaves at lot out for a novice.

I did some research on the price of clutch parts, OUCH!!!!!!! If everything bad another $500. Checked Duane's site for info, not much on the /6. Inspection tomorrow.

[Rob]

Sit back and do some reading:

Disassembling the clutch:

around 1/4 the way down the page:
http://bmwmotorcycletech.info/clutch.htm

[Duane Ausherman]

The clutch for the /6 is almost the same as the /5. Be sure to inspect it and measure the thickness of the parts. Remove one of the bolts and take it to a hardware store to buy 2 longer ones. Then remove another bolt directly across from the first one. Screw in the 2 longer ones. Now back out the rest of them. Lastly, evenly back out the remaining shorter bolts.

I would inspect the swing arm bearings. Since they were incorrectly tightened at the factory, it is a small chance that they are OK. I would just plan to replace the seals and bearings. Just don't follow the stupid steps in the manual, or they will be too tight and fail in only a few years.

Check the length of the clutch pushrod. They get worn down.

[jagarra]

Pulled the clutch assemblies out today. Made a flywheel lock and bought three 8x1.0x35 mm bolts long enough that I could use nuts on them to back off the pressure. Had mixed results. the clutch disc had a 2/73 date code on it, thickness was 4.66mm book says min is 4.5mm . Outside plate and spring assembly are the current numbers, haven't measured how much taper is worn into their surfaces yet. Spring height is between 18.00-17.5mm book says 19.0 +-.5. Not looking great on using anything again.