BMW Motorcycle (R1100RT, R1100RS, R850/1100GS, R850/1100R). Manual - part 27

23.16

Removing/dismantling/reassembling 
selector shaft

•

Remove selector shaft (1).

•

Attach sliding sleeve (2), BMW No. 23 4 612,  and 
pull out selector shaft with washer (3).

23 4 612

2

1

3

RS230060

23.17

Removing and installing detent lever

•

Remove washer (1).

•

Remove keeper (2).

•

Remove stop lever (3) with spring and washer.

Removing and installing shift pawls

•

Remove keeper (4).

•

Remove pawl (5) and spring from pawl holder.

Removing and installing torsion spring

•

Remove retaining ring (6).

•

Remove torsion spring (7) with washers.

Removing and installing selector shaft 
seal 

•

Remove bearing bushing (1) from sliding seat.

•

Force out shaft seal with drift, working from the 
inside

•

Drive in the seal with drift, BMW No. 23 4 611.

•

Install bearing bushing.

1

4

3

5

6

7

RS230071

2

23 4 611

1

RS230100

23.18

Removing deep-groove ball bearing 
from selector drum

•

Remove retaining ring and spacers.

•

Heat gearbox housing to 100 °C.

•

When heated, deep-groove ball bearing will slide 
out of seat.

Shimming selector drum

•

Fit deep-groove ball bearing.

L

 Note:

Retaining ring must locate firmly in groove.

•

Install retaining ring, width 1.0 mm (0.039 in).

•

Measure clearance with feeler gage. 

End-play: ............................... 

< 

0.1 mm (0.0039 in)

•

If necessary, use a wider retaining ring to elimi-
nate play.

Removing taper roller bearing race 
from input shaft and roller bearing 
from idler shaft

•

Heat gearbox housing to 100 °C.

•

Depending on tolerance, the bearing races may 
already slide out of their seat when the housing 
is heated.

•

Pull out taper roller bearing race, if necessary us-
ing counter-support,  
BMW No. 00 8 562, and internal puller,
BMW No. 00 8 561.

•

Pull out roller bearing, if necessary with counter-
support,  
BMW No. 00 8 572, and internal puller,
BMW No. 00 8 573.

j

100

RS230120

RS230130

j

100

RS230110

23.19

Installing deep-groove ball bearing on 
selector drum

•

Heat gearbox housing to 100 °C.

•

Using drift, BMW No. 23 4 640, insert the deep-
groove ball bearing.

e

 Caution:

Bearing must be firmly located.

•

Shim out bearing (zero backlash)/insert retaining 
ring.

End-play: ............................... 

<

 0.1 mm (0.0039 in)

Installing taper roller bearing race on 
input shaft and roller bearing for idler 
shaft

•

Heat gearbox housing to 100 °C.

•

Insert roller bearing with drift, 
BMW No. 23 4 660, and handle, 
BMW  No. 00 5 500.

•

Insert taper roller bearing race with drift,
BMW No. 23 4 670, and handle, 
BMW  No. 00 5 500.

e

 Caution:

Bearing must be firmly located. Note different diam-
eters of taper roller bearing outer races on input 
shaft.

23 4 640

j

100

RS230141

RS230142

00 5 500

23 4 660

23 4 670

00 5 500

RS230143

23.20

Removing and installing deep-groove 
ball bearing and race/roller bearing for 
idler shaft

L

 Note:

If defective, the complete idler shaft must be 
replaced.

•

Pull off deep-groove ball bearing or race/roller 
bearing with universal puller, 
BMW No. 00 7 500.

•

To install deep-groove ball bearing or race/roller 
bearing, heat to 80 °C and push into position.

e

 Caution:

If necessary, drive further on by striking inner race 
only.

e

 Caution:

Be careful of the sealing washer as you heat the 
bearing (Clean Bearing); risk of damage.

00 7 500

RS230181

23.21

Dismantling/reassembling input shaft

•

Clamp input shaft spline in vise with chuck jaws.

•

Relieve tension on retaining ring (1), if necessary 
with gentle blow on bearing inner race.

•

Remove retaining ring/washer (1)

•

Using a universal puller, BMW No. 00 7 500, and 
pressure head (arrow), pull off spur gear (3) 
together with taper roller bearing (2).

•

Remove washer (6), coil spring (5), pressure 
piece (4) and spur gear (3).

•

Pull off the taper roller bearing (7) in the same 
way.

•

Slide on washer (6) with chamfer facing the end 
away from the spring. 

•

Slide coil spring (5), pressure piece (4) and spur 
gear (3) onto shaft.

6

7

5

4

1

2

3

RS230150

00 7 500

RS230160

23.22

•

Use universal puller to tension spur gear against 
coil spring until entire step (arrow) protrudes from 
the spur gear.

•

To install using a press, press on taper roller 
bearing cold, or heat it to 80 °C and position it on 
the input shaft.

e

 Caution:

If necessary, drive further on by striking inner race 
only.

•

Install retaining ring/washer (1) in front of taper 
roller bearing.

•

Fit universal puller under spur gear and press ta-
per roller bearing firmly against retaining ring.

e

 Caution:

To prevent measuring errors when installing shims 
later, zero backlash is required between 
bearing and retaining ring.

•

Using a press, press on taper roller bearing (7) 
cold, or heat it to 80 °C and position it on the 
input shaft.

L

 Note:

If the input shaft has to be shimmed again, do not in-
stall taper roller bearing (7) until measuring work is 
complete.

e

 Caution:

If necessary, drive further on by striking inner race 
only.

00 7 500

RS230170

00 7 500

7

RS230171

23.23

Disassembling/assembling input shaft 
(Clean Bearing)

L

. 

Note:

The 42x52x1.25 (1.65x2.05x0.049) washers are 
installed only for the “interim solution”.
Calculate distances DAn and GAn.
If DAn = 41.28

+ 0.08 

(1.625

+ 0.00315 

)

and GAn = 100.23

+ 0.08

 (3.946

+ 0.00315)

)

install a 42x52x1.25 (1.65x2.05x0.049) washer for 
each.
If DAn = 39.5

+ 0.1

 (1.555

+ 0.00393 

)

and GAn = 99.0

+ 0.1

 (3.898

+ 0.00393

)

do not install 42x52x1.25 (1.65x2.05x0.049) 
washers.

42 x 52 x 1,25

42 x 52 x 1,25

20 x 28 x 0,5

42 x 52 x 0,30
42 x 52 x 0,35
42 x 52 x 0,40
42 x 52 x 0,45
42 x 52 x 0,50
42 x 52 x 0,55

20 x 1,75
20 x 1,85
20 x 1,95

25 x 52 x 15

20 x 52 x 15

7

5

4

1

3

2

6

8

RT230151