23 BMW 1983 R100RS Remove Transmission

With the air box and swing arm removed, I can remove the transmission. It is secured to the engine block with three bolts and a nut. To get it out of the frame, I remove the clutch throw-out rod mechanism from the back of the transmission and the foot shift mechanism.

Remove Clutch Throw-out Arm

On the 1983 transmission, the throw-out arm is secured with a bolt, nut and washer.

Throw Out Arm Mounting Detail

Throw Out Arm Mounting Detail

Throw Out Arm Mounting Detail

Throw Out Arm Mounting Detail

Throw Out Arm Mounting Detail

Throw Out Arm Mounting Detail

Remove Throw Out Arm

Remove Throw Out Arm

Throw Out Arm Mounting Hardware Detail

Throw Out Arm Mounting Hardware Detail

Throw Out Arm Mounting Hardware Detail

Throw Out Arm Mounting Hardware Detail

Throw Out Arm Out of Bushing

Throw Out Arm Out of Bushing

Throw Out Arm Removed

Throw Out Arm Removed

There is a clutch adjuster nut on the throw-out arm. This adjusts clutch engagement.

Throw Out Arm Adjuster Detail

Throw Out Arm Adjuster Detail

Then I remove the rubber bellows that is secured with a steel strap. I use a screw driver to get the bellows off the housing. Inside the bellows is a return spring for the throw-out arm.

Throw Out Arm Bellows Strap

Throw Out Arm Bellows Strap

Remove Throw Out Rod Bellows Strap

Remove Throw Out Rod Bellows Strap

Throw Out Rod Strap Removed

Throw Out Rod Strap Removed

Remove Throw Out Rod Bellows

Remove Throw Out Rod Bellows

Throw Out Rod Bellows and Spring

Throw Out Rod Bellows and Spring

Remove Foot Shift Adjustment Linkage

The foot mechanism is attached to the transmission shift shaft lever and the left foot peg assembly.

Shift Lever and Adjuster Linkage

Shift Lever and Adjuster Linkage

The foot shift adjustment linkage has a wire clip that secures the cup end of the linkage on the ball of the foot shift lever. I remove the wire clip and then press the cup of the shift adjuster linkage off the ball.

Shift Lever Adjuster Wire Clip

Shift Lever Adjuster Wire Clip

I use the screw driver blade to push the end of the wire clip out of the groove in the cup end of the adjustment linkage and then I rotate the wire 180-degrees. Then I pull the wire out toward the rear.

Remove Shift Lever Adjuster Wire Clip

Remove Shift Lever Adjuster Wire Clip

Remove Shift Lever Adjuster Wire Clip

Remove Shift Lever Adjuster Wire Clip

Shift Lever Adjuster Wire Clip Detail

Shift Lever Adjuster Wire Clip Detail

Sometimes I can pull the shift adjuster linkage cup off the ball with my fingers, but it’s a tight fit so sometimes I use a screw driver blade on the edge of the cup to push it off the ball.

Remove Shift Lever Adjuster From Shift Lever

Remove Shift Lever Adjuster From Shift Lever

Shift Lever Adjuster Cup & Foot Shift Ball Detail

Shift Lever Adjuster Cup & Foot Shift Ball Detail

Shift Lever Adjuster Removed From Shift Lever

Shift Lever Adjuster Removed From Shift Lever

I repeat the procedure on the other end of the shift adjustment linkage that attaches to the transmission shift shaft arm.

Remove Shift Lever Adjuster Wire Clip

Remove Shift Lever Adjuster Wire Clip

Remove Shift Lever Adjuster Wire Clip

Remove Shift Lever Adjuster Wire Clip

Shift Lever Adjuster Wire Clip Detail

Shift Lever Adjuster Wire Clip Detail

Shift Lever Adjuster Removed

Shift Lever Adjuster Removed

Shift Lever Adjuster Detail

Shift Lever Adjuster Detail

Transmission Shift Arm Ball Joint

Transmission Shift Arm Ball Joint

Remove Left Foot Peg and Foot Shift Lever

The shift lever is attached to the left foot peg. The foot peg has to be removed to remove the shift lever.

Location of Left Foot Peg Countersunk Mounting Bolt

Location of Left Foot Peg Countersunk Mounting Bolt

Left Foot Peg Mounting Hardware Detail

Left Foot Peg Mounting Hardware Detail

Remove Left Foot Peg

Remove Left Foot Peg

The washer is not the correct kind. I will replace it.

Left Foot Peg Mount Hardware Detail-Washer is Incorrect

Left Foot Peg Mount Hardware Detail-Washer is Incorrect

Left Foot Peg Mounting Hardware Detail

Left Foot Peg Mounting Hardware Detail

Shift Lever Mounts to Left Foot Peg

Shift Lever Mounts to Left Foot Peg

The shift lever attaches to the foot peg with a countersunk Allan bolt from the back side of the foot peg. I remove it.

Shift Lever Countersunk Allan Pivot Bolt

Shift Lever Countersunk Allan Pivot Bolt

Remove Shift Lever Pivot Bolt

Remove Shift Lever Pivot Bolt

There is a washer between the foot peg and the foot shift lever.

Foot Shift Lever Washer Fits Next To Foot Peg

Foot Shift Lever Washer Fits Next To Foot Peg

Shift Lever Pivot Bolt Detail

Shift Lever Pivot Bolt Detail

The foot shift lever wobbled on the foot peg. There is an aluminum shim that was added to try and fix this. The bushing is wallowed out. I will replace it.

Damaged Shift Bushing Attempted Repair

Damaged Shift Bushing Attempted Repair

Shift Lever Bushing is Wallowed Out

Shift Lever Bushing is Wallowed Out

Remove Transmission and Clutch Throw-out Rod

The top of the transmission is mounted using the left side bolt and right side nut that secure the air box. The left bottom bolt is a blind Allan bolt and the right lower Allan bolt has a nut to secure it. I remove them.

Upper Left Transmission Bolt

Upper Left Transmission Bolt

Upper Right Transmission Mounting Nut

Upper Right Transmission Mounting Nut

Transmission Lower Right Mounting Bolt

Transmission Lower Right Mounting Bolt

There is minimal clearance on the bottom left bolt for an Allan wrench. I break the bolt free and then back it out with my fingers.

Remove Transmission Lower Left Bolt

Remove Transmission Lower Left Bolt

Remove Transmission Lower Right Bolt

Remove Transmission Lower Right Bolt

Transmission Lower Left Bolt Detail

Transmission Lower Left Bolt Detail

Transmission Lower Right Bolt

Transmission Lower Right Bolt

Remove Transmission Lower Right Bolt

Remove Transmission Lower Right Bolt

Transmission Lower Right Bolt Detail

Transmission Lower Right Bolt Detail

Transmission Lower Right Bolt Detail

Transmission Lower Right Bolt Detail

After the bolts are removed the transmission will hang by the output shaft.

Transmission Ready to Remove

Transmission Ready to Remove

I use a magnet to pull out the clutch throw-out bushing and ball bearing from the throw-out arm hole in the back of the transmission.

Throw Out Rod Bushing

Throw Out Rod Bushing

Removing Throw Out Bushing With A Magnet

Removing Throw Out Bushing With A Magnet

Throw Out Rod Bearing and Bushing Detail

Throw Out Rod Bearing and Bushing Detail

Throw Out Rod Bushing Rear Face The Throw Out Lever Engages

Throw Out Rod Bushing Rear Face The Throw Out Lever Engages

I pull the transmission back off the clutch spline to expose the clutch plate push rod. I push it to the rear to remove it.

Clutch Push Rod Extends Through The Center of The Transmission Spline

Clutch Push Rod Extends Through The Center of The Transmission Spline

Push Throw Out Rod To Rear to Remove It

Push Throw Out Rod To Rear to Remove It

Here is the clutch throw-out rod assembly.

Clutch Throw Out Rod Rear End Bush

Clutch Throw Out Rod Rear End Bush

The rear end of the clutch throw out rod has a bushing that connects to the other side of the ball bearing. It has become welded to the throw out rod.

Bushing On Rear of Clutch Throw Out Rod Has Become Welded to the Rod

Bushing On Rear of Clutch Throw Out Rod Has Become Welded to the Rod

And, there is a garter (retaining spring) from the transmission clutch push rod seal on the clutch push rod.

Clutch Throw Out Rod Detail

Clutch Throw Out Rod Detail with “Garter” Spring From Transmission Input Shaft Seal 🙁

Clutch Push Rod Seal in Rear Transmission Cover-Damaged

Clutch Push Rod Seal in Rear Transmission Cover-Damaged

Someone was not careful when they pushed the rod in from the front of the transmission and caught the garter and pulled it out. If that seal is damaged or the garter removed, the transmission gear lube can migrate down the clutch push rod into the engine bell housing and coat the clutch plates.

The end of the rod is in good shape.  I’ll clean it up and try to remove the frozen ball bearing bushing and reuse it.

Clutch Throw Out Rod Detail

Clutch Throw Out Rod Detail

The bushing shows were on the end the the throw-out arm connects with.

Clutch Throw Out Rod Bushing Wear

Clutch Throw Out Rod Bushing Wear

Here is the clutch assembly.

Clutch Carrier Detail

Clutch Carrier Detail

The amount of oil in the bottom of the clutch bell housing and on the top of the engine indicate the rear main seal is likely leaking and this could also include transmission gear lube from the damaged transmission input shaft seal. The oil pump cover o-ring could be leaking as well. No worries, as I planned to replace the seal and o-ring.

Sign That Engine Rear Main Seal is Leaking

Sign That Engine Rear Main Seal is Leaking

Here is the transmission after it’s removed. You can see a lot of grunge around the outside of the input shaft seal in the middle of the transmission. Indication of gear lube leaking past that seal.

Transmission Front Detail-Grunge On Input Shaft Seal Points to Input Shaft Seal Leaking

Transmission Front Detail-Grunge On Input Shaft Seal Points to Input Shaft Seal Leaking

Transmission Rear Cover Detail

Transmission Rear Cover Detail-Grunge Indicates Engine & Transmission Seal Leaks

Transmission Top Detail

Transmission Top Detail

Transmission Bottom Showing Neutral Switch

Transmission Bottom Detail Showing Neutral Switch

The bushing cast into the transmission where the clutch cable fits is not damaged.

Clutch Cable Bushing Not Cracked

Clutch Cable Bushing Not Cracked

Here is what the bike looks like now the transmission has been removed.

Bike After Transmission Removed

Bike After Transmission Removed

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