I removed the twin front disk brake system and the rear single disk brake system. The rear brake pedal assembly had a kludge repair to fix the wobbling brake lever. And, the rust was so bad on the rear master cylinder linkage that I couldn’t remove the rear brake pedal and had to remove the master cylinder and rear brake pedal together.
I’ve been hosting tech classes for the Colorado Airhead Beemers Club using my small workshop, affectionately called “Brook’s Airhead Garage”. If you live in Colorado and want to join our Down To Meet group, click here and join.
It is a way to help disseminate knowledge about the care and feeding of these 40+ year old motorcycles. I’m hopeful that the more our members know, the more inclined they will be to do their own work, and the longer these motorcycles will keep running.
Last Saturday, one of our members, Chris, brought his 1974 R90/6 in so he can learn-by-doing. We had about 10 others come to lend a hand, kibitz and hang around with like-minded folks.
I wrote up a check list for Chris on how to do this work.
Transmission Spline Lube & Swing Arm Bearing Replacement
Transmission Removal, Lube, Install
Remove air intake tubes and carburetors (leave cables on carbs).
Remove air box clam shells and air filter (leave choke lever connected)
Remove battery box
Remove drive shaft bolts (4)
Remove luggage rack (if attached)
Remove rear brake rod
Remove rear wheel
Remove shocks (not needed if all you do is a spline lub)
Remove drive shaft front nuts (4)
Remove swing arm pivot pins
Remove swing arm
Remove transmission bolts (3) and nut (1)
Slide transmission off splines (protect frame tubes from scrapes)
I’m making progress on getting to where I can remove the electrical system. I finished taking off, and taking apart, the rear fender assembly that includes the license plate bracket with side reflectors, tail light housing, turn signals and stalk, the cowling tool box and the rear wiring sub-harness.
You can see what I found and how I did the work here.
Due to the blizzard in Denver yesterday, I had time to finish up some documentation on the project so far and post it to my site. The focus has been on the fairing disassembly and a catalog of the fairing mounting hardware and where it goes. I found existing parts fiche aren’t very helpful about what fasteners go where.