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
- 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)
- Inspect & clean splines
- Lube splines with Honda Moly 60 paste (or Honda Moly 77 paste)
- Slide transmission back on splines
- Attach transmission bolts (3) and nut (1) & torque
Swing Arm Bearings Removal
- Remove dust caps
- Remove inner bearing race
- Inspect for brineling to outer race and/or damage to inner race
- Replace if necessary
- If replacing swing arm bearings, pull outer races with Cycle Works bearing puller.
- Install new outer races with Cycle Works tool
- Pack inner bearing race with red LP-2 grease
- Install inner bearing race
- Install dust cover
Swing Arm Installation
- Install swing arm pivot pins
- Install drive shaft bolts (4) to transmission output coupling
- Center swing arm
- Torque swing arm pivots and lock nuts
- Recheck swing arm is centered
- Inspect rear drive splines. Clean and lube with Honda Moly 60 or Moly 77 paste.
- Install rear drive on swing arm with new gasket and (4) bolts and washers and torque
- Install shocks and torque
- Install luggage rack (if used)
- Install rear wheel and torque nut
- Install rear brake rod and adjust rear brake
- Install battery box
- Install battery
- Install air box filter and clam shells
- Install carburetors and inlet air tubes
It took about 6 hours to complete this work including a pizza lunch and the general banter that takes the place of wrench twisting at these gatherings.