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Old 10-05-2011, 11:41 AM   #72
Dieselboy OP
Journey not Destination
 
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Joined: Sep 2003
Location: Port of the Gasparilla
Oddometer: 1,122
Started out the day on the drill press and grinder.


Creating a crank locking pin.

102


Creating a shim holder.

103


First parts of the day: radiator brackets.


104


Remove the heat shield.


105


106


Next to go is the side stand kill switch. Trace the wire up to the middle of the bike.


107


Drop the left foot rest mounting plate.


108


Here she is on the bench.


109


Ooops. Did I do that?


110


No more side stand kill switch. No wire to fight during reassembly. Plug is back in place. Wire the red and white together and seal it all with shrink tubing.


111


Pull coils next. Mine came out by hand. No tool required. Book says not to unplug the coils.


112


Unplug oil pressure switch and coolant-temp sensor (vicinity cam chain tensioner).


113


Unscrew ground wire.


114


Unhook throttle cable.


115


116


Disconnect injection valve plugs.


117


Pressure sensor.


118


Throttle valve potentiometer plug. (right side)


119


Clip a bunch of zip ties. Three on this bar. You are not removing the assembly just moving it a little.


120


121


122


Release the clamps on the air intake ducts and plug the ducts. I used shop towels. The clamps have a special tool associate. I used needle nosed pliers.


123


Disengage clutch cable.


124


Separate pressure modulator from the retaining plate. This was a bit confusing at first. But simple in the end. There is a plate with a hole in the middle affixed to the engine. This module is grommeted to it. Pop it up out of the plate. The module stays with the bike.


125


Release the brake lever pin.


126


Unscrew and remove brake lever. Watch the spring.


127


Release the brake lines. They stay but it gives some flex when the engine drops.


128


129



Tape up the engine forward edges and the frame rails. It would help if the engine were cleaner. The tape wasn’t sticking. Note the ratchet strap in the center of the pic. At this point I moved them from the handle bars where they were initially to this point which is what BMW shows in the book.



130


Remove left side frame bolts. (There are three but I only have two left because my engine guards used one and that came off as the first item of business on day 1).


131


132


Remove right side frame bolts. Note spacers on this side. At all three points.


133


I put a strap around the front of the engine not wanting it to pitch forward when released from the last bolt. Wasn’t an issue though.


134


Floor jack was in place all night. Now we use it to lower the engine. The unmounted tire was there to act as a bumper. Again not necessary.


135


Wiggle wiggle

136


The back of the engine is in conflict with the frame at this point. So a straight drop is not possible.


137


So the come along is used one click at a time to raise the frame and allows us to push it back away from the engine.


138


She’s free.


139


I estimate the weight at around 150lbs.


140


Now she looks ill.



141


Removing the ABS pressure-modulator bracket.


142


Here’s another look at the modulator. Note the rubber plug on the bottom. That’s what you have to pop up when releasing the brake lines earlier.


143


Next phase is clean up of the engine and then I open her up. Time to remove engine was 7 hours 45 minutes.


According to BMW, apparently I now have 15 minutes theft to repair the cam chain and reinstall the engine.
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The Adventure Continues

Dieselboy screwed with this post 08-26-2013 at 09:58 AM
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