BMW F650 Transmission

BMW F650 with engine out
With the engine removed

It is a 1999 BMW F650. The transmission was slipping out of 2nd gear. This is the process of replacing the gears.

Step 1. Remove the engine. Use the instructions from http://faq.f650.com/main.html

This is the document I wrote about Splitting the engine case_(pdf) Download this document for detailed descriptions of my process for splitting the cases

BMW F650 with engine out
Removing the exhaust and the airbox seemed to be the easiest way to get the carbs out.
BMW F650 with engine out
There isn’t much left after the engine is out.

 

 

 

 

 

 

 

 

 

Engine on the table
Here is the engine out and on the helpful wooden jig described on the F650.com website.
Engine on table. Right side view
I think it would be a real PITA without the jig.

 

 

 

 

 

 

 

 

 

 

 

The valve cover off
The valve cover off

 

 

 

 

 

Cam Shaft view
Top view of those cam shafts.

 

 

 

 

 

Remember to mark those valves
Remember to mark those valves

 

 

 

 

 

cam chain
Remember to keep the cam chain facing the same way. Use some twist ties to keep in together with the sprockets.

 

 

 

 

Ouch! That can be welded. It broke off when the bolt was loosened. It welded up fine in the end.
Ouch! It broke off when the bolt was loosened. That can be welded.

 

 

 

 

 

 

 

welded jug
The bolt hole welded up fine. A little time with a file and a counter bore, it is good as new.

 

 

 

 

 

 

Top of piston
The top of the Piston and Jug

 

Buy a new head gasket.

 

 

Case is split
Read my document before you do this.

 

Spend some good time learning how it works before tearing it all apart. It will help when it comes time to put it all back together.

Case split
My opinion is this is the wrong side to open up. You want to keep all that shifter stuff in place in the right side of the case.
snap rings
removing the snap rings
gears
This is both new and old gears. Can you tell the difference? Very little to make me think this is the cause of the slipping but the new gears fit much more sound. It might just work.
Tools for Transmission.
The type of tools you need to take off those gears.
GE DIGITAL CAMERA
Snap rings are not easy
without the shifter
The gears without the shifter in place
IMG_4396
A work of art
IMG_4393
The case won’t go back together without the counter balancer being in alignment.
IMG_4398
All together and ready for the other half.