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
Removing the exhaust and the airbox seemed to be the easiest way to get the carbs out.
There isn’t much left after the engine is out.
Here is the engine out and on the helpful wooden jig described on the F650.com website.
I think it would be a real PITA without the jig.
The valve cover off
Top view of those cam shafts.
Remember to mark those valves
Remember to keep the cam chain facing the same way. Use some twist ties to keep in together with the sprockets.
Ouch! It broke off when the bolt was loosened. That can be welded.
The bolt hole welded up fine. A little time with a file and a counter bore, it is good as new.
The top of the Piston and Jug
Buy a new head gasket.
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.
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.
removing the snap rings
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.
The type of tools you need to take off those gears.
Snap rings are not easy
The gears without the shifter in place
A work of art
The case won’t go back together without the counter balancer being in alignment.
All together and ready for the other half.