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It would be a lot easier if we had access to all the special tools that BMW developed to service their motorcycles. I like most others had none so I had to improvise and use standard tools to get the jobs done. Here are a couple of tools that I asked friends to make and that I made myself.

A friend of mine made this tool on the left. It's the tool used to release the wheel-bearing cap. It has to be made with some precision so that the four pins line-up and fit exactly into the bearing cap holes. A little beyond my tool making skills so I asked Peter to make it for me.

The 6203 cam shaft bearing of the engine and 3203 and 6303 bearings of the gearbox reside in blind holes, so they can't be removed by hitting them from behind with a drift. It's said that if you heat the engine or gearbox case that these bearings will just fall out. Well I heated and nothing happened so I had to make this bearing puller to get them out. The nose of the puller clips into the inside bearing race and can then be used to extract the bearing by turning the nut on the threaded bar.

The front 6206 bearing of the crankshaft sits in a bearing carrier, so the bearing can not be pulled using a standard bearing puller. The whole carrier and bearing must be removed in one piece. I made this tool to do the job.

This is a valve spring compressor. It's actually an Ed Korn design except for the fact that he suggest using a large C clamp for the body of the press. I didn't have and couldn't find a large enough C clamp so I just bent a steel bar for the body.

While your adjusting the shift forks of the gearbox, the out put shaft via the 6204 C3 bearing needs to be supported. Unless you have an old gearbox cover that you can cut and modify for the job you must make one yourself. I made this from an 8mm thick piece of aluminum although you could probably use just about any kind of material as long as it's rigid.

This is simply a thick plank of wood with a few large holes drilled into it. It's used to support the gearbox and engine while your working on them on the bench. I saw this on the Ed Korn gearbox rebuild video.

The round disk is the front pressure plate of the clutch assembly. It was bent and no longer useable with the clutch. So I welded on a piece of square steel tube and used it as a very handy brace for when I needed to torque the fly wheel nut, or when I just wanted to prevent the engine from turning.

Home	Tools	It would be a lot easier if we had access to all the special tools that BMW developed to service their motorcycles. I like most others had none so I had to improvise and use standard tools to get the jobs done. Here are a couple of tools that I asked friends to make and that I made myself. A friend of mine made this tool on the left. It's the tool used to release the wheel-bearing cap. It has to be made with some precision so that the four pins line-up and fit exactly into the bearing cap holes. A little beyond my tool making skills so I asked Peter to make it for me.

		The 6203 cam shaft bearing of the engine and 3203 and 6303 bearings of the gearbox reside in blind holes, so they can't be removed by hitting them from behind with a drift. It's said that if you heat the engine or gearbox case that these bearings will just fall out. Well I heated and nothing happened so I had to make this bearing puller to get them out. The nose of the puller clips into the inside bearing race and can then be used to extract the bearing by turning the nut on the threaded bar.
			The front 6206 bearing of the crankshaft sits in a bearing carrier, so the bearing can not be pulled using a standard bearing puller. The whole carrier and bearing must be removed in one piece. I made this tool to do the job.
			This is a valve spring compressor. It's actually an Ed Korn design except for the fact that he suggest using a large C clamp for the body of the press. I didn't have and couldn't find a large enough C clamp so I just bent a steel bar for the body.
			While your adjusting the shift forks of the gearbox, the out put shaft via the 6204 C3 bearing needs to be supported. Unless you have an old gearbox cover that you can cut and modify for the job you must make one yourself. I made this from an 8mm thick piece of aluminum although you could probably use just about any kind of material as long as it's rigid.
			This is simply a thick plank of wood with a few large holes drilled into it. It's used to support the gearbox and engine while your working on them on the bench. I saw this on the Ed Korn gearbox rebuild video.
			The round disk is the front pressure plate of the clutch assembly. It was bent and no longer useable with the clutch. So I welded on a piece of square steel tube and used it as a very handy brace for when I needed to torque the fly wheel nut, or when I just wanted to prevent the engine from turning.