Maintenance BMW I (Stybba)

- replaced small output shaft bearing in transmission. With a NRB (Indian licensed NGK) 6304 C3 bearing

- replaced output seal with the "old style" green seal.

- re-shimmed all the shafts

- replaced spring in rear brake

- replaced missing rubber dampers in rear brake

- replaced missing plastic plugs in wheel

- cleaned and oiled air filter

- checked rear shock (spring is broken), bearings and sleeves need replacing

- replaced rear shock and complete unit (with 110nm spring), including sleeves and bearings.

- welded exhaust bracket (again)

- cleaned in-line fuel filter

- straightened handlebars (still not straight!!)

- removed transmission and checked output seal = ok.

- tightened bolts in transmission housing

- replaced lower accessory socket which had a short

- greased driveshaft. No play = good.

- changed cylinder gasket and o-rings on both sides

- adjusted valves

- changed exhaust gaskets

- Changed oil & filter (20w40)

- fixed box frame right side, cut re-welded with a short extension as well as triangular braces. Now it clears the swingarm with no problem

- Changed gear oil 90w (transmission & final drive)

- re-torqued heads

- updated rubber gaskets on box frame

- re-set valves

- cleaned carbs, and changed o-rings and needle

- installed new triple-tree (top/bottom)

- installed new fork tubes

- replaced lower fork bridge

- new fork oil both sides

- installed new handlebar

- replaced bracket and screw for centerstand bashplate

- replaced missing screws in headlight bracket

- replaced headlight bulb

- replaced lower left transmission bolt (head was stripped)

- replaced two spokes in front wheel

- replaced bearing in clutch lever (frozen)

- replaced missing screws/spacer in fairing

- replaced bolt in fork (to let out oil) with a slightly larger one as the threads in the fork are stripped

- mounted left hand grip with 2 pop rivets.

- straightened both front forks

- straightened wheel shaft

- straightened lower and upper fork brace (lower tripple tree)

- new brake pads (front)

- new steering head bearing (Toyo)

- replaced two missing bolts in the front fender

- adjusted valves

- cleaned carb bowls

- tightened steering head nut

- changed oil, 15w40 (2lt)

- changed transmission/final drive oil, 80w90

- changed left fork seal

- installed new rear brake pads and a new spring

- repacked steering head bearings and re-torqued

- new front tire, Metzeler Enduro 3

- new rear tire, Mentzeler Enduro 3

- fixed centerstand bash plate, which had schered a bolt.

- inserted a wedge into right side box frame to try and keep the frame from hitting the swingarm.

- cleaned/oiled air filter

- cleaned carb float bowls

- adjusted idle settings

- removed and inspected rear shock. Lower connection had some play, but spacer and bearing seemed ok. Re-lubed and put it back together.

- re-welded broken frame (down tube), strengthened front and back

- welded box frame (again), right side

- re-welded broken frame (down tube)

- re-welded box frame (right side)

- seat bracket broke

- replaced lost screw for stone guard with zip tie.

- tightened bolts in the box frame 3 of which were pretty loose.

- welded broken box frame, right side

- welded muffler support bracket

- added .5 lt oil (15w40)

- replaced light relay

- found a broken muffler support bracket (used wire to temporarily hold it in place)

- changed shift lever output shaft seal

- changed oil, 15w40

- changed all the gear oil, 80w90

- checked and cleaned carb floats

- lubricated shift lever

- checked battery fluid leve (one cell a little low)

- lubricated starter switch

- changed fork seal, left fork (again)

- fixed broken headlight adjustment screws with zip ties!

- checked problem with headlight highbeam, bad connection at the headlight

- Lubricated electrical connectors (relays and misc)

- adjusted clutch play

- adjusted the left control switch position on the handlebar

- moved left blinker cable position, as it was being crushed by handlebars when turned

- retorqued steering head bearing

- 1lt oil

- checked tranny oil = ok

- put on a new shift lever rubber cover

- put on a new bump stop on center stand

- Replaced left front fork gasket, it has been leaking pretty bad since Egypt.

- Tire pressure checked

- Adjusted valves

- re-torqued right cylinder (it was leaking a little oil at the block)

- checked the carb bowls

- tightened carb connectors

- oil change, 2lt 20w50

- changed oil filter

- changed gear oil, tranny and final drive

- Replaced, battery and diode board.

The battery held no charge and the system was putting out 16/17v, tried replacing the regulator but that didn't solve the problem. (see FAQ under question 17)

- changed engine oil (20w50)

- changed gear oil rear drive and transmission (80w90)

- 1lt transmission oil.

- 2lt engine oil

- adjusted valves

- tightened the center stand bolts on the right side.

- Left side valves required no adjustment.

- Cleaned (shook out) the air filter and re-oiled it.

- Checked the carb bowls for dust and dirt. Everything ok.

- Cleaned the accessory socket top / bottom.

- Replaced the contacts top / bottom.

- Bottom accessory socket, has a bad ground contact, tried direct wire, but no luck, will need to replace the socket.

- checked tires

- replaced “pilot” light

- checked carb bowls

- checked front brake pads

- Adjusted handlebars up a little

- checked rear shock

- Changed engine oil (20w50)

- Changed transmission oil (1lt)

- Changed final drive oil.

- Lubricated, locks, gps mount, gas cap lock, ignition lock.

- adjusted valves

- replaced 3x valve adjustment screws

- checked center stand screws

- adjusted steering head bearing. 

- Added 1lt. Oil (still a little low)

- New Rear tire (Metzeler Tourance)

- Fixed left rear blinker (contact rusted)

- Installed re-built Ohlins

-   Installed new (used) front forks

-  Replaced lower fender brace (used)

-  Replaced lower fork brace (used)

-  Replaced steering head bearings

-  Fixed luggage frame

-  Replaced side cover (used)

-  Replace front wheel bearing

-  Installed new light/horn switch

-  Installed new handlebars

-  Installed new left front mirror

-  Installed new front brake pads

-   Installed new windshield (used)

-    Oil = 100%