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BMW recommends to have the fluid warmed up when you change, as such you will be working on and near the exhaust - ensure the you take the appropriate safety pre-cautions if you plan to work with the bike warmed up.
Subject bike is a 2005 R1200ST non-abs version
Bike should be on a flat level surface on its center stand and the saddle bags removed.
3/8" Drive Tools:
- Torque Wrench
- 6" Extension
- 15mm Deep Socket
- 16mm Deep Socket
- T45 Torx
- T50 Torx
1/4" Drive Tools
- 6" extension
- T25 Torx
2 small standard screw drivers, short and long blade
- Pro Honda Moly 60 Paste (can obtain from most Honda dealerships)
- BMW 75W90 Gear Oil
- New Nut for strut bolt BMW Part Number 07 12 9 964 676
General Process Review
1 - relocate muffler - not required to remove
2 - remove rear tire/wheel assembly
3 - remove rear caliper
4 - remove speed sensor and wiring from final drive
5 - remove strut connection to drop final drive for draining and spline lubing
6 - drain FD, lube spline
7 - reconnect FD
8 - fill FD
9 - re-install speed sensor
10 - re-install caliper
11 - re-install wheel assembly
12 - re-located the muffler
13 - ride
Here you lossen the muffler clamp and remove the muffler hanger bolt to swing the muffler out of your way
Loosen muffler clamp and push down onto pipe to clear
Remove Muffler Hanger Bolt
Now swing muffler out of the way - if you place your right hand on the tail pipe end and your left by the clamp end you can wiggle slightly and it will easily "walk" it's way down.
Remove the rear wheel - put bike in gear.
Use a T-50 Torx - note bolts have already been removed
Special Note - please look closely at the threads - these bolts are to have NO lubricate or anti-seize or any other substance on them - they come out dry, they go in dry.
Remove the caliper
Use a T-45 Torx and remove the two bolts. Once the bolts are removed, pull caliper off of the bike and support to keep caliper out of the work area.
Loosen the "drain" bolt of the final drive
This is a T-45 Torx
Speed Sensor Removal - Put bike in neutral
Location of speed sensor is shown with screwdriver
Remove securing speed sensor screw with a T-25 Torx
Remove speed sensor wire routing clamp - please note the small detent of clamp recessed in the final drive - this placement is critical for re-assembly so that the disc does not chafe thru the wire - again use a T-25 Torx
Carefully pry off the wire clip off of the mount of the drive shaft section.
Next step is to remove the speed sensor and wiring from the final drive so as to be able to drop the FD section
CAREFULLY pry out the speed sensor - there is some slight resistance due to a sealing o-ring
Move the disc accordingly to be able to maximize clearance for the sensor removal
Wipe off material on the sensor as it is magnetic.
Route speed sensor and wire harness out of the way for the next step