BMW R60/5 4-Speed Gearbox Assembly - BMW Airhead

[@chiefeng6951]

I'm still thinking that your work shop skills and knowledge are awesome!!!!

[@WorkshopRebuild]

I appreciate all your comments, it means a lot to me! Thanks again!! Regards Andreas

[@jusfranx]

This is the best/ most important video you have made so far to help me with my basket case 1970 r75/5! i appreciate you so much and am eagerly awaiting your video on engine assembly, specifically the timing area.

[@WorkshopRebuild]

Thank you SO MUCH for this comment and for your feedback! I‘m so happy this video helped you with your r75/5 gearbox😃👍🏽👍🏽 95% of the engine components are ready for assembly, but I ran into a slight issue with brand new parts I just received🥲 I‘ll have a new video very soon and I really hope I can showcase this engine assembly video ASAP! Thank you for your patience and support😊 Regards Andreas

[@MorningNapalm]

I really like your videos, they are super useful, thanks! I don't need all the American-KZbinr stuff though :D Like "let's get right into it", all the hand-waving, the "in the description just below" and all these formulaic things. Content is king.

[@WorkshopRebuild]

Thanks for sharing your thoughts and giving me valuable feedback! It's much appreciated!! I will consider this while filming new videos. Regards Andreas

[@tunza60]

Demystified the inner workings for me.. Great videos..thanks a lot from Australia.

[@RDHGarage]

This is a great video, and I wish I would have found it before I disassembled my 4-speed. It was super helpful anyway. However, I question the shifter fork adjustment procedure. Following my Clymer manual, I shifted the transmission into neutral and removed all three shafts. I reinstalled only the output shaft so I could see the shifter forks on the dog rings when making adjustments to both forks. I installed an output shaft holder tool and set the transmission on its side to make sure the dog rings were located where they would sit in the riding position. I used a mirror to adjust both shift forks on the dog rings centered in between gears, and marked the shifter forks where the eccentric marks lined up. I removed the output shaft, reinstalled all three shafts (per your video) and adjusted the eccentric marks to my previously marked shifter forks. This ensured that both shifter forks were adjusted correctly, centered between the gears when in neutral.

[@mikedall9527]

I am working my way through this video library. I am absolutely astonished by the quality of your production and the depth of your knowledge. These are absolutely superb visual and factual references for anyone looking to maintain or restore one of these excellent, older German machines. Thank you for your dedication. Fantastic!!!

[@WorkshopRebuild]

Hello Mike, thank you for watching my video series and leaving such an amazing comment! Some assemblies like this gearbox take a long time to film and edit, but that's just part of the process...and I enjoy every second of it!! These bikes are half a century old and it will probably only get harder to repair these bikes as time goes by. My goal is to share as much information as possible so that likeminded enthusiasts can wrench on their own bikes in the future. I will continue to work on this bike until completion and I hope to be finished this coming summer. Thanks again for your kind words! Regards Andreas

[@mikedall9527]

Keep them coming....please! 👍🙂

[@johneastman1905]

I must say … That You do a very fine job of explaining and illustrating the whole process. There are fine books, but your carefully made videos are the best education plausible !

[@WorkshopRebuild]

Hello John, thank you for your valuable feedback and very kind comment! I always to share as much as I possibly can. Hopefully this way my videos will help fellow enthusiasts manage their own BMW projects. Thanks again for tuning in! Regards Andreas

[@johneastman1905]

@@WorkshopRebuild I would like to respond by saying that I have just sent this video to a friend Bruce here in New England, he is well know and respected for his fine skills Pin Striping BMW, but will most certinly enjoy.

[@adlinnes]

What an amazing undertaking! I am in awe. Thank you for doing this & sharing. I have a 1976 R100S, so an update on your machine, but OMG! what helpful videos you are sharing. Thank you so much. They will be very helpful come the day I decide to turn a spanner on my bike. Thank you from a very impressed Australian.

[@WorkshopRebuild]

Hello Andrew, thank for your amazingly positive comment and feedback! You have yourself a very neat machine and yes, BMW already made some neat improvements between the 1972 and 1976. I am trying to share as many videos as I can, so other BMW enthusiasts can work on their own bikes. The R100S has a 5-speed gearbox instead of the old 4-speed gearbox, like the one you see in this video. I have some other projects lined up and maybe you'll see something that is closer to your bike very soon! If you ever have any questions, feel free to leave another comment and I'll try to answer as best I can. If you need to send pictures along with your questions, you can email me (My email is in the description of each video). Thanks again for watching all the way from Australia!! Greetings from Canada! -Andreas

[@リトルピピン]

こんな詳しいギアボックスの組み立て動画は初めてです。 細部をクリアーな拡大映像で示していただき、大変参考になりました。 ありがとうございました。

[@WorkshopRebuild]

I'm glad you found this video informative and thank you for leaving such a great comment! Regards Andreas

[@rvanderw998]

Wonderful step by step video that will help anyone undertaking a transmission rebuild... well done!

[@WorkshopRebuild]

Thank you for your positive words Richard! I always try to share as much as I can, so fellow enthusiasts can follow along. I hope as I share these videos it will encourage BMW airhead owners to prolong the life of their bikes, with a little bit of maintenance or repair. Thanks for tuning in, Regards Andreas

[@dcxplant]

Your shopcraft and mise en plas is just 👌

[@WorkshopRebuild]

Thank you for your kind words!!

[@cratecruncher4974]

That was pretty thorough gearbox rebuild video! Loved the home made tools. I'm surprised how simple the gear and slider rings engage. No synchro teeth to wear.

[@WorkshopRebuild]

Thank you very much for your positive feedback on this video!! Since I don‘t have all the „OEM BMW tools“ I have to come up with my own tools to proceed with the assembly. Most of the time it works out in my favour😁 This gearbox is fairly simple as it‘s still a design from the 60‘s BMW airheads…just surrounded in a different gearbox housing. I appreciate your comment! Regards Andreas

[@John-in-Boothbay]

Best explanation of a gearbox operation/assembly I've seen - very thorough!

[@WorkshopRebuild]

Thank you for your kind words John! I always try to share as much knowledge as I possibly can. Hopefully this will help many BMW Airhead riders out there. Regards -Andreas

[@mannewolf308]

Wow. Great Job. Great explanations. This is the best BMW /5 Gearbox video I have ever seen. Thank you very much. Sorry for I can not do more than one Like. I would give you a ten likes. Thanks.

[@WorkshopRebuild]

Hi Manne, thank you so much this comment! I tried to bundle as much information as possible into this video and I hope many viewers can benefit from this. Regards Andreas

[@bertcuthbert6332]

excellent video and spoken in a way most of us can understand

[@felixschopf6423]

It's a dream to have a video like yours! First thought I have to create my own 3D model for the printing. But than saw your description, you provide it for free... Awesome Andreas!! Thank you for that! Also you make me feel way more safe with the rebuild of my r50. With your help its a piece of cake...in comparison to the books. Appreciate your work man!

[@WorkshopRebuild]

Felix, thank you so much for your uplifting comment and thank you for your support with a Super-Like! I'm doing my best to share as much as I can, by offering videos, helping in the comment section and providing valuable links to the topics I discuss. With a couple tools and a little bit of patience, I believe you will be able to rebuild your transmission without any issues. If you do have any, feel free to reach out to me in the comment section or via email (My email is in the description of every video). I wish you a fun time once you start to work on your BMW R50! Thanks again!! Freundliche Grüsse aus Kanada - Andreas!

[@arjuckes]

Very clear, a baby cound recondition a BMW gearbox now!!

[@WorkshopRebuild]

Hi Andrew, thank you for your kind words! I tried to make this video comprehensible and easy to follow, hence all the chapters in this video. Thanks for viewing, I really appreciate it. Regards Andreas

[@giusepperocchi8161]

Ciao! Gran bel lavoro, Mi piace molto come esegui il lavoro, ordinato e pulito. Al prossimo video! Saluti da Milano Italia.

[@WorkshopRebuild]

Hi Giuseppe! First of all, thank you for your kind words! I like to keep all components clean, but my goal is to make it easier for my viewers to see and understand. I have updates on this motorcycle coming very soon...as you know everything takes time☺️ Thank you for viewing my video and leaving a positive comment. It‘s much appreciated!! Regards, Andreas

[@bohusluptak2872]

Ďakujeme.

[@WorkshopRebuild]

Hi Bohuš! I'm very glad you found this video helpful and I appreciate your generous donation! Thank you very much. Regards Andreas

[@bristolfashion4421]

one day a small spring in my gear box snapped… the lever return spring, I think. Weird that all the other parts are so strong and beefy, while the spring was so weak.

[@WorkshopRebuild]

The return (locating) spring is quite weak, but then again it doesn’t need to be very strong. If it were made of thicker wire, you’d feel it in your left foot if you’d ride often within city limits😁

[@chrisreeves8155]

Fantastic video! Thank you for taking the time to create such a detailed outline of this process. I will definitely reference this when I go to rebuild my gearbox. The shift fork adjustment process alone is worth it's weight in gold, as the 4 speed is unique, and not much out there on how to do it.

[@WorkshopRebuild]

Thank you for tuning in and thank you for your feedback!!! I hope I was able to share enough camera angles within the gearbox, as it is a very small area. The fork adjustment is crucial and if you have any questions just let me know, I'll try my best to help out. -Andreas

[@mjguinan3847]

Really fantastic video Andreas. I have a 71 R60/5 that is a project waiting in line. These videos are so well done and I will reference every step of the way!

[@WorkshopRebuild]

Thank you very much MJ! It's always nice to hear positive feedback like yours!! I'm glad you have an R60/5 as well and I hope with a little bit of "elbow grease" you'll have a fine motorcycle once everything is in place. I'll do my best to document as much as I can until the end. Regards Andreas

[@ffmundt]

Dear Andreas, I just recently found your videos and channel and I have to say that your videos are amaaaaazing!!!!! Sooo much to learn from you!!! Please keep going :) I wish we had a project together :)

[@WorkshopRebuild]

Hi there! Thank you so much for your uplifting comment!! It means a lot to me. I'm glad you're able to learn from my videos and I'll do my best to share more content just like this. I have many videos in line and I'm working on them as I write this comment. Maybe a joint-project with a subscriber would be a cool way to showcase a rebuild. I'm open for a challenge and we'll see what happens in the future! Thanks again for your comment! Regards Andreas

[@thomasmace4096]

Thanks!

[@WorkshopRebuild]

Thank you so much, Thomas. I really appreciate your support!!! Best regards -Andreas

[@Slash7FPV]

Wow, good job! 👍

[@WorkshopRebuild]

Thank you so much😃

[@1lindyloo]

Great vids ❤

[@WorkshopRebuild]

Thank you so much! Regards Andreas

[@dawshill1400]

Well done!

[@WorkshopRebuild]

Thank you so much!😊👍🏽👍🏽

[@HennieBours]

Isn't it needed to add some sealant onto both sides of the gasket in order to make sure that everything is well sealed? At minute 1:03:03 you give a value to torque the nut. Do you need a special tool to hold the flange into position by the four holes in the flange? I saw somebody using a special tool to tighten the big nut.

[@WorkshopRebuild]

If you find your mating surfaces to be uneven you can always use a sealant to help prevent your gearbox from leaking. I usually check them before and if they are straight I only use a gasket. I have not had any flaws with gasket surfaces up until today (while ONLY using a gasket). To remove and retighten the output flange nut, there is a specialty tool...but I do not have that. In the gearbox disassembly video I designed my own holding tool for this. You will probably only need this once, so you can always make something of a flat piece of metal. Great questions once again and thanks for viewing! Regards Andreas

[@HennieBours]

@@WorkshopRebuild Thanks for the complete answers. You're of great help. Thanks.

[@WorkshopRebuild]

You're more than welcome Hennie!

[@cvonp]

Awesome video, thanks! What clearance does your arbor press have? I'm shopping for an airhead to restore and would like to know what is the smallest size arbor required for the rebuild.

[@WorkshopRebuild]

I'm glad you enjoyed it! I will have a few BMW engine videos in the next few days, which you might like. The arbor press I have does not have any indication marks on it, but according to the sizes it should be a 3-Ton unit. From the base to the ram it's exactly 12" and the base is just around 6". With this size you'll be able to press on pretty much any radial bearing. I wouldn't be able to tell you the which arbor press you need, because it depends on the tooling you use. The gearbox shafts are roughly 6" long, but maybe you'll need the arbor press for another part which is longer. It's hard to say exactly which one you should get. Work on the bike and then as you run into issues, find an arbor press that suits your needs. Bigger is always better. Regards Andreas

[@cvonp]

@@WorkshopRebuild Thanks, Andreas. Much appreciated =)

[@HennieBours]

Is it possible to tap the new bearings with a hammer on to the shaft or do you need a press?

[@WorkshopRebuild]

Hi Hennie, yes that is possible but you must be very careful. I would suggest if you choose this method to warm up the inner race of the bearing and cool the shaft. This way merging the parts will be much easier for you.

[@HennieBours]

@Workshop Rebuild Thanks. I'll try that method first in the future. 💪

[@jimwilson8509]

nice video. would love to see more. like a 5speed that many of us have. too bad the voice level was lower during the final summation about the measuring procedures. we do have a elder ownership of airheads .... BiG Thanks

[@WorkshopRebuild]

Thank you very much Jim, I will be working on more subassemblies of the BMW R60/5 in the near future. I currently only have one BMW Airhead, but I wouldn't mind accepting a new project down the line. A 5-Speed gearbox would be another lesson for me and I'd love to work on one. I will keep that in mind with the volume levels. I try to keep them on the road!...This bike is much older than me. Regards -Andreas

[@stephendavies2309]

Do u use a shim on the input shaft cover end

[@WorkshopRebuild]

Great question Stephen! The input shaft does have a shim and you can see it at minute 06:55. If you are need of this shim they make them in different thicknesses from 0.38mm up to 1.00mm. According to the BMW parts number it is: 23 21 1 230 448 (This is the 0.38mm shim only)! I hope this helps you determine the shim you need! Regards Andreas

[@Stinopino74]

Great video! Do you want to share the plan for de measuring plate that you printed with a 3D printer? Or can i find that somewere on the internet? Thankx and keep up the great video’s

[@WorkshopRebuild]

Thank you for your comment, it's much appreciated! Yes, I will create a link down below in the description of this video in the upcoming days. I have a couple uploads already on ThingyVerse, but I will make sure this one is up there too for you to download. Once I have this updated I will get back to you with another comment. Thanks for your inquiry, Stino. Regards Andreas

[@WorkshopRebuild]

Hi Stino, I just updated the video description with a link to the 3D Print. If you want here is a quick-link to Thingyverse: www.thingiverse.com/thing:5506928 If I ever upload any other specialty tools, you'll find them there as well. I hope this helps! Cheers

[@Stinopino74]

@@WorkshopRebuild That is super! Thanks verry much. I have two gearboxes to rebuild.

[@WorkshopRebuild]

@@Stinopino74 You're more than welcome! I hope all goes well and just make sure to double or even triple check your shaft heights before putting the cover on. This way you will be sure all shaft bearings have enough clearance.

[@trevorpeel3003]

great vid/tutorial,just one question please.when i installed the gearshift mechanism only and fitted the shifter pedal i found it was very easy to go beyond 1st and 4th gear with no bump stop so to speak and it wouldnt return wih the lever,i had to turn it by hand,,,is this normal or have i done somthing wrong?? thx

[@WorkshopRebuild]

Hi Trevor, thanks for your feedback! The shifting mechanism consists of various components and it's important to install all over them in the correct order. I highly recommend you review the shifting mechanism assembly once more starting at minute 27:09 in this video. It's very possible that you installed your shifting return spring the wrong way around, but there are other parts inline that could have been assembled the wrong way. While shifting you should always rotate your input shaft for the synchronizers to engage more easily. You should feel a bump stop below first gear and above 4th gear. The shifting mechanism and the forks will not allow you to exceed this position, therefore something in your assembly must not be 100% correct. Please let me know what you find out and if you have found a solution, please let me know. I'm curious to know what went wrong. Thanks for sharing this comment. Regards Andreas

[@trevorpeel3003]

i dont think i explained it very well,,i think i ment to say that on initial assembly (without shafts or selector forks fitted)the gearshift cam plate is letting the gear shift pawl go past 4th and 1st gear when test shifting,is this normal until the shafts and selector forks are fitted and functioning properly,,,thankyou Andreas

[@AbBer-y9t]

merci pour cette vidéo :)

[@gavinteakle9208]

What is the white lube you are using during assembly?

[@WorkshopRebuild]

The white lube in this video is Assembly Grease. I have a link in the description to the exact product. I use this on all my engines and transmissions: When applied it acts as a thin grease and when an engine or tranmission heats up, it will turn into oil. I'd highly suggest this product if you like to rebuild mechanical components.

[@gavinteakle9208]

@@WorkshopRebuild Thanks. Loved the vid btw

[@WorkshopRebuild]

I appreciate that Gavin, Thank you! -Andreas

[@martinhjelseth6949]

What kind of grease do you use? Is it a grease that desolves in the gear oil ? And what kind of marker do you use? Is it a marker that does not contaminate gear oil ?

[@WorkshopRebuild]

Hi Martin, the grease I use is called Assembly Grease. This grease is derived from an oil grade ISO 68. This is perfect for engine and gearbox rebuilds and prevents dry-starts, scoring, scuffing and friction during the startup period. The marker I used was oil based and that little amount will not harm the gearbox. Thank you for your great questions and I hope you enjoyed this video. Regards Andreas

[@dmsheckler]

How did you remove the pressed on spring retaining washer for the kickstart ratchet pawl gear on the input shaft? After you removed it did you require a new one as it was a press on fit?

[@WorkshopRebuild]

The gear must be pressed down in order to remove the c-clip. If it's worn or damaged from the side where it touches the gear I replace them. If they aren't damaged, you can reuse them.

[@BrookeFarquhar]

I respect what you are doing. I really do. The videos are a tremendous amount of work, to shoot and edit. The problem, and this is a very important problem, is that people are going to try to do this work based on your techniques and tools. A depth scale, and digital vernier are wholly and completely inadequate for shim calculations. This is not a subjective statement. Your numbers could not have been done accurately enough. A trained/experienced machinist could not have gotten accurate readings with the tools employed. Though the the 'shim plate' is not a requirement (it is the best way). A depth mic IS a requirement. Keep up the good work, but please refrain from 'teaching' things that are outside your skills and experience.

[@WorkshopRebuild]

Hi Brooke, thank you for your comment and acknowledgment. The way I performed the shimming of the shafts in this gearbox video is different than a repair shop and that’s because I do not own a shim plate. Shimming on this gearbox can be done multiple ways and there is not “one correct“ way of doing it. The shims can even be pre-determined prior to the installation process of the shafts, but I didn’t want to share that option with my viewers. The tools I am using in this video are more than accurate enough for measuring shims that are roughly 0.10mm (0.004”) different in thickness. I would argue BMW should have machined their housings more accurately in order to eliminate shims, but that cannot be changed now. I will continue to share as much as I can, but I also don’t personally (not professionally) think it’s necessary to justify my skills or experience, even though some might claim them to be very good. Regards Andreas

[@cozydram1]

I have to say great video again the only thing I would ask you is to get a microphone fitted Close to your mouth as I and maybe others just can't hear you.......yes its partly to do with my old age hearing, it's easier to turn down but in my case the volume is on full even with my headphones on...........it's a shame as your vids are awesome. thank you

[@WorkshopRebuild]

Thank you for your feedback Phil, I really appreciate it! I've recently upgraded my audio equipment and got myself an external microphone. This will help pick up all the sounds when I speak. Another measure I can take is to manually adjust the volume in my editing software, so I will test this again when my microphone is fitted. Comments like your help me create better videos in every way and I always try my best. Thanks again Phil!! Regards Andreas

[@richardr9859]

Thanks!

[@richardr9859]

Great work. Looking forward to more R60 videos.

[@WorkshopRebuild]

Thank you very much Richard! I have been doing many things off-camera to get everything sorted out and I will continue to share video on this BMW R60/5 very soon. Thanks for tuning in! -Andreas

[@WorkshopRebuild]

Thank you for your kind support Richard, it's much appreciated!! 😃👍