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The first time I rebuilt a transmission I relied heavily upon the video from Cycle Works BMW -
http://www.cycleworks.net/index.php?main_page=product_info&cPath=29_35&products_id=243

Another excellent source of information are the youtube videos - the bit below is from an earlier post in another thread -

There is a nicely documented series of videos on YouTube that show the overhaul process for an airhead 5 speed transmission. Links for these videos follow. These videos are by a fellow going by the name "Moto Phoenix".

R100RS Gearbox Overhaul Part 1 Special Tools
https://www.youtube.com/watch?v=qqaXNmJ3Igg

R100RS Gearbox Overhaul Part 2 Dismantling the Gearbox
https://www.youtube.com/watch?v=cx_F8416uDk

R100RS Gearbox Overhaul Part 3 Inspection
https://www.youtube.com/watch?v=boMi-ouHcqI

BMW R100RS Gearbox Overhaul Part 4 Gear Pawl Spring and Input Shaft
https://www.youtube.com/watch?v=9JJy8T2AWUc

BMW R100RS Gearbox Overhaul Part 5 Counter Shaft and Output Shaft
https://www.youtube.com/watch?v=7UXcXqoS6Kc

BMW R100RS Gearbox Overhaul Part 6 Measuring Bearing Extension
https://www.youtube.com/watch?v=MZTfH7RPeU8

BMW R100RS Gearbox Overhaul Part 7 Measuring End Cover and Final Assembly
https://www.youtube.com/watch?v=-lf-91SDP1s#t=49.525397
 
Is there a handy way to easily find these links in the future when I've forgotten this post?

This forum area is where the "knowledge" is being kept:

https://forums.bmwmoa.org/forumdisplay.php?76-Links-and-References

Some of those threads can be reached through the link in my signature line.

Also, look at the list of tags at the bottom of this thread. If you type one of those tags into the box, you'll see other threads as well as this one come up after your search. With that, you might be able to track this thread down.

Someone else had a suggestion for a different sort of problem...a way to find the thread he was reading on his last visit. You can copy the URL for this entire thread, or even just your post, and create a shortcut on your desktop. That shortcut will take you directly to the thread. If you end up doing that a lot, your desktop will get a bit cluttered, but you could further put those shortcuts into a special folder on your desktop for organization. That's for Windows...I suppose something similar will work for the Mac.
 
Is it possible to have my local shop disassemble the tranny, and send only the output shaft to one of our reputable sources for machining the groove? This vs shipping the entire tranny to the machinist? I have a local BMW tech who is comfortable reassembling the tranny, but isn't versed in cutting the output shaft groove.
 
I took apart my transmission and send the bare shaft to George Thomas In Kitchener Ontario. He owns Airhead Parts Online, and offers machining services as well as complete rebuilds.
 

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