Originally Posted by ipokebadgers
Does anyone have a picture of where they drilled the hole in the clutch housing? I would like to do that but would like to see where others have put it.
Here are a few pictures of where I drilled the hole on my clutch housing and the clutch slave cylinder....note the depth measurement of how far I drilled the hole from the outside in. In case you're considering ordering the parts, I am also including the parts list I used for my experience. I ordered my slave cylinder and a 12/24 maintenance kit from Beemer Boneyard.
I would strongly recommend cutting a tin can (soup can or soda can) down, bend it so it fits the curve/radius of the slave cylinder so you can protect the walls from your drill bit. Use a good (new) high quality 5/32" (I believe that's the size we used) metal drill bit on you power drill and TAKE YOUR TIME when drilling.
dshealy hit the mark on the loss of power at in 4-5 gears....mine went form 4K down VERY quickly and within 30 miles the power drop was noticeable at 3K RPM....very dangerous if I had to roll-on the throttle to avoid something.
If you are going to do the job yourself, it will take all of two days and cost you ~$700. I would also recommend you buy (unless you already have one) Clymer's Manual
....I read, researched, and referenced it every step of the way! If you take it to the dealer, they quoted me 11-13 hours at a cost of ~$2K-2.3K. I plunged in and volunteered my bike for a Tech Session which cfell hosted in his man cave at his palace! This is definitely a job you want to attack with the use of a bike lift. Sure, it can be done on the ground, but the lift will save your knees, back, and prevent you from getting up and down countless times....just roll around on your roller chair and have the tools close by and the efficiencies go up exponentially (Thanks Chann!)!!
I have absolutely no experience on bike or car maintenance beyond the basics.....given the price for the dealer to do the job, it was an easy decision for me and I learned all along the way!
My best advise is the following:
1. Research the whole process and get organized (tools, parts, shop) before you start. The only tools I purchased was a torque wrench, seal puller, and metric sockets & wrenches....others came to the tech session with their tools that were of great use and cfell has the man cave I wish I could have!
2. Use the Forum as a reference....I found tons of info here and used the PM to contact those I felt would be able to steer me straight.
3. I used Bentonville BMW for my parts....they were great!
4. TAKE YOUR TIME......no need to rush to failure and finding out you missed something or did something wrong after you get it all back together.
I am working on a document with pictures that should help others do this process and provide it in a stepwise procedure.....I may have it finished by next week.
Good luck and I'm sorry you're experiencing this problem.