BOSCH PERFORMANCE LINE BEARING CHANGE Outline Instructions

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Valerie Wiggins
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1 BOSCH PERFORMANCE LINE BEARING CHANGE Outline Instructions Saturday, 30 June

COMPONENTS 1. Crank shaft 2. Reduction gears 3. Idler gear 4. Security nut for torque sensor 5.

Left-hand outer crank arm circlip 8. Right-hand outer crank arm circlip 9.

Transfer gear from motor to main motor drive assembly 12. Circuit board screws 13. Right hand cover screws 14.

2 COMPONENTS 1. Crank shaft 2. Reduction gears 3. Idler gear 4. Security nut for torque sensor 5. Main motor drive gear and clutch bearing assembly 6. Left-hand crankshaft bearing 7. Left-hand outer crank arm circlip 8. Right-hand outer crank arm circlip 9. Crankshaft gear circlip (not necessary to remove) 10. Left hand crank shaft bearing circlip 11. Transfer gear from motor to main motor drive assembly 12. Circuit board screws 13. Right hand cover screws 14. Right hand motor cover 1. Remove both crank arms and plastic motor outer covers, next remove both crank arm circlips from the crank shaft 2. Remove the 6 T25 Torx screws from the right-hand motor cover Page 2 of 7

3. Gently tap around the outside edge of the motor casing to break the

bearing assembly out of the motor cover.

3 3. Gently tap around the outside edge of the motor casing to break the seal. (Don t worry there is no gasket just a thin re-usable seal bonded to the cover) 4. You will probably have to drift the main motor drive gear and clutch bearing assembly out of the motor cover. Use a soft hammer or lump of wood between your hammer and the drive gear to avoid any damage. 5. Press or knock the main motor bearing from the housing with a hammer and punch or similar. 6. Remove the transfer gear (No 11) from its locating pin (if it doesn't come off with Step 3) Page 3 of 7

7. Remove the wiring plugs from the sockets on the lefthand side of the

Bosch ﬁt a security nut to hold the torque/movement sensor.

If you don t have a specialist tool, you can use a punch or chisel to

9. Remove the 6 T15 torx screws from the printed circuit board (PCB) and

4 7. Remove the wiring plugs from the sockets on the lefthand side of the engine. (This will aid moving the circuit board later on). 8. Bosch ﬁt a security nut to hold the torque/movement sensor. This MUST be removed. If you don t have a specialist tool, you can use a punch or chisel to loosen the nut. It can be replaced by a nice 10 x 1.5mm threaded lock-nut. 9. Remove the 6 T15 torx screws from the printed circuit board (PCB) and gently pry it away from the motor (It is stuck by a few blobs of silicone). DON T pull it away to far! 10. Gently move the PCB up and out the way. Page 4 of 7

11. Remove the torque/movement sensor. 12.

you knock the crank shaft out of the left-hand crankshaft bearing (Again, use a

Remove this circlip and knock the bearing into the motor area from the left-hand

5 11. Remove the torque/movement sensor. 12. The reduction gears (No2) and the crank shaft gear will all come out together when you knock the crank shaft out of the left-hand crankshaft bearing (Again, use a soft hammer or block of wood to avoid damaging the shaft). Keep an eye on the PCB too! 13. You can now access the left-hand crank shaft bearing (No 6) and circlip (No 10). Remove this circlip and knock the bearing into the motor area from the left-hand side. 14. Once the new bearing has been ﬁtted the crank shaft and reduction gears must all go back in as an assembly. Tap the crank shaft into the new bearing and replace the torque/movement sensor. Page 5 of 7

15. When replacing the PCB, take note of the exact wiring route for

50mm lock nut replacing the Bosch security nut. 17.

replacable with specialised equipment and a lot of finger crossing

basis to extend its life as far as possible.

6 15. When replacing the PCB, take note of the exact wiring route for the torque/movement sensor wires x 1.50mm lock nut replacing the Bosch security nut. 17. It s up to you but the right-hand crank bearing would be only replacable with specialised equipment and a lot of finger crossing so I tend to pack this bearing with silicone grease on a regular basis to extend its life as far as possible. (I am working on a solution for righthand bearing replacement, bear with me). 18. Replace both left and right crank arm circlips. Page 6 of 7

7 19. Plenty of silicone grease around the main motor bearing, fit or refit the dust seal. 20. Refit your sprocket, O-ring and crank arms. 21. Job done and we didn t even remove the motor! Page 7 of 7

1. Remove the crankshaft pulley, engine coolant pump pulley and drive belt. 2. Remove the timing belt cover.

DISASSEMBLY 1. Remove the crankshaft pulley, engine coolant pump pulley and drive belt. 2. Remove the timing belt cover. 3. Turn the crankshaft clockwise and align the timing marks so as to bring the No.