BMW HP2 ENDURO Manual Download

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Service

Service

BMW Motorrad service . . . . . . . 120

BMW Motorrad service
quality . . . . . . . . . . . . . . . . . . . . . . . 120

BMW Motorrad Service Card:
on-the-spot breakdown
assistance . . . . . . . . . . . . . . . . . . . 121

BMW Motorrad service
network . . . . . . . . . . . . . . . . . . . . . . 121

Maintenance work . . . . . . . . . . . . 121

Confirmation of maintenance
work . . . . . . . . . . . . . . . . . . . . . . . . . 123

Confirmation of service . . . . . . . 128

119

Service

Summary of Contents for HP2 ENDURO

Page 1: ...HP2_Titel fm Seite 9 Freitag 28 Juli 2006 12 00 12...

Page 2: ...Rider s Manual HP2 Enduro...

Page 3: ...Motorcycle data dealership details Motorcycle data Model Dealership details Person to contact in Service depart ment...

Page 4: ...in this booklet may differ from the motorcycle s actual specification as pur chased the accessories fit ted or the national market specification No claims will be entertained as a result of such disc...

Page 5: ...rtant data for refuelling Fuel Recommended fuel grade 98 ROZ RON Super plus premium 91 ROZ RON Regular unleaded fuel grade usable with power and consumption related restrictions Usable fuel capacity 1...

Page 6: ...W riders Familiarise yourself with your new motorcycle so that you can ride it safely and confid ently in all traffic situations authorised BMW Motorrad dealer will gladly provide ad vice and assistan...

Page 7: ...topic or item of in formation 1 General instructions 5 Overview 6 Abbreviations and 3 Status indicators 19 Multifunction display 20 Warning and telltale lights 20 Function indicators 20 Warnings gene...

Page 8: ...Clutch 77 Tyres 78 Laying up the motorcycle 102 Restoring motorcycle to use 102 9 Technical data 105 Troubleshooting chart 106 Threaded fasteners 107 Engine 108 10 Service 119 BMW Motorrad service 12...

Page 9: ......

Page 10: ...General instructions General instructions Overview 6 Abbreviations and symbols 6 Air Damping System 7 Equipment 7 Technical data 7 1 5 tions...

Page 11: ...er 10 This record of the maintenance work you Abbreviations and symbols Indicates warnings that you must comply with for reasons of your safety and the safety of others and to pro tect your motorcycle...

Page 12: ...motorcycle might not be exactly as illustrated in this manual on account of country specific differences If your BMW was supplied with equipment not described in this Rider s Manual you will find thes...

Page 13: ...1 8 tions...

Page 14: ...General views General views General view left side 11 General view right side 13 Underneath the seat 15 Handlebar fitting left 16 Handlebar fitting right 17 2 9 iews...

Page 15: ...2 10 iews...

Page 16: ...General view left side 1 Fuel level indicator on fuel tank 62 2 Adjuster progressive characteristic of com pression stage front 50 3 Clutch fluid reservoir 77 2 11 iews...

Page 17: ...2 12 iews...

Page 18: ...General view right side 1 Brake fluid reservoir rear 76 2 Power socket 67 3 Adjuster for rebound stage front 48 4 Brake fluid reservoir front 75 2 13 iews...

Page 19: ...2 14 iews...

Page 20: ...Underneath the seat 1 Battery 95 2 Rider s Manual 3 Toolkit 70 4 Table of tyre pressures 2 15 iews...

Page 21: ...Handlebar fitting left 1 Control odometer 31 Adjuster clock 34 2 Pushbutton horn 3 Pushbutton left flashing turn indicators 41 Pushbutton hazard warning flashers 30 2 16 iews...

Page 22: ...Handlebar fitting right 1 Pushbutton starter 59 2 Emergency off switch kill switch 33 3 Pushbutton right flashing turn indicators 41 Pushbutton hazard warning flashers 30 2 17 iews...

Page 23: ...Instrument cluster 1 Speedometer 2 Warning and telltale lights 3 Multifunction display 4 Sensor for instrument cluster lighting 5 Adjuster clock 34 Control odometer 2 18 iews...

Page 24: ...Status indicators Status indicators Multifunction display 20 Warning and telltale lights 20 Function indicators 20 Warnings general 20 3 19 ators...

Page 25: ...function display Warning and telltale lights Function indicators Gear Shows which gear is en gaged If no gear is engaged the gear indicator shows N and the neutral telltale light also lights up 3 20 a...

Page 26: ...same time all the appropriate telltale lights and warning symbols appear Warnings in text form alternate 3 21 ators...

Page 27: ...iew Mode of presentation Meaning Lights up yellow The EWS warn ing appears on the display Electronic immobiliser active 23 Lights up yellow The FUEL warning appears on the display Fuel down to reserve...

Page 28: ...ngine misfiring and cutting out unexpectedly Misfiring can damage the catalytic converter a hazard ous situation can result if the engine cuts out unexpectedly Do not run the fuel tank dry The estimat...

Page 29: ...ne reason why a warning indicating in sufficient oil pressure is is sued Checking engine oil level 70 If the oil level is too low Top up the engine oil If the warning indicating in Do not continue you...

Page 30: ...The LAMPR warning ap pears on the display A defective bulb places your safety at risk be cause it is easier for other users to oversee you and your motorcycle Replace defective bulbs as soon as possib...

Page 31: ...s defective General warning light lights up yellow The LAMPS warning ap pears on the display A defective bulb places your safety at risk be cause it is easier for other users to oversee you and 3 26 a...

Page 32: ...ation Operation Ignition switch and steering lock 28 Electronic immobiliser EWS 29 Hazard warning flashers 30 Odometer and tripmeters 31 Pneumatic pump 44 Spring preload 45 Damping 48 Tyres 52 4 27 at...

Page 33: ...Keys You receive one master key and one spare key plus a key for removing the seat Please consult the informa tion on the electronic immob iliser EWS if a key is lost or Switching on the ignition Swit...

Page 34: ...y Ignition lights and all func tion circuits switched off Handlebars locked Key can be removed your authorised BMW Mo torrad dealer bar individual keys for example if a partic ular key goes missing Th...

Page 35: ...key Replacement and extra subsequently be cleared and reactivated for use Hazard warning flashers Switching on hazard warning flashers Switch on the ignition The hazard warning flashers place a strai...

Page 36: ...Switching off hazard warning flashers Odometer and tripmeters Operating the odometer reappears on the multifunc tion display 4 31 ation...

Page 37: ...Operating hours counter 4 32 ation...

Page 38: ...range The residual range is only an approximate reading Consequently BMW Motorrad recommends that you should not try to use the full residual range before refuelling Emergency off switch kill switch 4...

Page 39: ...ar wheel to lock and thus cause a fall Do not operate the kill switch when riding The emergency off switch is a kill switch for switching off the engine quickly and easily Clock Setting the clock 4 34...

Page 40: ...ot twist the handlebar fitting or the handlebars Attempting to adjust the clutch lever while riding the motorcycle can lead to accidents Do not attempt to adjust the clutch lever unless the motor cycl...

Page 41: ...Adjustable footbrake lever You can adjust the footbrake lever for riding seated or standing on the footrest pegs 4 36 ation...

Page 42: ...Adjusting handlebars Make sure the ground is level and firm and place the motorcycle on its stand 4 37 ation...

Page 43: ...Handlebars toward rider shorter reach 4 38 ation...

Page 44: ...tom clamping blocks where the large screws are located If necessary slacken screws 1 and retighten screws 2 to the specified tightening torque Tighten small screws 1 to the specified tightening torque...

Page 45: ...is switched on The side lights place a strain on the battery Do not switch the ignition Switching on high beam headlight The high beam headlight is switched on until you re lease the button headlight...

Page 46: ...witch on the ignition Parking lights switched off Headlight Beam throw and air pressure in the Air Damping System Headlight beam throw is gen erally kept constant when the air pressure in the Air Damp...

Page 47: ...Cancelling turn indicators Seat Removing the seat Make sure the ground is level and firm and place the motorcycle on its stand 4 42 ation...

Page 48: ...4 43 ation...

Page 49: ...ing mirrors Adjusting mirror arm Push protective cap 1 over the threaded fastener Pneumatic pump Use You can use the pump to check the pressure in the Air Damping System 45 and in the tyres and increa...

Page 50: ...the top of the pump compress the pump and engage it in the top mount in the seat shell Pull the retaining strap tight around the pump and the frame tube Spring preload can use the valve on the Air Dam...

Page 51: ...he motor Air pressure and temperature When the Air Damping Sys tem is working hard to absorb shocks the air inside the sys tem becomes warmer This causes the air pressure to rise which increases sprin...

Page 52: ...th the adapter The pneumatic pump now has an airtight connection to the valve Turn hose 2 clockwise to screw it as far as possible into threaded adapter 3 The valve is now open Pressurise the Air Damp...

Page 53: ...Two up 9 bar Screw the valve cap onto the Air Damping System valve Sit on the motorcycle hold it upright and allow as much of your weight as possible to rest on the motorcycle 4 48 ation...

Page 54: ...setting influences com pression of the front forks un der load The harder the setting the more the movement that the forks can make to absorb sur becomes harder as spring travel increases Adjusting li...

Page 55: ...as it will go in the clockwise direction then back it off 15 clicks in the counter clockwise the adjusting screw in the direction If you want softer damping use a screwdriver to turn the adjusting sc...

Page 56: ...to turn the adjusting screw in the direction Basic setting rebound stage Adjusting damping for rear wheel Your motorcycle s hand ling will suffer if you do not match the spring preload and damping ch...

Page 57: ...ressure reduces the operating life of the tyres Always check that the tyre pressures are correct Check tyre pressures against the data below Tyre pressure front If tyre pressure is too low Correct tyr...

Page 58: ...Use only the tube valve to in flate the tyre 4 53 ation...

Page 59: ...4 54 ation...

Page 60: ...Riding Riding Safety instructions 56 Checklist 58 Starting 58 Running in 60 Riding off road 61 5 55 iding...

Page 61: ...strut and shock absorber system Imbalanced load Loose clothing Insufficient tyre pressure Poor tyre tread Etc Maximum speeds for tyres Do not exceed the permiss ible gross weight and be sure to compl...

Page 62: ...o not attempt to start or run the engine with a spark plug cap disconnected Stop the engine immediately if it misfires Use only unleaded fuel Comply with all specified maintenance intervals Do not per...

Page 63: ...s com Brakes Brake fluid levels front and rear Clutch Clutch fluid level Shock absorber setting and air pressure in the Air Damping System Tyre tread depth and tyre pressures gear before retracting th...

Page 64: ...below 0 C disen gage the clutch after switch ing on the ignition The start attempt is ing light shows first yellow and then red so that you can check that it is in working or der This pre ride check i...

Page 65: ...refer Exceeding the specified engine speeds while run ning in will lead to increased engine wear Keep to the specified engine speeds for running in Do not exceed the rpm lim its recommended for run ni...

Page 66: ...the tyre frequently on unsurfaced tracks or poor roads Check the thickness of the brake pads more frequently and replace the brake pads in good time Suspension settings The off road settings for air p...

Page 67: ...of the ground will de termine whether it is better to turn the handlebars to the left or right However the mo Removing motorcycle from side stand Unlock the steering lock Switch on the ignition From t...

Page 68: ...e near the fuel tank Fuel expands when hot Leaded fuel will destroy the catalytic converter Use only unleaded fuel Make sure the ground is level and firm and place the motorcycle on its stand are quot...

Page 69: ...kes have dried out Salt on brakes The brakes may fail to take effect immediately if the motorcycle was ridden on salt covered roads and the brakes were not applied for some time Dirt or mud on brakes...

Page 70: ...Accessories Accessories General instructions 66 Grip heating switchOA 66 Power socket 67 Luggage 68 Sporty off roading 68 6 65 ories...

Page 71: ...W parts and ac cessories and other products which BMW has approved BMW Motorrad cannot assess each non BMW product to determine whether it can be used on or in con nection with BMW motor cycles withou...

Page 72: ...ower supply system is minimised the supply to the power socket is cut off ap proximately 15 minutes after the ignition is switched off and it is also temporarily in terrupted during the start pro cedu...

Page 73: ...cycle s handling Do not exceed the permiss ible gross weight and be sure to comply with the instruc Maximum load on guard for rear light 1 kg Sporty off roading Parts supplied with the motorcycle You...

Page 74: ...Maintenance Maintenance Feneral instructions 70 Toolkit 70 Engine oil 70 Brake system general 72 Brake pads 73 7 69 ance...

Page 75: ...ain wear parts Special tightening torques are listed as applicable The tightening torques for the threaded fasteners on your Toolkit A special toolkit has been assembled for the HP2 Enduro and is avai...

Page 76: ...level only after a lengthy trip The insufficient oil pressure warning does not fulfil the function of an If the oil level is below the MIN mark Top up the engine oil If the oil level is above the MAX...

Page 77: ...ol 2 from the toolkit to install cap 1 Brake system general Incorrect working prac tices endanger the reli ability of the brakes Have all work on the brake system performed by a spe cialist workshop p...

Page 78: ...Checking brake pad thickness front brakes Brake pads worn past the minimum permissible thickness can cause a reduc tion in braking efficiency and under certain circumstances they can cause damage to...

Page 79: ...ke pad thickness rear brakes Brake pads worn past the minimum permissible thickness can cause a reduc tion in braking efficiency and under certain circumstances they can cause damage to the brake syst...

Page 80: ...hecking brake fluid level front brakes A low fluid level in the brake reservoir can al low air to penetrate the brake system This significantly re duces braking efficiency Check the brake fluid level...

Page 81: ...brake fluid level at regular intervals Have the defect rectified as quickly as possible by a specialist workshop prefer ably an authorised BMW Motorrad dealer Checking brake fluid level rear brakes 7...

Page 82: ...hop prefer ably an authorised BMW Motorrad dealer Clutch Checking the clutch fluid level Make sure the ground is level and firm and place the motorcycle on its stand Move the handlebars to the straigh...

Page 83: ...Make sure the ground is level and firm and place the motorcycle on its stand Measure the tyre tread depth in the main tread grooves with wear marks Tyres have wear indic ators integrated into the main...

Page 84: ...tyres ap proved by BMW Motorrad for your type of motorcycle You can obtain detailed in formation from your author ised BMW Motorrad dealer or on the Internet at www bmw motorrad com Fitting the auxil...

Page 85: ...in the correct direc tion Note the direction of rotation arrows on the tyre or the wheel rim The brake caliper does not have to be removed for the work described in this manual If the brake caliper 7...

Page 86: ...Front wheel axle screw in axle holder Thread locking compound Optimoly TA 40 Nm Without operating the brakes firmly compress the forks and release repeat 7 81 ance...

Page 87: ...otorcycle on auxil iary stand 84 Engage first gear Installing rear wheel Threaded fasteners not tightened to the spe cified torque can work loose or their threads can suffer damage Always have the sec...

Page 88: ...iliary stand Use BMW Motorrad offers a ser vice stand that holds the mo torcycle securely upright for maintenance work You can obtain the service stand from your authorised BMW Motor rad dealer 7 83 a...

Page 89: ...lbs General instructions A warning appears in the mul tifunction display if a bulb is defective If the brake light or rear light fails the warn ing is accompanied by the General warning light light in...

Page 90: ...t of spare bulbs if possible The bulb is pressurised and can cause injury if damaged Wear protective goggles and gloves when changing bulbs The types of bulb fitted Removing headlight Ignition is swit...

Page 91: ...Pull high beam low beam bulb 3 out of the headlight housing Replace the defective bulb Bulb of low beam and high beam headlight H4 12 V 55 W 60 W 7 86 ance...

Page 92: ...7 87 ance...

Page 93: ...Install three screws 1 Replacing brake light and rear light bulb Make sure the ground is level and firm and place the motorcycle on its stand Removing the seat 42 7 88 ance...

Page 94: ...Pull the rear light back and out of the holders 7 89 ance...

Page 95: ...7 90 ance...

Page 96: ...7 91 ance...

Page 97: ...7 92 ance...

Page 98: ...7 93 ance...

Page 99: ...ng the en gine do not disconnect the battery from the on board electrical system Remove the protective cap from the battery s positive terminal Run the engine of the donor vehicle during jump starting...

Page 100: ...pen the battery Do not top up with water Be sure to read and com ply with the instructions for charging the battery on the following pages Do not turn the battery up side down BMW Motorrad has de velo...

Page 101: ...flat it has to be disconnec ted from the on board circuits and charged with the char ger connected directly to the battery posts Charge via the power sock et with the battery connec ted to the motorcy...

Page 102: ...positive battery lead 2 Remove screw 3 of the bat tery holder Without disconnecting the cables manoeuvre the bat tery holder to the left and lay it over the frame tery holder then turn it to the corre...

Page 103: ...Connect battery positive lead 2 first The connect battery negat ive lead 1 Install screw 3 of the battery holder Installing the seat 43 Set the clock 34 7 98 ance...

Page 104: ...Care Care Care products 100 Washing the motorcycle 100 Cleaning easily damaged components 101 Paint care 101 8 99 z Care...

Page 105: ...ctice Washing the motorcycle BMW Motorrad recommends that you use BMW insect re mover to soften and wash off insects and stubborn dirt on painted parts prior to washing the motorcycle To prevent stain...

Page 106: ...t lens made of surfaces can produce scratches Soften stubborn dirt and insects by covering the affected areas with a wet cloth Chrome Use plenty of water and BMW Take care not to bend the fins when cl...

Page 107: ...ting BMW Motorrad recommends applying only BMW car wax or products containing carnauba wax or synthetic wax The best way to see whether the paint has to be protected is that water no longer forms that...

Page 108: ...pressure in the Air Damping System and adjust if neces sary 8 103 z Care...

Page 109: ...8 104 z Care...

Page 110: ...Technical data Technical data Troubleshooting chart 106 Threaded fasteners 107 Engine 108 Riding specifications 111 Clutch 111 9 105 data...

Page 111: ...Kill switch activated Kill switch in operating position run Side stand extended and gear engaged Retract the side stand 58 Gear engaged and clutch not disengaged Select neutral or pull clutch lever 58...

Page 112: ...Threaded fasteners Handlebars Value Valid Handlebar clamping block to fork bridge M10 x 100 grease thread Optimoly TA 38 Nm Handlebar to handlebar clamp ing block 9 107 data...

Page 113: ...Front wheel Value Valid Grease threads M22 x 1 5 Elox H Optimoly TA 40 Nm Rear wheel Value Valid Rear wheel to wheel carrier M10 x 53 x 1 25 Tighten in diagonally opposite 9 108 data...

Page 114: ...min 1 Maximum permissible engine speed 7800 min 1 Idle speed 1150 50 min 1 Fuel Recommended fuel grade 98 ROZ RON Super plus premium 91 ROZ RON Regular unleaded fuel grade usable with power and consu...

Page 115: ...n A2 or bet ter BMW Motorrad recommends not using synthetic oils for the first 10 000 km Please do not hesitate to contact your authorised BMW Motorrad dealer if you have any ques tions relating the c...

Page 116: ...ding specifications Top speed 200 km h Maximum speed with massive bar tyres comply with tyre specific speed restrictions Clutch Clutch type Single dry plate with high leverage pressure plate 9 111 dat...

Page 117: ...Rear wheel drive type Shaft drive with bevel gears Final drive gear ratio 2 82 1 Running gear Front suspension type upside down telescopic fork Front suspension total suspension travel 270 mm at wheel...

Page 118: ...rake with 2 piston floating caliper and floating brake disc Brake pads front wheel material Sintered metal Rear brakes type hydraulically operated disc brake with 2 piston floating caliper and fixed d...

Page 119: ...sure front 2 2 bar One up tyre cold with OA Rear footrest 2 2 bar Two up and or with luggage tyre cold Tyre pressure rear 2 5 bar One up tyre cold with OA Rear footrest 2 5 bar Two up and or with lugg...

Page 120: ...urer and designation Bosch YR5LDE Spark plug electrode gap When new 0 8 0 1 mm Spark plug electrode gap Wear limit 1 mm Lighting Bulb of low beam and high beam headlight H4 12 V 55 W 60 W Parking ligh...

Page 121: ...Frame Frame type Tubular steel spaceframe drive unit not load bearing Type plate location on steering head left Vehicle identification number VIN location on steering head right Dimensions 9 116 data...

Page 122: ...Weights Unladen weight 195 kg DIN unladen weight ready for road 90 load of fuel without optional extras Permitted gross weight 380 kg Maximum payload 185 kg 9 117 data...

Page 123: ...9 118 data...

Page 124: ...Service Service BMW Motorrad service 120 BMW Motorrad service quality 120 BMW Motorrad Service Card on the spot breakdown assistance 121 10 119 rvice...

Page 125: ...supplied with the latest technical information and have the necessary tech nical know how BMW Mo torrad recommends that you contact your authorised BMW Motorrad dealer if you have ularly preferably b...

Page 126: ...xtensive brochures along with information on Mobile Service and the dealership network BMW Motorrad service network BMW Motorrad has an ex tensive after sales service network in place to look after Ma...

Page 127: ...within a year BMW Inspection After the first 20 000 km from your authorised BMW Motorrad dealer Maintenance work for sporty off roading Sporty off roading particu larly in muddy sandy and wet terrain...

Page 128: ...of maintenance work BMW Pre delivery Check Carried out in accord ance with manufacturer s instructions BMW Running in Check Carried out in accord ance with manufacturer s instructions Odometer reading...

Page 129: ...with manufacturer s instructions BMW Service BMW Annual In spection BMW Service BMW Inspection Carried out in accord ance with manufacturer s instructions BMW Service BMW Annual In spection BMW Servic...

Page 130: ...with manufacturer s instructions BMW Service BMW Annual In spection BMW Service BMW Inspection Carried out in accord ance with manufacturer s instructions BMW Service BMW Annual In spection BMW Servic...

Page 131: ...with manufacturer s instructions BMW Service BMW Annual In spection BMW Service BMW Inspection Carried out in accord ance with manufacturer s instructions BMW Service BMW Annual In spection BMW Servic...

Page 132: ...with manufacturer s instructions BMW Service BMW Annual In spection BMW Service BMW Inspection Carried out in accord ance with manufacturer s instructions BMW Service BMW Annual In spection BMW Servic...

Page 133: ...of service The table is intended as a record of maintenance warranty and repair work the installation of optional accessories and if appropriate special campaign recall work Item Odometer reading Date...

Page 134: ...Item Odometer reading Date 10 129 rvice...

Page 135: ...ary stand 83 Brake fluid checking fluid level front brakes 75 Checking fluid level rear brakes 76 Reservoir front 13 Reservoir rear 13 Brake lever Adjusting footbrake lever 36 replacing low beam and h...

Page 136: ...116 E Electrics Topping up 71 Warning engine oil pres sure 24 Equipment 7 EWS Function description 29 Warning 23 F Final drive G Gear indicator 20 Grip heating 17 66 H Handlebar fittings Feneral view...

Page 137: ...Overview 18 Lights Switching off parking lights 41 Switching on high beam headlight 40 Switching on low beam headlight 40 Switching on parking lights 40 O Odometer and tripmeters 20 Operation 31 Rese...

Page 138: ...chnical data 112 Spring preload rear Adjusting 46 Air Damping System 13 45 Starter 17 Starting 58 Steering lock 29 Suspension damping front 48 50 adjusting linear component T Technical data Brakes 113...

Page 139: ...oubleshooting chart 106 Turn indicators Left 16 41 Right 17 41 Switching off 17 42 Telltale lights 20 Feneral view right side 13 Laying up 102 Parking 61 Restoring to use 102 Vehicle identification nu...

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