BMW K 1200RS Repair Manual Download

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23.17

23 12 Assembling output shaft

Note:

Assembly starts at the shift
gearwheel for 4th gear (9). Before assembly, oil all
friction faces lightly with gear oil.

•

Clamp the output shaft into the vise with soft
jaws and with the splines facing upwards.

•

Install circlip (6/arrow).

•

Install thrust washer (7).

Important:

To avoid damaging the needle roller bearings on the
splines when installing, spread the rollers carefully
at the end faces.

•

Install needle roller bearing (8).

•

Install shift wheel for 4th gear (9) with the pockets
facing circlip (6).

•

Install support washer (10) and needle roller
bearing (11).

•

Install shift wheel for 3rd gear (12) with pockets
facing away from the 4th gear shift wheel (9).

•

Install backup washer (13) and circlip (14).

•

After installing, measure endplay at 3rd and 4th
gear shift wheels.

•

Install shift wheel for 5th gear (15) with recess for
shift fork facing towards the 3rd gear shift wheel
(12).

•

Install backup washer (1) and needle roller bear-
ing (2).

•

Install shift wheel for 1st gear (3) with the pockets
facing towards the 5th gear shift wheel (15).

•

Install spacing washer (4) and grooved ball bear-
ing (5).

–

After installing, check endplay at 1st gear shift
wheel (

23.19).

KR230120

18 17

KR230130

Summary of Contents for K 1200RS

Page 1: ...BMW Motorrad After Sales K 1200 RS Repair Manual ...

Page 2: ...S 2 All rights reserved Not to be reprinted translated or duplicated either wholly or in part without prior written permission Errors and omissions excepted subject to technical amendment Printed in Germany 03 01 Order number 01 79 0 137 531 ...

Page 3: ... a 12 5 Work to be performed during an Inspection is described in Group 00 The various inspection routines are numbered I II III and IV This numbering is repeated in the work descriptions which follow so that work can take place without interruption Use of the BMW special tools needed for certain tasks is described in the work instructions If the need arises repair instructions are also issued in ...

Page 4: ...tial in order to protect the rider or other persons from possibly severe or fatal injury Contents The titles of the tasks described in this chapter complete with page numbers Activities Activities The bullet symbol means that work steps are described in greater detail under another headline Preceding activities A line indicates work steps described in greater detail under another headline or in an...

Page 5: ...id every 2 years at the latest 2 Replace fuel filter generally every 40 000 km 24 000 miles if the fuel is of poor quality every 20 000 km 12 000 miles 40 000 Check coolant level and concentration top up if necessary and check cooling system for leaks Replace the coolant at least every 2 years 2 Check battery acid level if necessary add distilled water Clean grease battery terminals if necessary R...

Page 6: ...r wheel studs for tightness note correct tightening torque Checking and adjusting the motorcycle Check function of side stand contact switch Headlight Seat Spring strut Handlebars footrest system gearshift lever Integral ABS perform bleed test with BMW MoDiTeC Add fuel Final inspection and function check Check engine oil when engine is cold Clutch gearshift mechanism Lights and signalling equipmen...

Page 7: ...without Integral ABS with cruise control Cruise control cable 0 5 0 02 1 1 5 0 04 0 06 2 3 0 08 0 12 mm in mm in on throttle twist grip mm in Tightening torques Oil filter Oil filter cover Engine oil drain plug 11 10 30 Nm Nm Nm Gearbox oil drain plug Gearbox oil filler plug 55 30 Nm Nm Oil drain plug filler plug rear wheel drive 23 Nm Cylinder head cover Cylinder head sealing surface edges half m...

Page 8: ...00 Pre delivery check 00 Maintenance 11 Engine 12 Engine electrics 13 Fuel preparation and control 16 Fuel tank and lines 17 Radiator 18 Exhaust system 21 Clutch 23 Gearbox 31 Front forks 32 Steering Continuation Contents Back Group Chapter ...

Page 9: ... Continuation Group Chapter 33 Rear wheel drive 34 Brake 36 Wheels and tyres 46 Frame 51 Equipment 52 Dualseat 61 General electrical equipment 62 Instruments 63 Lights Back ...

Page 10: ...haust system 6 21 Clutch 6 23 Transmission 7 31 Front fork 8 32 Steering 9 33 Rear wheel drive 9 34 Brakes Integral ABS 10 34 Brakes Optional extras without Integral ABS 11 36 Wheels and tyres 11 46 Frame 12 51 Equipment 13 61 General electrical equipment 14 62 Instruments 14 63 Lights 14 Table of operating fluids 15 00 Tightening torques operating fluids ...

Page 11: ...00 2 Contents Page ...

Page 12: ...block Shouldered bearing Nm 40 Needle roller bearing Nm 18 Lower part of crankcase Nm 10 Oil mesh strainer Nm 10 Oil filter Nm 11 Oil sump Nm 10 Oil filter cover Nm 10 Oil drain plug Nm 30 Freewheel Cover plate Nm 10 Intermediate flange Thrust plate to intermediate flange Nm 9 Clean thread Loctite 243 Intermediate flange to crankcase Nm 9 Driver to auxiliary shaft Nm 50 Crankshaft Rotor flange to ...

Page 13: ...Nm 20 Oil pressure relief valve screw plug Nm 35 Water pump impeller to pump shaft Nm 33 Pump housing to crankcase Nm 10 Pump housing cover Nm 10 Oil cooler Oil lines to oil cooler Nm 25 Model K 1200 RS Connection 12 Engine electrics Spark plugs Nm 20 Ignition coil Nm 9 Ignition trigger Rotor Nm 4 Magnetic gate Nm 6 Ignition trigger cover Nm 9 Alternator Alternator to intermediate flange M8 Nm 21 ...

Page 14: ...ose clips for fuel line Nm hand tight Hose clip at intake stub pipe Nm hand tight Intake stub pipe Nm 9 Retaining clip fastener clips to engine Nm 9 Screws throttle valve actuator Nm 5 Clean thread Loctite 243 Screws throttle valve potentiometer Nm 2 Clean thread Loctite 243 Model K 1200 RS Connection 16 Fuel tank and lines Rubber mounts to frame Nm 22 Fuel tank to frame Nm 22 Fuel pump unit to fu...

Page 15: ... to frame Nm 20 Oxygen sensor to silencer Nm 45 Apply Optimoly TA to thread Retaining plate to silencer muffler Nm 20 Retaining hoop to holder Nm 13 Cover Nm 8 Model K 1200 RS Connection 21 Clutch Clutch housing to output shaft Tighten to Nm 140 Slacken off Tighten to Nm 50 Wrench angle 60 Housing cover to clutch housing Nm 12 Slave cylinder to gearbox Nm 9 Banjo bolts to slave cylinder Nm 7 Fille...

Page 16: ...selector shaft Nm 9 Gearshift pedal to transverse tube pivot bushing Nm 8 Staburags NBU 30 PTM Gearshift lever M6 adjustable Nm 8 Ball end to gearshift lever shift lever Ball head Nm 5 Clean thread Loctite 243 Staburags NBU 30 PTM Gearbox mounts Gearbox to frame Nm 70 Gearbox to intermediate flange Nm 22 Clamp rubber mount Do not release left rubber mount TORX Nm 9 ...

Page 17: ...holders Nm 20 Handlebar holder clamp Nm 21 Clean thread and Loctite 243 Handlebar holder to fork bridge Nm 9 Fork bridge clamp Nm 21 Fork bridge to frame nut micro encapsulated Nm 130 Clean thread and Loctite 2701 Ball joint to fork bridge Nm 230 Lightly grease threads with Optimoly TA Sliding tube bridge Sliding tube bridge to sliding tube M8 Nm 21 Clean thread and Loctite 243 Steering damper to ...

Page 18: ... input bevel pinion Nm 200 Clean thread and Loctite 2701 Oil filler drain plug Nm 23 Rear wheel drive to swinging arm Fixed bearing stud bolt Nm 160 Floating bearing stud bolt Nm 7 Locknut Nm 160 Reaction link Reaction link to rear wheel drive Nm 43 Reaction link to frame Nm 43 Swinging arm to frame Stud bolt left right Nm 160 Threaded ring right Nm 200 Threaded ring left Nm 10 Lock ring Nm 160 Sp...

Page 19: ...e disc to rear wheel drive Nm 21 Clean thread and install new screws Bracket for ABS sensor to rear brake cali per M6 Nm 8 Clean thread and Loctite 243 Master cylinder to footrest assembly Nm 9 Clean thread and Loctite 243 Brake hose line banjo bolt Nm 18 Bleed screw to brake caliper Nm 10 Pressure modulator Pressure modulator to battery holder Nm 10 Filler adapter Filler adapter to brake line Nm ...

Page 20: ...Nm 21 Clean thread and install new screws Bracket for ABS sensor to rear brake cali per M6 Nm 8 Clean thread and Loctite 243 Master cylinder to footrest assembly Nm 9 Clean thread and Loctite 243 Brake hose line banjo bolt Nm 18 Bleed screw to brake caliper Nm 10 Filler adapter Filler adapter to brake caliper right Nm 18 Grub screw in filler adapter Nm 10 Battery carrier Battery carrier to frame N...

Page 21: ...s Intake air pipe to fairing bracket Nm 10 Heat shield to gearbox Nm 22 Heat shield to coil Nm 9 Footrests Front footrest holder to frame Nm 20 Locknut for stop screw foot brake lever Nm 7 Brake pedal Nm 41 Clean thread and Loctite 243 Master cylinder to footrest holder Nm 9 Clean thread and Loctite 243 Brake light switch to footrest holder Nm 5 Fastener for heel angle warning device to footrest p...

Page 22: ...lder front to frame Nm 22 Frame Lower cross tube to frame Nm 41 Cross member left right to frame Nm 74 Cross member to engine left Nm 41 Cross member to engine right Nm 41 Twist lock M8 stud for threaded bushing of swinging arm bearing Nm 2 Clean thread and Loctite 2701 Model K 1200 RS Connection 51 Equipment Mirror M8 Nm 20 Non removable screw ignition steering lock to fork bridge Nm 15 Model K 1...

Page 23: ...n frame Nm 9 Cables to main frame Nm 6 Temperature sensor to cylinder head Nm 30 Fastener side stand switch M6 Nm 5 Clean thread and Loctite 243 Control unit for cruise control to fairing bracket Nm 8 Model K 1200 RS Connection 62 Instruments Instrument cluster to fairing bracket Nm 6 Model K 1200 RS Connection 63 Lights Headlight to fairing bracket Nm 6 ...

Page 24: ... piston pins 11 00 7 660 831 60 g tube MOLYKOTE 111 Water pump water pump chamber shaft sealing rings 11 00 7 660 832 100 g tube Tyre mounting paste Tyres oil sight glass shaft sealing ring in timing case cover 36 32 1 239 263 36 32 1 239 264 2 5 kg 100 g Never Seez compound Lubricating paste for brake carriers 83 23 9 407 830 100 g tube Sealants 3 Bond 1110 B Surface sealant 07 58 9 056 998 5 g t...

Page 25: ...ange Metal Polish Polish for chrome plated parts 82 14 9 400 890 100 g tube Testing agents Penetrant MR 68 Crack testing agent for aluminium housings 83 19 9 407 855 500 ml spray Developer MR 70 Crack testing agent for aluminium housings 81 22 9 407 495 500 ml spray Installation aid BMW chilling spray Cooling spray 83 19 9 407 762 300 ml spray Item Use Order number Quantity ...

Page 26: ...ndscreen 22 Installing mirrors left right 22 Installing bracket for engine spoiler 23 Installing the engine spoiler 23 Filling and charging the battery 24 Remove the battery 24 Filling and charging the battery 24 Installing the battery 24 Checking tyre pressures 25 Checking tightness of rear wheel studs 25 Checking and adjusting the motorcycle 26 Checking the function of side stand contact switch ...

Page 27: ... 18 Contents Page Adjusting footrests left right 28 Adjusting gearshift lever 28 Integral ABS Performing bleed test with BMW MoDiTeC 29 Final inspection and function check 29 Final cleaning 29 Handover 30 ...

Page 28: ...00 19 00 General view of crated motorcycle ...

Page 29: ...sit Notify the supplier without delay e g freight company or DB and also Bavaria Wirtschaftsagentur GmbH Abteilung ZW 12 80788 München Tel 089 14327 632 Fax 089 14327 709 00 00 Damage discovered in importer markets Note the damage on the delivery slip Comply with specific national market proce dures If in doubt please refer your queries to Bavaria Wirtschaftsagentur GmbH Abteilung ZW 12 D 80788 Mü...

Page 30: ...are on account of residual braking function Wait until self diagnosis completes and with ignition switched on push the motorcycle onto the platform The brake booster is active 00 00 Inspecting motorcycle for dam age Check for damage Express message to BMW Motorrad UX VS 1 Fax number 089 382 33220 Rectify the fault If parts are needed order them by using the electronic parts list Costs are to be pr...

Page 31: ...tions Raise the windscreen holder Push the bushings arrows into the holes at the sides of the windscreen 1 Push in the studs 2 from the inside of the windscreen 00 00 Installing mirrors left right L Note Align mirrors and spacers Fit the corrugated washer arrow from below X Tightening torque Mirrors left right 20 Nm K41UB0020 2 1 K41UB0010 ...

Page 32: ...ening torque Lower bracket for engine spoiler 22 Nm 00 00 Installing the engine spoiler Secure the engine spoiler to the lower bracket Secure the engine spoiler to the left and right side panels and to the bracket for the engine spoiler at the front left X Tightening torque Engine spoiler to lower bracket 9 Nm KR460120 1 KR460110 ...

Page 33: ...ling and charging the battery Pull off the battery breather hose 3 Battery sulphuric acid Density 1 28 Top up the battery acid to the MAX mark Allow the battery to stand for at least an hour Shake the battery slightly to allow the remaining air bubbles to escape If necessary top up again to the MAX mark with battery acid Charge the battery and allow to stand for 24 hours Charge current A 10 of rat...

Page 34: ...Route the breather hose making sure it is free of kinks L Note Disconnecting the battery clears all entries such as errors adaptations from the Motronic control unit memory The loss of the adaptations may sometimes lead to engine performance being temporarily impaired when the engine is restarted Motronic restores the lost adaptations itself over the following operating hours Switch on the ignitio...

Page 35: ...necessary Vertical adjustment L Note Set the pivot lever only in the centre position neutral position Pivot lever 1 is in centre position Adjust headlight beam throw with adjusting screw 2 Anti clockwise rotation longer throw higher Clockwise rotation shorter throw lower Adjust beam throw with a suitable adjuster Setting for headlight beam angle adjuster 10 cm 3 937 in Setting for headlight beam x...

Page 36: ... Pull the seat upwards and to the rear out of its catch as far as the first detent position At the front push the seat into the lower or upper guide depending on the rider s height Press down on the rear end of the seat to engage the second detent position of the catch 00 00 Adjusting the handlebars left right dWarning Do not twist the handlebars because this leads to air getting into the brake ci...

Page 37: ...Install the left right footrest support in the alter native position L Note Make sure that the left and right footrest supports are both in either the upper or the lower position 00 00 Adjusting gearshift lever Remove screw arrow and reposition the gear shift lever to suit the altered footrest position X Tightening torque Footrest system to frame 21 Nm Gearshift lever 8 Nm KR460190 ...

Page 38: ...gnosis and moving of test the ABS warning lamp and the general warning lamp must be off 00 00 Final inspection and function check Fill up with fuel L Note Wait at least 10 minutes after a test run before checking the oil place the motorcycle on its centre stand and check the oil level topping up if necessary Check engine oil level when cold and correct if necessary Upper ring marking MAX Lower rin...

Page 39: ...Toolkit and stowage space Oil funnel dWarning The motorcycle may be operated only with the cap for the battery s positive terminal closed and the tool tray in position Integral ABS When installing the battery make sure that the position of the protector for the brake hose is correct How to remove and install the battery How to adjust the mirrors Controls Instruments and telltale and warning lights...

Page 40: ...shaft 38 cruise control system does not switch off 38 cruise control system cannot be set or continually shuts down 38 Changing engine oil replacing oil filter element 39 Inspections I II III and IV 39 Gearbox oil change 40 Inspection III 40 Rear wheel drive oil change every 40 000 km 24 000 miles 40 Inspections I and III 40 Integral ABS Checking brake pads brake discs for wear replacing if necess...

Page 41: ...leeding 51 Inspection IV every 2 years 51 Integral ABS Preliminary work front rear control circuit 51 Integral ABS Replacing brake fluid in the front control circuit bleeding 52 Bleeding the control circuit at the filler adapter 53 Front metering cylinder 53 Front integral circuit 53 Front control circuit 54 Front metering cylinder see above 54 Integral ABS Filling front control circuit to specifi...

Page 42: ...s 63 Inspection III 63 Removing installing fuel pump unit 63 Removing installing fuel filter 64 Removing installing fuel pump 65 Checking coolant level and concentration topping up if necessary checking cooling system for leaks if necessary 66 Inspections I and III 66 Changing coolant 67 Draining coolant 67 Adding coolant 68 Checking battery 69 Inspections III and IV 69 Check battery acid level an...

Page 43: ...tion without BMW Integral ABS Cleaning inductive signal transmitter at rear wheel 73 Clean the inductive sensor at the rear wheel every 40 000 km 24 000 miles or every 2 years at the latest 73 Inspections III and IV 73 Checking valve clearances adjusting if necessary 74 Inspection III 74 Checking valve clearances 74 Adjusting valve clearances 74 Replace the lining of the chain tensioning rail chai...

Page 44: ...year e g changing brake fluid If these tasks cannot be carried out during a Service or an Inspection an Annual Service must be perfor med In this Repair Manual the individual maintenance in tervals are shown by the following codes BMW Inspection at 1 000 km 600 miles I BMW Service every 10 000 km 6 000 miles II BMW Inspection every 20 000 km 12 000 miles III BMW Annual Service IV General instructi...

Page 45: ...on by itself Preset throttle cable play with the engine cold to 1 5 mm 0 0591 in dWarning Observe the hazard avoidance instructions for run ning internal combustion engines in enclosed spa ces Warm the engine up to its normal operating tem perature radiator fan starts to run Adjust throttle cable play to 0 5 mm 0 0197 in Setting Default setting of throttle cable play cold engine 1 5 mm 0 0591 in T...

Page 46: ... in Back off adjusting screw 3 of the closer cable 4 until total play of the two cables opener and closer cables is approx 1 max 1 5 mm 0 0394 in max 0 0591 in Tighten the locknuts dWarning Observe the hazard avoidance instructions for run ning internal combustion engines in enclosed spa ces Settings Total play of both cables at the throttle twistgrip 1 mm max 1 5 mm 0 0394 in max 0 0591 in Cruise...

Page 47: ...es into account Check the operation of the throttle twist grip When released the twistgrip must snap back to the closed position cruise control system cannot be set or continu ally shuts down Increase play on throttle opener cable to a maxi mum of 1 5 mm 0 0591 in Check operation of the microswitch 2 and the actuating mechanism on the throttle valve spind le Check attachment 3 of opener cable 4 wi...

Page 48: ...nscrew and remove the oil filter L Note Always install the oil drain plug with a new sealing ring Install the oil drain plug with a new sealing ring and tighten Coat the sealing rings on the new oil filter with oil Screw the oil filter in hand tight note the instruc tions on the filter Replace the seal in the oil filter cover if necessa ry Installation is the reverse of the removal proce dure Pour...

Page 49: ...l filler plug 23 Nm Quantities Initial fill approx 0 8 l 1 41 Imp pint 0 85 US quart Oil change Add oil up to bottom edge of filler hole 33 00 Rear wheel drive oil change every 40 000 km 24 000 miles Inspections I and III Drain the oil from the gearbox only at regular operating temperature Place the motorcycle on its main centre stand in a horizontal position Take out the oil filler 2 and drain 1 ...

Page 50: ...ke pads brake ca lipers Colour code white 34 00 Integral ABS Checking rear brake pads for wear Remove the cover from the brake caliper Check the wear indicator 1 to assess brake pad wear L Note If the tip of the wear indicator is in contact with the opposing brake pad remove the brake pads and re place if necessary Minimum pad thickness 1 0 mm 0 0394 in 34 00 Integral ABS Checking brake discs for ...

Page 51: ... force back pistons with inner pads so far that new pads just fit in Fit new inner pad Press back outer pad Fit new outer pad L Note After switching on the ignition always wait for the BMW Integral ABS to complete its self diagnosis Do not operate the brake lever until self diagnosis has completed After replacing the pads of a caliper bed in the new pads with the ignition switched on L Note Note p...

Page 52: ...to complete its self diagnosis Do not operate the brake lever until self diagnosis has completed Bed in pads with the ignition switched on Perform a function check on the brake system with the ignition switched on 34 00 Integral ABS Checking brake fluid level at handlebar fitting Inspections II and III L Note The brake fluid level in the sight glass brake fluid le vel remains constant despite wear...

Page 53: ... on the ignition always wait for the BMW Integral ABS to complete its self diagnosis Do not operate the brake lever until self diagnosis has completed dWarning When performing maintenance and repair work on the BMW Integral ABS avoid rapid and forceful pumping of the brakes Apply the brake hard and hold on in this position for a short time After this inspect the brake lines for leaks dWarning If d...

Page 54: ... tank 34 00 Integral ABS Replacing brake fluid in the front wheel circuit bleeding eAttention Integral brakes the rear brake must be ready for use Force the front brake pistons back L Note If the brake pistons were forced back the general warning lamp lights up briefly the first time the igni tion is switched on and the brake lever is pressed Remove cap 2 of front wheel circuit reservoir 1 Draw of...

Page 55: ...w brake fluid as necessary Pump out the brake fluid with virtually no pressu re to begin with then vary the brake pressure L Note The higher the brake pressure the faster the fluid is pumped through the system which means that the level in the wheel circuit reservoir drops all the more rapidly Pump off brake fluid until it emerges clear and free of air bubbles Close the bleed screw Release the han...

Page 56: ...elease the handbrake lever Top up the front wheel circuit reservoir 1 to the MAX mark Screw the filler bottle BMW No 34 1 581 onto the front wheel circuit reservoir Remove the adapter BMW No 34 1 533 and press back the pistons with the reset device until the brake pads can be inserted Install brake pads Bed in pads with the ignition switched on Perform a function check on the brake system with the...

Page 57: ...servoir 4 Draw off the old brake fluid from the wheel circuit reservoir 4 eAttention Do not scrape the wheel mask it off if necessary eAttention Install piston resetting tool BMW No 34 1 531 only when the cap has been removed from the wheel circuit reservoir Using resetting tool BMW No 34 1 531 force the pistons fully back KR340571 3 1 4 MAX MIN MIN MAX F R 2 4 KR340820 34 1 531 ...

Page 58: ... bleed screw while topping up the filler bottle with new brake fluid as necessary Pump out the brake fluid with virtually no pressu re to begin with then vary the brake pressure L Note The higher the brake pressure the faster the fluid is pumped through the system which means that the level in the wheel circuit reservoir drops all the more rapidly When the brake fluid is clear and free of bubbles ...

Page 59: ... self diagnosis has completed Very gently press the footbrake lever until the pump just starts up Release the brake lever Top up the wheel circuit reservoir 4 to the MAX mark Undo the fasteners on the wheel circuit reservoir 4 Screw the filler bottle BMW No 34 1 581 onto the rear wheel circuit reservoir Remove the 23 adapter BMW No 34 1 533 and press back the pistons with the reset device until th...

Page 60: ...ntrol circuit leads from the handbrake foot brake cylinder to the pressure modulator The brake fluid level is independent of brake pad wear L Note The wheel circuit must be filled with brake fluid 34 00 Integral ABS Preliminary work front rear control circuit dWarning When performing maintenance and repair work on the BMW Integral ABS avoid rapid and forceful pumping of the brakes Place the motorc...

Page 61: ... again if this happens a 34 19 Shift the handbrake lever to position 4 d Warning When performing maintenance and repair work on the BMW Integral ABS avoid rapid and forceful pumping of the brakes In sequence bleed the Filler adapter 1 front dosing cylinder 2 front integral circuit 3 front control circuit 4 and again front dosing cylinder 2 bleed the system in accordance with instructions for bleed...

Page 62: ...ve the bleed screw Disconnect the brake bleeding device from the bleed screw eAttention The motorcycle must not be ridden without the in ternal hexagon grub screw arrow screwed into the filler adapter Install the socket head grubscrew in the filler ad apter and tighten X Tightening torque Grubscrew at filler adapter 10 Nm Front metering cylinder Connect the brake bleeding device to bleed screw 2 b...

Page 63: ...above 34 00 Integral ABS Filling front control circuit to specified level Turn the handlebars to the left Top up the reservoir on the handlebar fitting to the MIN mark Screw on the reservoir lid finger tight L Note The brake fluid level is independent of brake pad wear Integral ABS Specified level at handlebar fitting not below MIN top edge of the marking ring eAttention After all the work on the ...

Page 64: ...gral ABS avoid rapid and forceful pumping of the brakes In sequence bleed the rear dosing cylinder 1 rear integral circuit 2 rear control circuit 3 and again rear dosing cylinder 1 bleed the system in accordance with instructions for bleeding Regulations for bleeding 1 Pull the brake lever slowly until the brake light switch clicks snifter hole closed 2 Open the bleed screw 3 Pull the brake lever ...

Page 65: ...ing the brakes always top up the fluid in the wheel circuit reservoir to the correct level in accordance with the instructions Fill rear wheel circuit reservoir with brake fluid in accordance with instructions a 00 50 Fit the protective caps on the bleed screws Hand tighten cap 3 of the rear wheel reservoir eAttention Integral ABS When installing the battery make sure that the position of the prot...

Page 66: ...ding Motorcycle resting on its centre stand Handlebars turned fully to the right Specified level Upper ring marking 34 00 Checking the rear brake fluid level L Note The volume of the brake fluid MIN MAX is suf ficient for pad thicknesses from new to the wear li mit It is not normally necessary to add fluid to compensate for pad wear A level below MIN indicates the possibility of other faults Place...

Page 67: ...ke calipers all the way back and hold them in this position Change and bleed the front brake circuit eAttention When bleeding the brake system always begin on the left side of the motorcycle Turn the handlebars to the left eAttention Do not allow brake fluid to come into contact with painted parts of the motorcycle because brake fluid destroys paint Take off reservoir cover with rubber diaphragm e...

Page 68: ...per Disconnect the brake bleeding device from the bleed screw Installation is the reverse of the removal proce dure Pay particular attention to the following L Note The brake fluid level depends on brake pad wear Top up the brake fluid in the handlebar reservoir to the specified level a 00 57 L Note Wipe the rim of the reservoir the rubber diaphragm and the cover to remove brake fluid and carefull...

Page 69: ...liper Open the bleed screw by half a turn e Attention Brake fluid level must not drop below the MIN mark during the bleeding process otherwise air will be drawn into the brake system Bleed the system again if this happens Draw off brake fluid until it emerges clear and free from air bubbles Close the bleed screw Bleed the system again if necessary Installation is the reverse of the removal proce d...

Page 70: ...el Turn the handlebars to the right L Note The level of fluid in the expansion tank increases as wear to the clutch lining increases eAttention Reliable operation of the clutch is not ensured when the level of the fluid arrow is below the upper mar king ring The clutch fluid should never drop below the le vel for initial filling if it does check the clutch sy stem for leaks Specified level with a ...

Page 71: ...apter Connect the brake bleeding device to the bleed screw Open the bleed screw by half a turn eAttention While bleeding the system do not allow the brake fluid level to drop below the MIN mark as otherwise air will be drawn into the clutch system Bleed the system again if this happens Draw off brake fluid until it emerges clear and free from air bubbles eAttention Dispose of old brake fluid in an...

Page 72: ...h safety precautions when handling or working with fuel Drain fuel tank 16 00 Removing installing fuel pump unit Remove seal 6 and union nut 7 Pull fuel pump unit 5 far enough out of the fuel tank to enable the clips on drain hose 3 and breather hose 4 to be undone with pliers Pull off the hoses Remove fuel pump unit 5 completely with gasket 6 K41160020 8 13 8 12 9 7 14 10 16 17 18 11 5 3 4 6 1 2 ...

Page 73: ... nut 7 and tighten X Tightening torque Union nut 30 Nm 16 00 Removing installing fuel filter Open fasteners 8 with pliers Disconnect fuel hoses 12 and 9 from fuel filter 13 eAttention Note correct direction of flow through fuel filter Connect fuel hoses to new fuel filter Close retainers 8 with pliers BMW No 13 1 500 K41160020 8 13 8 12 9 7 14 10 16 17 18 11 5 3 4 6 1 2 15 19 16 1 710 ...

Page 74: ...amper 17 off holder 19 Pull pump inlet vibration damper 17 off fuel pump 15 Lever off intake filter 18 eAttention When installing note correct position of intake filter 18 and do not damage it Offer up the new intake filter and secure it with pliers BMW No 13 1 500 Further installation is the reverse of the removal procedure X Tightening torque Union nut 30 Nm K41160020 8 13 8 12 9 7 14 10 16 17 1...

Page 75: ...eed to at least 30 C 22 F Use only nitrite free long term antifreeze and corrosion inhibitor Do not top up expansion tank over the MAX mark arrow Remove the cap from the expansion tank 1 Check antifreeze concentration in the expansion tank top up antifreeze if necessary L Note Top up with coolant in a mix ratio of 50 antifreeze 50 water Check coolant level in the expansion tank top up coolant if n...

Page 76: ...the coolant hose arrow from the oil water pump and drain the coolant Release fastener 1 and remove and empty the expansion tank Slacken fastener 2 for breather hose Disconnect the breather hose raise the expansi on tank and drain the breather hose completely Reconnect the breather hose eAttention Dispose of old coolant in an environmentally friendly manner KR170110 KR170020 1 KR170010 2 ...

Page 77: ...ll the expansion tank up to the MAX mark arrow Capacity 2 5 l 4 40 Imp pint 2 64 US quart In expansion tank 0 6 l 1 06 Imp pint 0 63 US quart Mixture Use only nitrite free long life antifreeze and corrosi on inhibitor Concentration Antifreeze 50 Water 50 Turn the engine over with the starter and at the same time squeeze the hose between the water pump and the right hand radiator If necessary add c...

Page 78: ...battery and insulate it Swing up the cap covering the positive battery terminal Disconnect positive battery lead 4 from the battery and swing it up out of the cable guide Remove fasteners 2 for battery retaining plate 1 Take off battery retaining plate 1 Lift out the battery complete with battery breather hose 3 Pull off battery breather hose 3 e Attention Reconnect the battery only when the ignit...

Page 79: ...led water up to the MAX mark Seal the cells tightly with the cell plugs Install the battery a 00 69 13 00 Replacing intake air filter ele ment Inspection III L Note If the motorcycle is used in very dusty or dirty con ditions replace the intake air filter every 10 000 km 6 000 miles or even more frequently dWarning Comply with safety precautions when handling or working with fuel note that the fue...

Page 80: ... bearing bush arrow with a grease gun until fresh grease emerges at the lubricated fa ces Lubricant for bushing Shell Retinax EP2 46 00 Checking the centre stand grea sing it if necessary Checking the centre stand Remove the engine spoiler a 46 14 Remove engine spoiler holder a 46 14 Attach engine lifter Check whether the centre stand retracts auto matically The centre stand has to be lubricated i...

Page 81: ...right Check O rings 3 and replace if necessary Installation is the reverse of the removal proce dure Pay particular attention to the following eAttention When refitting use new bolts or clean thread and bores and fit bolts using Loctite 243 Lubricant for sleeves Shell Retinax EP 2 X Tightening torque Centre stand to support clean thread apply Loctite 243 41 Nm 31 00 Checking the steering damper In...

Page 82: ...ections I and III Grip the rear wheel by the tyre and attempt to move it sideways while holding the grap handle with your other hand Tighten bearings if there is perceptible play a 33 24 33 00 Option without BMW Integral ABS Cleaning inductive signal transmitter at rear wheel Clean the inductive sensor at the rear wheel every 40 000 km 24 000 miles or every 2 years at the latest Inspections III an...

Page 83: ...clearances L Note The camshafts must be removed before the bucket tappets can be replaced Remove left side section of fairing a 46 10 Remove cylinder head cover a 11 15 Remove the screw plug arrow for the chain ten sioner in the timing case cover L Note Turn the camshaft in the direction of rotation or press until the oil is forced out of the chain tensioner and the pin for the chain tensioner can...

Page 84: ... camshafts so that the grooves at the rear opposite end from timing end are vertical in relation to the cylinder head The grooves at the timing end must face towards the crankshaft Install the aligning device BMW No 11 3 700 and secure it to camshaft bearing caps eAttention When turning the crankshaft make sure that the ti ming chain does not come away from the crankshaft sprocket Turn crankshaft ...

Page 85: ...utouts arrows L Note Do not forget the contact spring Install the cylinder head cover Insert the front centre screw timing end arrow and both rear screws arrows in order to locate the gasket Tighten all screws until sealed Tighten the screws in diagonally opposite se quence working from the inside outwards Install the cover plate X Tightening torque Cylinder head cover 9 Nm Spark plugs 20 Nm Secur...

Page 86: ...IV Road safety check Check wheels and tyres Check tyre pressures and correct if necessary Wait at least 10 minutes after a test run to check and correct the engine oil level Tyre pressures one up front 2 5 bar 36 26 psi one up rear 2 9 bar 42 06 psi two up front 2 5 bar 36 26 psi two up rear 2 9 bar 42 06 psi two up and luggage front 2 5 bar 36 26 psi two up and luggage rear 2 9 bar 42 06 psi Road...

Page 87: ...aft sealing ring 13 Removing the oil pressure relief valve 13 Installing the oil pressure relief valve 13 Removing the oil pressure switch and regulating element 14 Installing oil pressure switch and regulating element 14 Install the pump shaft with shaft sealing ring and slipring seal 14 Installing water pump impeller 14 Removing timing chain cover 15 Remove the crankcase cover 15 Removing igniti...

Page 88: ...26 Measuring backlash at the countershaft 26 Removing intermediate flange 27 Removing driver 27 Removing clutch housing 28 Removing intermediate flange 28 Disassembling assembling intermediate flange 29 Removing the driver bearing 29 Installing driver bearing 29 Removing installing shaft sealing ring for driver 30 Removing countershaft and layshaft with freewheel 30 Disassembling assembling freewh...

Page 89: ...ing crankshaft 39 Measuring crankshaft bearing play 40 Measuring radial play 40 Measuring endplay 40 Installing piston with conrod 41 Installing big end bearings 41 Measuring big end bearing play 41 Checking dimensions of crankshaft 42 Installing cylinder head 43 Installing camshafts 44 Installing timing chain 44 Installing timing case cover 46 Checking valve clearances 46 Installing ignition trig...

Page 90: ...11 4 Contents Page ...

Page 91: ...ximum engine speed rpm 9 400 Idle speed rpm 1 050 Direction of rotation Counter clockwise looking at ignition system Compression test pressure good bar psi above 10 0 142 normal bar psi 8 5 10 0 121 142 poor bar psi below 8 5 121 Lubrication system Engine lubrication Pressurised oil circuit Oil filter Full flow type Differential pressure to open bypass valve bar psi 1 5 21 80 Oil pressure warning ...

Page 92: ...nd 3 mm 0 1181 in lift Inlet opens 3 before TDC Inlet closes 27 after BDC Exhaust opens 31 before BDC Exhaust closes 1 before TDC Valve head dia Inlet mm in 26 45 1 0413 Exhaust mm in 22 95 0 9035 Stem dia Inlet mm in 4 966 4 980 0 1955 0 1960 Wear limit mm in 4 946 0 1947 Exhaust mm in 4 956 4 970 0 1951 0 1956 Wear limit mm in 4 954 0 1950 Max runout of valve head at valve seat Inlet exhaust mm ...

Page 93: ...rsize 0 2 mm 0 0079 in Inlet mm in 27 70 27 91 1 0905 1 0988 Exhaust mm in 25 20 25 41 0 9921 1 0004 Valve guide Length of valve guide Inlet mm in 45 1 7716 Exhaust mm in 57 5 2 2637 Valve guide Extl dia mm in 11 533 11 544 0 4541 0 4545 Bore in cylinder head mm in 11 500 11 518 0 4528 0 4335 Overlap mm in 0 015 0 044 0 0006 0 0017 Repair stage Oversize valve guide Extl dia mm in 11 700 11 718 0 4...

Page 94: ...262 1 0270 Wear limit mm in 26 170 1 0303 Radial clearance mm in 0 072 0 106 0 0028 0 0042 Wear limit mm in 0 200 0 0079 Timing chain Type Pre stretched endless single roller chain with 128 links Crankshaft Main bearing and crankpin markings no colour spot Grinding stage 0 with colour spot Grinding stage 1 0 25 mm 0 0098 in Main bearing dia Grinding stage 0 mm in 44 976 45 000 1 7707 1 7717 Grindi...

Page 95: ...ar clearance of piston and cylinder mm in 0 130 0 0051 Permitted out of roundness of cylinder bore at 20 mm 0 7874 in from the top edge mm in 0 05 0 0019 Pistons Piston dia Make KS Measuring plane A see Checking pistons and cylinders A mm in 70 466 70 480 2 7742 2 7748 Wear limit mm in 0 080 0 0031 B mm in 70 476 70 490 2 7746 2 7752 Wear limit mm in 0 080 0 0031 Installed clearance mm in 0 015 0 ...

Page 96: ... 30 0 0039 0 0118 Wear limit mm in 1 50 0 0590 Float mm in 0 030 0 065 0 0012 0 0026 Wear limit mm in 0 20 0 0079 3rd groove U flex ring with spring Height mm in 1 960 1 990 0 0771 0 0783 Wear limit mm in 1 90 0 0748 Float mm in 0 020 0 070 0 0008 0 0027 Wear limit mm in 0 3 0 0118 Installed direction of piston rings Top marking uppermost Piston pin Piston pin dia mm in 16 995 17 000 0 6691 0 6693...

Page 97: ...left and right fairing side sections a 46 8 dWarning Comply with safety regulations fuel lines are pres surised Remove fuel tank a 16 5 Remove the engine spoiler a 46 14 Remove exhaust system a 18 5 Remove fuel injection rail a 13 7 Remove throttle valve rail together with intake air silencer Detach the engine from the front cross member at the left Disconnect the temperature sensor plug at the cy...

Page 98: ...starter motor and generator a 12 10 a 12 13 Remove the gearbox a 23 9 Transfer engine to assembly frame Installing engine Place the engine on the platform with lifting fix ture BMW No 00 1 510 Install the gearbox a 23 10 Install starter motor and generator a 12 12 a 12 15 Install the fuel lines on the engine block eImportant When lowering the frame make sure that clearance is correct at the right ...

Page 99: ...using into a vise at the seal ing faces using soft jaws Remove water pump impeller 9 holding pump shaft 5 to prevent it from turning Take off the water pump impeller with spacing bushing 8 Press out pump shaft 5 Examine the pump housing for damage Removing slipring seal and shaft sealing ring Drive out slipring seal 7 and shaft sealing ring 6 with a drift BMW No 11 6 721 Removing the oil pressure ...

Page 100: ...and install oil pres sure switch 11 XTightening torques Oil pressure switch to oil pump intermediate flange 11 35 Nm Water pump temperature sensor 17 9 Nm Screw plug M 12 20 Nm Install the pump shaft with shaft sealing ring and slipring seal L Note Clean the sealing ring seats Insert pump shaft 5 lightly oiled into the hous ing Place sliding sleeve BMW No 11 6 722 on pump shaft Insert shaft sealin...

Page 101: ...e in relation to the engine block Remove magnetic gate 1 noting the presence of semi circular shims Remove rotor 2 and take off adjusting disc 3 Removing cylinder head cover Remove heat shield 7 Pull off spark plug caps 6 with flat pliers Remove cylinder head cover 8 L Note Note spring at 3rd camshaft bearing of inlet camshaft KR110200 5 4 1 2 3 KR110210 KL000010 8 6 7 ...

Page 102: ...out of the chain tensioner and the pin can be inserted fully Take out the screws loosen the timing case cov er with light blows of a plastic faced hammer and take it off eImportant When the timing case cover is removed locate the preshaped shaft sealing ring in the timing case cov er with slip over sleeve BMW No 11 6 771 772 Insert slip over sleeve BMW No 11 6 771 into shaft sealing ring in timing...

Page 103: ...ver assembly sleeve BMW No 11 6 771 Remove assembly sleeve BMW No 11 6 772 Lubrication points Outside circumference of shaft sealing ring tyre assembly paste Apply tyre assembly paste to the outside circum ference of the shaft sealing ring install the ring with the sealing lip dry Using assembly sleeve BMW No 11 6 771 po sition the sealing ring on the rotor flange Using mandrel BMW No 11 6 773 and...

Page 104: ...osen the chain sprockets holding the cam shaft at the hexagon Take off the chain sprockets and slide rail Removing chain tensioner rail Remove the keeper and washer Take off tensioner rail 4 Removing chain guide rail Remove keepers 1 and washers 2 from pivot pins Take off guide rail 3 with bushing and timing chain Replace the lining of the chain tensioning rail and thrust piece Unclip the tensioni...

Page 105: ...gs to which valve Removing cylinder head L Note Place a drip tray in position underneath the engine to catch escaping coolant Unscrew the cylinder head bolts 4 with Torx in sert BMW No 00 2 630 Loosen the cylinder head with light blows of a plastic faced hammer and take it off Removing valves Install support plate BMW No 11 1 749 for the valve spring clamping device at the rear of the cylinder hea...

Page 106: ...and valve stem seal L Note If a valve is removed the valve stem seal must be re newed Oil the stem when installing the valve Insert the lower spring retainer Place a shrink fit tube approx 20 mm 0 7874 in long on the valve stem and heat it up Drive in valve stem seal 1 with the assembly tool BMW No 11 1 602 until resistance is felt eImportant Remove the shrink fit sleeve from the valve stem Insert...

Page 107: ...gle in its bore Use water pump pliers to remove coolant seal ing caps 1 and 2 eImportant Do not permit coolant sealing caps to drop into the coolant system use a magnetic grab to remove the sealing caps if necessary Clean the seating faces for the coolant sealing caps in the cylinder head Installation is the reverse of the removal proce dure Pay particular attention to the following Apply Loctite ...

Page 108: ...ders 2 and 3 Removing main bearings engine installed Loosen all but one arrow of the main bearing bolts L Note Make a note of which caps belong to which main bearings and note the installed positions Bearing caps 1 3 are marked for identification Bearing 4 thrust bearing and bearing 5 are not marked Cylinder 1 timing end of engine Take off the bearing caps Remove the final bolt Take off the bearin...

Page 109: ...e circlip 3 at one side Press out piston pin 2 with pressing out tool BMW No 11 6 710 Carefully remove piston rings 1 with piston ring pliers L Note Note the correct installed positions Clean the piston Checking piston dimensions Measure piston diameter with a micrometer at distance A Distance A 10 mm 0 3937 in Measure piston ring float with feeler gauges Measure the end gaps of the piston rings i...

Page 110: ...he gap in the spring must be offset 180 in relation to the Flex ring gap Checking cylinder dimensions Set the internal micrometer to the nominal cylin der bore diameter Measure the cylinder bore at three heights and in a crosswise pattern in the direction of forward travel and at a right angle to it Checking that conrod bores are parallel The difference over the reference length P must not exceed ...

Page 111: ...w on the piston crown must point in the forward direction of travel Only install pistons of the same weight group Check the marks on the piston crowns arrow to determine the weight class eImportant Always use two new wire circlips per piston pin when reassembling Assemble piston and conrod Weight class codes for conrods Class Weight in g oz Colour coding 0 413 416 9 14 579 14 717 2 x white 1 417 4...

Page 112: ...ermediate flange Use the clamping screw to secure the clamp BMW No 11 5 510 to the first vane of the driver Adjust the dial gauge BMW No 00 2 510 such that the mark on the tool 3 mm from outside edge is aligned with the needle of the dial gauge on the reference face Move the driver by hand Note dial gauge read ing Remove the clamp BMW No 11 5 510 Turn the crankshaft to turn the driver through 120 ...

Page 113: ...lutch a 21 5 Install the retaining device arrow BMW No 11 2 821 in the position illustrated Removing driver Take out screw arrow Pull the driver off by hand If necessary use a puller BMW No 00 8 400 with the pressure head from puller separator BMW No 00 7 500 KL110231 11 2 821 KR110080 ...

Page 114: ...mp housing Unscrew nut 1 and take off thrust ring 2 Move the clutch housing to and fro until O ring 3 is accessible then remove it eImportant Do not lever the puller against the stub shaft Pull off clutch housing 4 noting the presence of thrust washer 5 Removing intermediate flange Use Torx socket T30 BMW No 00 2 600 to re lease the screws Remove the intermediate flange KR110090 5 1 2 3 4 ...

Page 115: ...ng Install the snap ring 4 LNote Use temperature measuring device BMW No 00 1 900 to check heat rise Heat the intermediate flange at the bearing seat to approx 120 C 248 F Press the ball bearing on as far as the snap ring Insert the cup spring with the larger diameter fac ing the bearing Install the thrust plate with the large cutout at the top X Tightening torque Thrust plate to intermediate flan...

Page 116: ...ler BMW No 00 5 010 and the small pressure head from the puller separator BMW No 00 7 500 L Note Clean the sealing ring seat Pre shape the sealing ring with your thumbs and drive it in dry with a drift BMW No 11 1 620 and handle BMW No 00 5 500 1100 Removing countershaft and lay shaft with freewheel Pull the countershaft and layshaft out of the crankcase together Note flat spring 1 KR110140 00 5 0...

Page 117: ...ff the layshaft 1 Clamp the layshaft into a vice with soft jaws smooth side down Remove cover plate 4 Pull off freewheel cage 3 Take out cup spring 2 Pull needle roller bearing out of freewheel gear with a puller BMW No 00 8 570 and internal puller 21 3 BMW No 00 8 574 KR110160 1 2 3 4 5 6 00 8 570 KR110170 ...

Page 118: ...yshaft while turning it clockwise Push the thrust washer on to the layshaft 1100 Removing installing needle bear ings for layshaft and shaft sealing ring in crankcase Removing bearing Place support ring BMW No 11 6 731 in posi tion and remove bearing with puller BMW No 00 8 570 and internal puller 21 3 BMW No 00 8 574 If a defective bearing cannot be pulled out care fully cut through the needle ro...

Page 119: ...rankcase Remove screws 4 for the shouldered bearing and screws 3 for the needle roller bearing Loosen the gasket with light blows of a plastic faced hammer and take off the lower part of the crankcase Note the O rings for the water and oil passages Carefully lift out the output shaft the needle roller bearing and circlip are loose on the shaft Replacing oil level sight glass Pierce the plastic dis...

Page 120: ...ioning gear Clamp the damper housing into a vise with soft jaws to take the pressure off retaining ring 4 Remove retaining ring 4 with suitable pliers Insert a puller BMW No 00 8 400 in the oppo site cutout of the gearwheel and pull ball bearing 5 off with pressure block BMW No 33 1 307 Take off spacing ring 6 turn tensioning gearwheel 7 clockwise with counter holder BMW No 12 4 600 and pull upwar...

Page 121: ...seat to the tensioning gear eImportant The thickness of the spacing washer must never ex ceed this measurement Place a suitable spacing washer arrow on the tensioning gear L Note Use temperature measuring device BMW No 00 1 900 to check heat rise Heat the ball bearing to approx 80 C 176 F and place it in position with shoulder uppermost Clamp the damper housing and the ball bearing together in the...

Page 122: ...tput shaft Push on circlip 2 and needle roller race 1 Place the output shaft in the crankcase L Note Make sure that the gap of the circlip arrow is facing downward in the crankcase Install O rings 8 9 for the water and oil passag es Assembling the crankcase Check that sealing face is clean and degreased and apply a thin coat of Omni VISC 1002 see line on sealing face with grey shading Fill the exp...

Page 123: ... oil mesh strainer 1 in position Installing oil filter Coat the oil filter sealing ring with oil Tighten oil filter 2 with the special oil filter wrench BMW No 11 4 650 by not more that half a turn once it has made contact X Tightening torque Oil strainer 10 Nm Oil filter 11 Nm Installing oil sump Check that sealing face is clean and degreased and apply a thin coat of Omni VISC 1002 see line on se...

Page 124: ...diate flange Check that sealing face is clean and degreased and apply a thin coat of Omni VISC 1002 see line on sealing face with grey shading Fill the expansion groove arrow with sealing compound L Note Scrape off excess sealant with a spatula Install the intermediate flange with locating sleeves Use Torx socket T 30 BMW No 00 2 600 to tighten the screws X Tightening torque Intermediate flange 9 ...

Page 125: ...to tighten the nut fully X Tightening torque 1 Nut for clutch housing 140 Nm 2 Slacken off 3 Retighten 50 Nm 4 Additional angle of rotation 60 Installing driver L Note The driver can be installed only with the crankshaft installed Push driver on to layshaft Tighten the threaded fastener X Tightening torque Driver 50 Nm Remove the retaining fixture BMW No 11 2 821 Install the clutch a 21 5 Installi...

Page 126: ...securing screws X Tightening torque Main bearings 50 Nm L Note Do not turn the crankshaft any more Remove bearing cap Compare the width of the strip with the scale arrow in order to determine bearing play Radial play 0 020 0 056 mm 0 0008 0 0022 in Wear limit 0 130 mm 0 0051 in Measuring endplay Install the crankshaft Screw dial gauge holder arrow BMW No 00 2 500 with dial gauge attached into the ...

Page 127: ...ings eImportant Do not accidentally interchange conrods or bearing shells Take great care to reinstall the bearing shells in their original positions Always use new big end bolts Turn the crankpin of the relevant cylinder to bot tom dead centre Oil the crankpin and seat the conrod against it Place the big end bearing cap in position and tighten the screws to the specified torque Use an angle of ro...

Page 128: ... identifies the grind ing stage as 0 L Note The crankshaft can only be reground in stage 0 and must be hardened and finished afterwards 1100 Checking dimensions of crank shaft If measurement reveals that bearing clearance is excessive the crankshaft must be measured Grinding stages 0 and 1 are available the crankshaft is marked with the appropriate number of paint spots at the bearing journal Colo...

Page 129: ...sary The sealing faces must be clean flat and undam aged Place the cylinder head gasket in position no holes or passages must be obstructed Place the cylinder head in position noting the lo cating sleeves Oil bolts 1 and washers 2 and screw them in until sealed Check that the engine block and cylinder head gasket are correctly aligned if necessary use a whetstone to remove protruding edges of the ...

Page 130: ...n the bearing caps uniformly working from the inside outwards Install the thrust bearing timing end with slide rail last and do not tighten it until the chain sprockets have been installed Tighten the bearing caps uniformly working from the inside outwards X Tightening torque Bearing cap 10 Nm Installing timing chain Turn the camshafts until the grooves at the tim ing end arrows point toward the c...

Page 131: ...timing chain is taut at the guide rail Fully tighten screw 5 Install guide rail 7 Press the tensioning rail 4 onto the pivot pin and install the washer and snap ring Install the exhaust camshaft chain sprocket so that the timing chain is as taut as possible be tween the sprockets Fully tighten screw 6 Tighten the bearing cap with sliding rail 7 Remove the aligning device BMW No 11 3 700 Tighten th...

Page 132: ...g ring is correctly positioned a 11 17 Use assembly sleeve BMW No 11 6 771 to po sition the timing case cover on the rotor flange and tighten the fasteners making sure that the long screws are installed in the correct positions arrows Remove the chain tensioner pin and tighten the screw plug Turn the engine over and check the relative po sitions of the camshaft sprockets and the sprocket on the cr...

Page 133: ...lar shims X Tightening torque Rotor 4 Nm Magnetic gate 6 Nm eImportant Correct the ignition timing Installing ignition trigger cover Run the cable to the ignition trigger through a rubber grommet in the timing case cover Secure the cables for the oil pressure telltale and water pump temperature sensor with clip 2 Install the cover with gasket X Tightening torque Ignition trigger cover 9 Nm KR11071...

Page 134: ...her at the same time Tighten the screws to specified torque Check for any noticeable play at any position of the water pump impeller X Tightening torque Pump housing to crankcase 10 Nm Run the cables for the oil pressure telltale and water pump temperature sensor through the hole in the pump housing and connect them Check that sealing face of the pump housing cover is clean and degreased and apply...

Page 135: ...linder head timing case cover and cylinder head cover meet and at the half moon cutouts arrows L Note Do not forget the contact springs Install the cylinder head cover Insert the front centre screw timing end arrow and both rear screws arrows in order to locate the gasket Screw in all bolts until sealed Tighten the bolts in diagonally opposite se quence working from the inside outwards Mount the h...

Page 136: ...ving installing ignition leads 7 Timing the ignition 8 Removing installing coil 9 Replacing three phase generator 10 Removing three phase generator 10 Disassembling the three phase generator 11 Removing installing drive housing 11 Removing installing voltage regulator 11 Installing generator 12 Replacing starter motor 13 Removing starter motor 13 Disassembling and reassembling starter motor 14 Rem...

Page 137: ...12 2 Contents Page ...

Page 138: ...rator speed for start of charge rpm 1 400 Max operating speed rpm 18 000 Spark plugs Bosch XR 7 LDC Thread metric M 12 x 1 25 Electrode gap mm in 0 8 0 1 0 0315 0 004 Ignition Ignition system Motronic mapped characteristic control Ignition trigger Two magnetic gates Hall effect transmitters driven by crankshaft Static ignition timing CS 6 0 24 mm 0 0094 in before TDC Speed governing rpm 9 400 Igni...

Page 139: ...12 4 ...

Page 140: ...portant Switch off the ignition and disconnect and insulate the earth ground lead at the battery Open the lid of the electronic equipment box Detach the right hand radiator from its holder and press it forwards L Note Mark the position of the magnetic gate in relation to the engine block or remove it in the top dead centre TDC position Remove magnetic gate 1 noting the presence of semi circular sh...

Page 141: ...ghtening torque Rotor 4 Nm Magnetic gate 6 Nm eImportant Correct the ignition timing 12 11 Installing the cover of the Hall effect transmitter Run the lead to the magnetic gate through the timing case cover with a rubber sleeve Secure the cables for the oil pressure telltale and temperature display with clip 6 Install cover 5 with gasket 4 Further installation is the reverse of the removal procedu...

Page 142: ...and remove spark plugs 1 with spark plug wrench BMW No 12 3 500 Installation is the reverse of the removal proce dure X Tightening torque Spark plugs 20 Nm 12 12 Removing installing ignition leads Disconnect plugs at coil Remove ignition leads L Note When installing make sure that the ignition leads are correctly routed Installation is the reverse of the removal proce dure KR120010 3 2 1 KR120160 ...

Page 143: ... Connect BMW MoDiTeC to di agnosis plug Without Motronic Connect BMW MoDiTeC to plug connector 6 on the Hall effect transmitter Start the Timing ignition program at the BMW MoDiTeC Loosen the fasteners of magnetic gate 1 and turn it to the left or right until the BMW MoDiTeC displays the correct ignition firing point Adjusting ignition timing Turn counter clockwise retard timing Turn clockwise adv...

Page 144: ...n lead plugs 6 from the coil At plug 3 press in the clip in the direction shown by the arrow and disconnect the plug Release the fastener 5 for the earth ground lead 4 Remove screws 2 Remove ignition coil 1 e Important Note positions of ignition leads on coil Installation is the reverse of the removal proce dure X Tightening torque Coil to intermediate flange 9 Nm KR120110 5 4 1 2 6 3 KR120040 4 3...

Page 145: ...e swinging arm and universal shaft a 33 21 Detach the cross tube at the bottom a 46 25 Press left and right radiators with fans out of their holders Cut through the cable tie for the clutch bleed line at the frame eImportant Unscrew the three fasteners uniformly and in diago nally opposite sequence Remove the clutch slave cylinder and guide the clutch line through upwards Disconnect the plug for t...

Page 146: ...housing 3 Installation is the reverse of the removal proce dure X Tightening torque Drive housing 50 Nm 12 31 Removing installing voltage regulator L Note The regulator can also be removed installed without removing the generator Release fasteners 3 Unlock the clips 1 and take off the housing cover 2 Take out screws 4 Remove voltage regulator with carbon brushes 5 Installation is the reverse of th...

Page 147: ...tall the clutch slave cylinder Secure the cable tie Install the clutch bleed line and secure it to the frame Install the left right radiators with fans a 17 7 Install the lower cross tube a 46 25 Install drive shaft and swinging arm a 33 21 Install the rear wheel drive a 33 19 Remove lifter from engine sump Install fuel injection rail a 13 7 Install intake air silencer a 13 6 dWarning Comply with ...

Page 148: ...7 Remove swinging arm and universal shaft a 33 21 Detach the cross tube at the bottom a 46 25 Press left and right radiators with fans out of their holders Cut through the cable tie for the clutch bleed line at the frame eImportant Unscrew the three fasteners uniformly and in diago nally opposite sequence Remove the clutch slave cylinder and guide the clutch line through upwards Disconnect the plu...

Page 149: ...everse of the removal proce dure Removing installing brush holder Unscrew hex nut 6 Take off outer insulating washer 5 Take off brush holder plate 3 with carbon brush holder 9 inner insulator 8 and O ring 7 Installation is the reverse of the removal proce dure Replacing carbon brushes Using a small screwdriver raise spring 10 and pull the carbon brush out in the direction of the arrow L Note Inser...

Page 150: ...cylinder Secure the cable tie Install the clutch bleed line and secure it to the frame Install the left right radiators with fans a 17 7 Reconnect plugs and cables for engine and gearbox Install the lower cross tube a 46 25 Install drive shaft and swinging arm a 33 21 Install the rear wheel drive a 33 19 Remove lifter from engine sump Install fuel injection rail a 13 7 Install intake air silencer ...

Page 151: ...oving installing intake stubs 10 Replacing fuel hoses 11 Removing installing throttle valve actuator 12 Replacing and adjusting throttle valve potentiometer 13 Basic throttle cable setting a 00 36 13 Cruise control Removing installing throttle cables 14 Preparatory work for all Bowden cables 14 Removing installing throttle opener and throttle closer cables 14 Removing installing Bowden cable of cr...

Page 152: ...13 2 Contents Page ...

Page 153: ...pipe intl dia mm in 38 1 4960 Air filter Multi layer paper element Intake stub pipe With resonance damper Throttle cable play Without cruise control system engine at operating temperature mm in 0 5 0 0197 With cruise control system Total play throttle opener and throttle clos er cables mm in 1 1 5 0 0393 0 0590 Cruise control system cable mm in 2 3 0 0787 0 1181 ...

Page 154: ...13 4 ...

Page 155: ...t of central plug L Note Make sure that the seal at the central plug is cor rectly seated Installation is the reverse of the removal proce dure 13 72 Removing installing intake air filter a 00 70 13 62 Replacing air temperature sen sor Take off the left side section of the fairing a 46 10 Disconnect plug 1 of temperature sensor Remove temperature sensor 2 Install temperature sensor in intake air s...

Page 156: ... throttle valve stubs Activated charcoal filter Remove timing valve from its holder Move throttle and clutch cables to one side and pull off the intake air silencer Installation is the reverse of the removal proce dure Pay particular attention to the following Secure non reusable hose clips 2 3 with pliers BMW No 13 1 510 Make sure that screw of hose clamp 4 on cylin der No 3 is aligned exactly in...

Page 157: ...um hose from cable tie 1 Open the cable ties Disconnect all four plugs of injection valves 4 Slacken screws and remove fasteners Pull the injection rail with the injectors out of the intake stubs L Note Make sure that the O ring at the injector is in good condition Grease O rings lightly L Note Activated charcoal filter Note the position of the plug for the fuel evaporation control valve 2 Install...

Page 158: ... injectors Installation is the reverse of the removal proce dure 13 53 Removing installing pressure regulator Take off the left side section of the fairing a 46 10 Use hose clamps BMW No 13 3 010 to close off fuel hoses at injection rail Remove spring clip 2 Using pliers remove pressure regulator 1 Installation is the reverse of the removal proce dure L Note Before installing coat the sealing ring...

Page 159: ...lve actuator 1 Activated charcoal filter Disconnect breather hose to timing valve from y piece Disconnect the plug arrow for the fan L Note It is not necessary to open the cable ties when re moving the fuel injection rail Remove the fuel injection rail and secure it to the frame together with the wiring harness a 13 7 Slacken screws securing hose clips at intake stubs Remove throttle valve rail fr...

Page 160: ... following L Note Note the installed positions of the hose clamp screws arrows eImportant After installing check that Bowden cable pulls at throttle valve stubs move freely Check play of Bowden cables adjust if neces sary a 00 36 X Tightening torque Injection rail to cylinder head 9 Nm 11 61 Removing installing intake stubs Remove throttle valve rail L Note When installing the rear intake stub do ...

Page 161: ...fety precautions when handling or working with fuel Renew the fuel hose eImportant Make sure that the fuel hoses and protective sleeves are run correctly between the frame and the engine Insert the fuel hoses in the retaining clips L Note Renew retaining clips if necessary X Tightening torque Screw to intake stub 9 Nm Retaining clip to engine 9 Nm KR130100 KR130080 1 2 KR130270 2 1 ...

Page 162: ...not be run from the mo torcycle s 12 volt circuit e Important When a new throttle valve actuator is installed the idle switching point is not correctly adjusted Install throttle valve actuator Insert the screws with Loctite 243 and tighten them To adjust the idle switching point turn the screw arrow according to the display on the BMW MoDiTeC Mark the screw with paint Perform function test with BM...

Page 163: ... plug be neath front seat Open the TOOLBOX menu and select THROT TLE VALVE POTENTIOMETER or throttle valve actuator Follow the instructions of the BMW MoDiTeC Tighten screws securing throttle valve potenti ometer Perform function test with BMW MoDiTeC menu item THROTTLE VALVE POTENTIOMETER or throttle valve actuator Apply sealing lacquer to securing screws Installation is the reverse of the remova...

Page 164: ...move intake air silencer 32 72 Removing installing throttle opener and throttle closer cables Remove screw 5 and remove cover 4 Disengage adjusting screw 7 for throttle closer cable 3 Open adjusting screw 8 for throttle opener cable 2 Remove throttle cable relay 6 Disengage throttle opener cable 2 from its pull and remove Disengage throttle closer cable 3 from its pull Release cable ties at fairin...

Page 165: ...o avoid tight bends and make sure they are not kinked or pinched Route the two cables parallel the throttle opener cable 1 with green mark always to the outside Route the Bowden cables beneath the fairing bracket between the fork tubes and through the hole in the guide at the radiator Clip the Bowden cables together at the coloured mark arrow Check that Bowden cable pulls at throttle valve stubs m...

Page 166: ...and remove Bowden cable Installation is the reverse of the removal proce dure Pay particular attention to the following eImportant After installing check that Bowden cable pulls at throttle valve stubs move freely Preadjust Bowden cable play to obtain specified distance A by turning adjusting screw at thrott le valve rail Check play of Bowden cables adjust if neces sary a 00 36 Settings Distance A...

Page 167: ...nit until approx 1 cm 0 3937 in of cable is visible and secure Bowden cable in this position with clamp arrow Disengage nipple 3 move Bowden cable with clamp clear Disconnect plug arrow Remove screws 4 securing retaining plate to fairing bracket Remove retaining plate with control unit for cruise control system Remove screws 5 and remove control unit Installation is the reverse of the removal proc...

Page 168: ...ng or working with fuel note that the fuel lines are pressu rised Connect a test pressure gauge BMW No 16 1 500 to the delivery side lower line Start engine and allow to idle Fuel pressure Specification 3 5 bar 50 76 psi L Note If fuel pressure is lower than this check the fuel pump fuel filter pressure regulator and lines 16 1 500 KR130180 ...

Page 169: ...13 19 Troubleshooting Fault indication from BMW MoDiTeC Leak in air intake line Injector leaking yes Renew injector sealing ring no Intake air stub leaking yes Renew intake air stub ...

Page 170: ...oving installing fuel pump unit a 00 63 6 Removing installing fuel filter a 00 64 7 Removing installing fuel pump 7 Removing installing fuel filler pipe 7 Removing installing fuel tank vent 7 Removing installing immersion tube sensor 8 Calibrating the immersion tube sensor 8 Renewing front left right rubber mounting 8 16 Fuel tank and lines ...

Page 171: ...16 2 Contents Page ...

Page 172: ...ical Data K 1200 RS Tank capacity l Imp gal US gal 21 4 62 5 55 including reserve of l Imp gal US gal 4 0 88 1 06 Fuel pump Type Gear type Operating voltage V 12 Delivery volume l h Imp gal US gal h 110 24 21 29 06 ...

Page 173: ...16 4 ...

Page 174: ... Disconnect the fuel hoses at the quick action adapters 1 Disconnect the plug for the fuel pump 3 Release the fastener 6 for the tank cover at the frame Disconnect the plug for the immersed fuel level sensor 5 Release the fasteners 4 at the left and right of the fuel tank Pull the fuel tank to the rear away from rubber mounting 7 L Note The vent hoses 2 remain on the fuel tank when it is removed I...

Page 175: ...fuel filter and fuel pump Remove fuel tank dWarning Comply with safety precautions when handling or working with fuel Drain fuel tank 16 14 Removing installing fuel pump unit a 00 63 K41160020 8 13 8 12 9 7 14 10 16 17 18 11 6 3 4 5 1 2 15 19 16 1 710 ...

Page 176: ... Installation is the reverse of the removal proce dure X Tightening torque Union nut to fuel tank 30 Nm 16 11 Removing installing fuel filler pipe dWarning Comply with safety precautions when handling or working with fuel Release the retaining screws arrows Take off the fuel filler pipe Installation is the reverse of the removal proce dure X Tightening torque Fuel filler pipe to fuel tank 5 Nm 16 ...

Page 177: ...Note The immersion tube sensor has to be calibrated if it or the fuel tank has been replaced Calibration allows the reserve fuel capacity of the fuel tank to be adjusted to suit customer preferenc es Pour 4 litres 0 88 Imp gal 1 06 US gal of fuel or the quantity requested by the customer into the empty fuel tank Connect the MoDiTeC to the diagnosis connec tor beneath the saddle Call up the TOOLBOX...

Page 178: ...eft radiator 7 Removing installing right radiator 8 Removing installing fan 9 Removing installing left fan 9 Removing the right fan 9 Removing installing coolant hoses 10 Removing installing thermostat 11 Checking thermostat 11 Changing coolant a 00 67 11 Check cooling system for leaks 11 Troubleshooting 12 17 Radiator ...

Page 179: ...17 2 Contents Page ...

Page 180: ...rt 3 1 Coolant Use only nitrite free long term antifreeze and cor rosion inhibitor Thermostat opening temperature C F 85 Fan cut in temperature C F 105 Cut in temperature for coolant warning light C F 115 Pressure relief valve in end cover opens at bar psi 1 5 0 2 21 76 2 9 ...

Page 181: ...17 4 ...

Page 182: ...17 5 Coolant circuit ...

Page 183: ...17 6 ...

Page 184: ... the fasteners arrows Take off the radi ator air inlet guide Remove retaining clip with washer arrows for radiator L Note Press the radiator out of the holder at the top Release the retaining screws arrows Take off the radiator air outlet guide Disconnect the plug arrow for the fan KR170030 KR170040 KR170130 KR170140 ...

Page 185: ...essary remove the intake air pipe L Note Illustrations for the following work b Remove left radiator Remove retaining clips with washers for radiator Loosen air outlet guide mountings Take off air outlet guide Disconnect fan plug Disconnect the coolant hose from the lower stub pipe 2 on the right radiator Disconnect connecting hose 1 to left radiator at the top L Note First detach radiator from ho...

Page 186: ... Take off the fan Installation is the reverse of the removal proce dure X Tightening torque Fan to radiator clean thread apply Loctite 243 2 Nm 17 11 Removing the right fan Remove the right side section of the fairing a 46 10 Remove the fasteners arrows L Note Illustrations for the following work b Remove left radiator Remove retaining clips with washers for radiator Loosen air outlet guide mounti...

Page 187: ...discharge hose 2 Breather hose 3 to expansion tank Coolant hose to coolant stub pipe 4 Coolant hose 5 to oil water pump L Note Remove the coolant hose to the stub pipe 4 and the vapour discharge hose 2 after removing the right radiator Installation is the reverse of the removal proce dure X Tightening torque Hose clips for coolant hose hand tight KR170080 5 4 3 2 1 ...

Page 188: ...12 17 00 Changing coolant a 00 67 17 00 Check cooling system for leaks Take off the left side section of the fairing a 46 10 Unscrew the filler cap Screw pump BMW No 17 0 500 with adapter and threaded stub pipe BMW No 17 5 520 on to the filler pipe Pressure test the cooling system the pressure must remain unchanged for at least 5 minutes Setting Test pressure 1 5 bar 21 76 psi Installation is the ...

Page 189: ...mp Is water pump faulty yes Repair replace water pump Fan motor does not cut in Check fuse F7 Fuse blown yes Replace fuse no Check fan relay Fan relay defective yes Replace fan relay no Check electrical circuit Poor contact break in circuit yes Make good contact eliminate break in circuit no Check fan motor Fan motor defective yes Repair replace fan motor no Check thermostat Thermostat does not op...

Page 190: ...circuit Coolant circuit is inter rupted yes Repair the fault Engine remains cold or warms up very slowly Check thermostat Thermostat does not close Are both radiators equally warm and the cool ant hose to the water pump cold yes Replace thermostat ...

Page 191: ...18 1 Contents Page 18 Technical Data 3 Removing installing exhaust system 5 Removing installing oxygen sensor 5 Removing installing exhaust system sleeve 6 18 Exhaust system ...

Page 192: ...18 2 Contents Page ...

Page 193: ...18 3 18 Technical Data K 1200 RS Exhaust system Silencer muffler Closed loop catalytic converter ...

Page 194: ...18 4 ...

Page 195: ...f the removal proce dure Pay particular attention to the following eImportant When installing note correct cable routing and at tachment points for oxygen sensor L Note Replace the O rings at the cylinder head X Tightening torque Fasteners exhaust system to cylinder head 22 Nm Retaining hoop to silencer 13 Nm Retaining hoop to frame 24 Nm 18 30 Removing installing oxygen sensor Unscrew the oxygen ...

Page 196: ...ust system sleeve away from the si lencer with a turning movement arrows L Note When installing push the sleeve on to the silencer with a turning movement making sure that the holes in the sleeve and the silencer are aligned Installation is the reverse of the removal proce dure X Tightening torque Retaining plate to silencer 11 Nm Retaining hoop to bracket 13 Nm Cover 8 Nm KR180050 KR180060 KR1800...

Page 197: ...6 Installing clutch housing 7 Installing clutch 8 Removing installing clutch slave cylinder and pushrod 9 Removing installing clutch slave cylinder 9 Removing installing clutch pushrod 10 Removing installing clutch lines 11 Removing installing clutch pressure line 11 Removing installing bleed line 12 21 Clutch ...

Page 198: ...21 2 Contents Page ...

Page 199: ...21 3 21 Technical Data K 1200 RS Clutch Type Single dry plate clutch asbestos free Operation hydraulic Clutch plate dia mm in 180 7 0866 Wear limit Minimum clutch plate thickness mm in 4 5 0 1771 ...

Page 200: ...21 4 ...

Page 201: ...ar drive on its side before in stallation or else oil will leak out when the motorcy cle is ridden suction effect Remove rear wheel drive unit a 33 7 Remove the front section of the rear carrier a 46 7 Remove swinging arm a 33 21 Remove front drive shaft a 33 23 Remove transverse tube a 46 25 Remove starter a 12 13 Remove the gearbox a 23 9 21 21 Removing clutch Tale out the six retaining screws 1...

Page 202: ...older BMW No 11 2 821 as illus trated Unscrew hex nut 5 Remove thrust ring 4 Move clutch housing 2 to and fro until O ring 3 can be seen Cut through O ring 3 Pull off the clutch housing 2 Take off thrust washer 1 KR210020 1 2 3 4 5 11 2 821 KR210030 ...

Page 203: ... 11 2 821 on the clutch housing in the position shown e Important Fit new nut 5 Fit a new O ring 3 and thrust ring 4 Tighten nut 5 with the collar facing outwards Slacken and then retighten the nut Use angle of rotation gauge BMW No 11 2 500 to tighten the nut fully Remove the retaining fixture BMW No 11 2 821 X Tightening torque 1 Nut for clutch housing 140 Nm 2 Slacken 3 Retighten 50 Nm 4 Additi...

Page 204: ...essure plate 4 Insert diaphragm spring 5 into clutch housing 10 e Important Offset colour markings for residual imbalance by 120 yellow on clutch housing 8 white on thrust plate 4 and clutch housing cover 2 Install wire ring 6 diaphragm spring 5 thrust plate 4 clutch plate 3 and clutch housing cover 2 in clutch housing 8 Secure clutch with fasteners 1 KR210010 1 2 4 5 7 8 3 6 ...

Page 205: ... Integral ABS Install inductive signal transmitter a 61 15 Install the rear wheel a 36 8 21 52 Removing installing clutch slave cylinder and pushrod Removing installing clutch slave cylinder Remove rear wheel a 36 8 Without Integral ABS Install inductive signal transmitter a 61 15 Remove brake caliper fasten to the rear frame with the sensor using a cable tie a 34 5 Remove rear wheel drive unit a ...

Page 206: ...m Banjo bolts to slave cylinder 7 Nm 21 52 Removing installing clutch pushrod L Note Pressure line 3 and bleed line 5 remain on the clutch slave cylinder 2 Remove the clutch slave cylinder 2 Remove paper gasket 6 Pull clutch pushrod 7 out to the rear Installation is the reverse of the removal proce dure Pay particular attention to the following Clean mating surfaces on the gearbox housing and clut...

Page 207: ...uitable vessel and dispose of it in an environmentally acceptable manner Remove banjo bolt 3 and disconnect the pres sure line 4 Installation is the reverse of the removal proce dure L Note Route the clutch pressure line as illustrated Always use new sealing rings 1 Fill clutch system with brake fluid a 00 62 Bleed adjust the clutch a 00 62 Install left side section of fairing a 46 10 Install the ...

Page 208: ...nvironmentally acceptable man ner Remove sealing rings 3 and bleed line 2 Installation is the reverse of the removal proce dure Pay particular attention to the following L Note Route bleed line 2 as illustrated Always use new sealing rings 3 Fill clutch system with brake fluid a 00 62 Bleed adjust the clutch a 00 62 Install the front section of the rear carrier a 46 7 X Tightening torque Banjo bol...

Page 209: ...ts 13 Renew the grooved ball bearings for the intermediate shaft 13 Disassembling assembling input shaft 14 Disassembling input shaft 14 Assembling input shaft 15 Disassembling assembling output shaft 16 Disassembling output shaft 16 Assembling output shaft 17 Checking endplay 19 Checking adjusting fully assembled length of selector drum 19 Checking adjusting fully assembled length of gearbox shaf...

Page 210: ...23 2 Contents Page Installing gearbox housing 26 Aligning rubber mounts 28 Aligning left hand rubber mount 28 Aligning right hand rubber mount 29 ...

Page 211: ...98 95 199 00 7 8327 7 8346 Length of output shaft fully compressed mm in 192 95 193 00 7 5964 7 5984 Length of input shaft fully compressed mm in 138 60 138 55 5 4567 5 4547 Length of selector drum fully compressed mm in 111 80 111 90 4 4015 4 4055 Selector shaft endplay mm in 0 1 0 3 0 0039 0 0118 Output shaft endplay values Free gearwheel 1st gear mm in 0 1 0 33 0 0039 0 0130 Free gearwheel 2nd ...

Page 212: ...23 4 ...

Page 213: ...23 5 Gearbox cutaway drawing KR230000 ...

Page 214: ...23 6 ...

Page 215: ...end Lever the shaft sealing ring out with a screwdriv er Drive in the new sealing ring with the sealing lips facing inwards using slip over sleeve BMW No 23 4 712 and drift BMW No 23 4 711 23 12 Replacing output shaft sealing ring eImportant Do not press the output shaft sealing ring out with a screwdriver or the plastic disc behind it may be damaged Screw puller BMW No 00 8 750 into shaft seal in...

Page 216: ...t driver BMW No 23 4 721 23 31 Replacing shaft sealing ring for selector drum Lever the shaft sealing ring out with a screwdriv er Install the new sealing ring with the sealing lip facing inwards using impact driver BMW No 23 4 750 23 12 Replacing sealing ring for selector shaft Lever the shaft sealing ring out with a screwdriv er Install the new sealing ring with the sealing lip facing inwards us...

Page 217: ...eft right engine mountings at the cross member Cut through the cable tie arrow and disconnect the cable for the side stand switch Remove clutch release rod 3 from the gearbox Undo fasteners 4 5 and remove the heat shield Remove the 2 screws 8 and take off the starter motor 7 L Note If not removed the main centre stand must be re tracted when the gearbox is removed Undo the 6 fasteners 6 holding th...

Page 218: ... alignment of the left hand rubber mounts rela tive to the frame is preset at the factory do not slacken the securing screws The rubber mounts do not have to be re aligned un less the left hand rubber mount has been replaced Slightly lower the frame Tighten screw 2 holding gearbox to frame L Note When lowering the frame make sure that clearance is adequate on the right between frame and gear box d...

Page 219: ...r 6 Carefully press back centering pins arrows working from the back of the gearbox Remove the nine screws 7 securing the cover to the housing Insert gearbox into mount BMW No 23 4 700 Secure press off tool BMW No 23 4 780 to mount of clutch slave cylinder eImportant Avoid damage to the housing cover and painted sur faces Heat the bearing seats in the housing to 80 C 100 C 176 F 212 F Use press of...

Page 220: ...e cover hold it there and pull out selector drum 7 turning it slightly at the same time Remove the thrust washers and spacing washer Release the locking lever 6 Remove selector shaft 3 with spacing washer 10 Remove selector forks 2 8 9 23 31 Disassembling assembling selec tor shaft Remove torsion spring 14 with locking lever 13 from selector shaft 12 Remove torsion spring 11 Assembly is the revers...

Page 221: ... the intermedi ate shaft must always be renewed as a complete unit If the grooved ball bearings are replaced the fully assembled length must be re adjusted Pull off the grooved ball bearings with a universal puller BMW No 00 7 500 Press the output side grooved ball bearing on to the intermediate shaft Check adjust fully compressed length a 23 20 Place spacing washer of calculated thickness in posi...

Page 222: ... bearing 9 with spacing washer 8 L Note Note the thickness of spacing washer 5 Remove retaining sleeve 7 split segment wash er 6 backup washer 5 spring segment 4 corrugated washer 3 thrust piece 2 and con stant speed gear 1 Clamp input shaft 10 other way round in vise Use universal puller BMW No 00 7 500 and pressure head arrow to pull off grooved ball bearing 11 KR230080 11 9 8 7 6 5 4 3 2 1 10 0...

Page 223: ...kness as the original washer Compress spring segment 4 and insert split segment washer 6 into ring groove Install retaining sleeve 7 with the shoulder fac ing over segment washer 6 Check the fully compressed length and adjust if necessary a 23 22 Install spacing washer 8 of the calculated thick ness and press on deep groove ball bearing 9 eImportant Check endplay at the spring segment If endplay i...

Page 224: ...e the sliding gearwheel for 5th gear 7 Remove circlip 8 backup washer 9 shift gearwheel for 3rd gear 10 and needle roller bearing 11 Remove backup washer 12 4th gear shift wheel 13 needle roller bearing 14 and backup washer 15 Remove circlip 16 and sliding gearwheel for 6th gear 17 Turn output shaft 6 other way round and clamp into the vise with soft jaws Use universal puller BMW No 00 7 500 to pu...

Page 225: ...ing circlip 6 Install support washer 10 and needle roller bearing 11 Install shift wheel for 3rd gear 12 with pockets facing away from the 4th gear shift wheel 9 Install backup washer 13 and circlip 14 After installing measure endplay at 3rd and 4th gear shift wheels Install shift wheel for 5th gear 15 with recess for shift fork facing towards the 3rd gear shift wheel 12 Install backup washer 1 an...

Page 226: ...ackup washer 18 and needle roller bearing 19 Install the shift wheel for 2nd gear 20 with the dogs facing the 6th gear sliding gearwheel 17 Check adjust fully compressed length a 23 21 Install spacing washer 21 of the determined thickness and press on grooved ball bearing 22 Check 2nd gear endplay KR230140 16 KR230120 4 3 2 1 6 7 8 9 10 11 12 13 14 15 16 22 21 20 19 18 17 5 ...

Page 227: ... the affected parts Endplay values Endplay 1st gear 0 1 0 33 mm 0 0039 0 0130 in Endplay 2nd gear 0 1 0 33 mm 0 0039 0 0130 in Endplay 3rd 4th gear total play 0 1 0 67 mm 0 0039 0 0264 in 23 00 Checking adjusting fully assem bled length of selector drum Place spacing washer and both thrust washers on the selector drum Using slide gauge determine fully assembled length A If necessary adjust fully a...

Page 228: ...rooved ball bearing on the reference washer Insert intermediate shaft in measuring stand Using the dial gauge measure the deviation from zero of dimension B at the inner bearing race Deviation from zero is equivalent to the thickness C of spacer 1 Place spacer 1 of correct thickness on inner bearing race and check deviation from zero A B C eImportant The maximum deviation from zero must not be ex ...

Page 229: ... ball bearing on the reference washer Insert the output shaft into the measuring stand Using the dial gauge measure the deviation from zero of dimension B at the inner bearing race Deviation from zero is equivalent to the thickness C of spacer 1 Place spacer 1 of correct thickness on inner bearing race and check deviation from zero A B C eImportant The maximum deviation from zero must not be ex ce...

Page 230: ...put shaft with adapter disc BMW No 23 4 767 in measuring stand Using the dial gauge measure deviation from zero of dimension B at the inner bearing race Deviation from zero is equivalent to the thickness C of spacer 1 Place spacer 1 of correct thickness on inner bearing race and check deviation from zero A B C eImportant The maximum deviation from zero must not be ex ceeded Take the input shaft ou...

Page 231: ...rings Check that the gearbox shafts are correctly seated Insert the cover into gearbox mount BMW No 23 4 700 Align the input output and intermediate shafts so that their gearwheels mesh Insert slip over sleeve for input shaft BMW No 23 4 712 into cover Heat bearing points in cover to 80 100 C 176 212 F Insert input shaft 2 output shaft 3 and interme diate shaft 1 together at the same time Install ...

Page 232: ...ing mating face Measure distance C from the shoulder on the selector shaft to the back of the sleeve Calculate endplay as follows Dimensions A B D Distances D C E Distances E thickness of spacing washer end play 23 31 Installing selector shaft Place a spacing washer of the calculated thick ness in position and install selector shaft 1 Engage torsion spring 2 in position Endplay Selector shaft 0 1 ...

Page 233: ...mall amount of grease Swing locking lever 6 out towards the edge of the cover and install the selector drum Swing locking lever 6 towards selector drum 7 and engage it in position together with guide plate 4 Place shift forks 2 8 9 in the guide tracks Install selector rails 1 Install locking pin 5 Place thrust washer on selector drum KR23250 1 4 2 5 6 3 8 9 1 7 ...

Page 234: ...ten the secur ing screws Using the metering device apply Loctite 574 surface sealant to the mating face of the cover Place assembly sleeve BMW No 23 4 732 on the output shaft Place assembly sleeve BMW No 23 4 712 on the input shaft Place assembly sleeve BMW No 23 4 612 on the selector shaft Heat the bearing seats in the housing to 80 100 C 176 212 F and place the housing on the cover KR230240 KR23...

Page 235: ...tal particles off the magnet in drain plug 5 Install oil drain plug 5 Insert oil filler and level check plug 4 with a new sealing ring Install shift lever 6 in the correct position L Note In its correct position the lever points slightly down wards see illustration After assembling the gearbox perform a functional check 4 5 6 7 1 2 3 KR230020 KR230260 49 8 145 6 6 ...

Page 236: ...not slacken the paint marked Torx screws 1 unless the rubber mount has to be replaced Prepare a template as shown in the illustration above Insert template 2 between left right bearing mounts and press against machined face arrow on right Slide left bearing bushing into its mount Lightly press bearing bushing against template and uniformly tighten screws 1 KL230050 1 2 3 KL230060 ...

Page 237: ...e securing screws Position gearbox against intermediate flange and tighten securing screws Lower the frame Screw the left right engine mountings to the cross member Install and tighten bolt securing gearbox to frame eImportant To avoid damaging the spacing plate in the clamp slot uniformly tighten the left and right pinch bolts Uniformly tighten the pinch bolts 3 securing the right hand rubber mou...

Page 238: ...fork 13 Disassembling telescopic fork 13 Assembling telescopic fork 14 Measuring telescopic fork 14 Check slider tube bridge 14 Checking the fixed fork tube for runout 14 Removing installing front suspension strut 15 Removing installing steering damper 17 Checking the steering damper 17 Removing installing leading link 18 Removing leading link 18 Installing leading link 19 Removing left leading li...

Page 239: ...31 2 Contents Page ...

Page 240: ...rmissible fixed fork tube runout mm in 0 4 0 0157 Castor in normal load position mm in 124 4 8819 Steering head angle at unladen weight 62 75 Total suspension travel at wheel mm in 115 4 5276 at spring strut mm in 63 2 4803 Telescopic fork oil approved grades BMW telescopic fork oil Capacity per fork leg l Imp pint US quart 0 51 0 01 0 90 0 0176 0 54 0 0106 Front suspension element Type Non adjust...

Page 241: ...31 4 ...

Page 242: ...ply adhesive masking tape if necessary Remove front wheel a 36 5 Remove left and right fairing side sections a 46 8 Remove the rear section of the front mudguard a 46 6 Disconnect the ABS sensor and cable from the telescopic fork LNote If the telescopic fork is to be disassembled loosen end screws 1 on fixed fork tube 4 at left right Screws are secured with a thread locking com pound Loosen the le...

Page 243: ...the brake distributor 2 in the right brake line at the mount ing on the telescopic fork Unscrew the fastener arrow for steering damper 4 at the leading link Take off protective cap 3 e Important Screw is secured with a thread locking compound Unscrew the fastener for the leading link at the fork slider tube bridge using socket wrench in sert and internal hexagon BMW No 31 5 600 Pull the telescopic...

Page 244: ... strain on the assembly then install and tighten to the specified torques Insert left and right fixed fork tubes 3 into fork bridge 2 Fixed fork tubes 3 at left and right must be flush with the upper edge of handlebar holder 5 arrows eImportant Install screw 1 with Loctite 243 Tighten left and right handlebar clamps 1 Tighten left and right fork bridge clamps 4 Compress the telescopic fork KR31019...

Page 245: ...ticular eImportant When installing use a new screw Tighten holder for left brake line Check that the system moves freely by com pressing extending the suspension in the straight ahead position and with the steering turned to the full lock positions X Tightening torque Leading link to slider tube bridge clean thread apply Loctite 2701 130 Nm Steering damper to leading link clean thread apply Loctit...

Page 246: ...t fork bridge clamps 7 Undo the handlebar holder fastener 5 at fork bridge 2 eImportant Screw is secured with a thread locking compound Undo the fork bridge fastener 3 at the frame with socket wrench insert and internal hexagon BMW No 31 5 600 Take off fork bridge 10 Installation is the reverse of the removal proce dure Pay particular attention to the following KR310190 8 7 2 1 3 5 4 6 6 KR310040 ...

Page 247: ...ebar holder to fork bridge 9 Nm Screw plug 20 Nm Handlebar clamp clean thread apply Loctite 243 21 Nm Fork bridge clamp 21 Nm 31 42 Renewing ball joint Mount fork bridge 1 in retaining fixture BMW No 31 5 670 dWarning Note that high torque has to be applied to loosen the ball joint fastener Release the ball joint fastener with the 46 mm 1 8110 in socket wrench insert BMW No 31 5 630 Installation i...

Page 248: ...portant Screw is secured with a thread locking compound Undo the fasteners arrows at slider tube bridge 1 eImportant Make sure that brake line and front sensor cable are not stretched when telescopic fork extends Sup port the slider tubes Extend the telescopic fork Remove slider tube bridge 1 Installation is the reverse of the removal proce dure Pay particular attention to the following Install fr...

Page 249: ...lease the ball joint fastener with the 46 mm 1 8110 in socket wrench insert BMW No 31 5 630 Coat the ball joint fastener with Optimoly TA and secure it to the slider tube bridge 1 with 46 mm 1 8110 in socket wrench insert BMW No 31 5 630 X Tightening torque Ball joint to slider tube bridge 230 Nm Steering damper to slider tube bridge clean thread apply Loctite 243 21 Nm 31 5 630 KR310080 31 5 620 ...

Page 250: ...g telescopic fork LNote Do not pull oil filled fixed fork tube with oil bore ar row over shaft sealing ring Oil collects under the sealing boot Remove oil drain plug 3 Drain the oil eImportant Avoid damage to fixed fork tube 4 Remove fixed fork tube 4 Remove wiper 6 Remove retaining ring 7 Lever out shaft seal 8 Remove washer 9 5 KR310091 6 7 8 9 4 1 2 3 ...

Page 251: ...ube 1 using the combined weight ar row of drift BMW No 31 5 610 reducing adapt er with lugs BMW No 31 5 613 and sleeve BMW No 31 5 614 Install retaining ring Install fixed fork tube Install wiper 31 42 Measuring telescopic fork dWarning After an accident always examine the telescopic fork for cracks and signs of damage 31 00 Check slider tube bridge eImportant Replace distorted slider tube bridge ...

Page 252: ...leading link 2 Undo suspension strut pivot arrow at leading link 2 Unscrew fastener arrow for suspension strut on frame Take off washer 5 and plastic washer 6 eImportant Before removing the suspension strut mask off its thread with adhesive tape to protect it Unscrew brake line holder 4 from the frame eImportant Make sure that brake line and front sensor cable are not stretched when telescopic for...

Page 253: ... the following LNote If the telescopic fork was extended too far loosen the fixed fork tube clamps and push the fixed tube into the fork tube turning it at the same time Note the correct projection when securing the fixed fork tube eImportant When installing connecting hose 4 make sure that the fastener arrow is a sufficient distance away from the radiator Add coolant to the correct level a 00 68 ...

Page 254: ...h the sleeve and washer Installation is the reverse of the removal proce dure Pay particular attention to the following eImportant Use only new genuine screws because the steer ing damper could be damaged beyond repair if the screws are of the wrong length Tighten fastener securing steering damper 4 to slider tube bridge 3 X Tightening torque Steering damper to leading link clean thread apply Loct...

Page 255: ...at the bottom from the leading link Disconnect the leading link from the slider tube bridge Remove the lid of the electronic equipment box Remove Motronic control unit a 13 5 Detach the electronic equipment box and wiring harness from the frame Pull the wiring harness out of the electronic equipment box Take off the electronic equipment box Tie up the wiring harness e Important Always replace the ...

Page 256: ... bolt for the front suspension strut Tighten the leading link at the clamp sleeve X Tightening torque Leading link to frame clean thread apply Loctite 243 107 Nm Leading link to clamp sleeve 21 Nm Route the wiring harness into the electronic equipment box Secure the electronic equipment box and wiring harness to the frame Install the Motronic control unit a 13 5 Install the lid of the electronic e...

Page 257: ... the spacing bushing out of the ball thrust bearing 31 42 Installing left leading link pivot mount Press the spacing sleeve fully into the ball thrust bearing Chill the spacing sleeve with ball thrust bearing down to at least 10 C 14 F Heat the frame at the left pivot bearing seat to approx 100 C 212 F Apply assembly grease to the outside diameter of the ball thrust bearing Install angular contact...

Page 258: ...hen telescopic fork extends Extend the telescopic fork Insert test pin BMW No 31 5 681 with distance gauge BMW No 31 5 682 into leading link 3 Stylus of gauge BMW No 31 5 682 must be lo cated in punch mark arrow in leading link on right Installation is the reverse of the removal proce dure Pay particular attention to the following eImportant When installing use a new nut Secure the leading link fa...

Page 259: ...ght grip tube 6 Removing installing clutch lever fitting 7 Removing installing brake lever fitting 8 Removing installing left handlebar tube 9 Removing installing right handlebar tube 10 Removing installing left and right handlebar levers 11 Removing installing throttle cables a 00 36 11 32 Steering ...

Page 260: ...32 2 Contents Page ...

Page 261: ...S Type One piece forged stub handlebars adjustable from lower front to upper rear position without anti vibration weights Handlebar tube diameter mm in 22 0 8661 Steering lock angle 32 Handlebar width with grip tube mm in 720 28 3464 ...

Page 262: ...32 4 ...

Page 263: ...eated grip Option with heated grip Release cable shoes 3 from plug connector 2 Undo fasteners arrows for grip tube 5 Pull grip tube 5 off handlebar tube 1 Option with heated grip Pull grip tube 5 with cable 4 off handlebar tube 1 Installation is the reverse of the removal proce dure Pay particular attention to the following K41320010 2 3 1 5 4 ...

Page 264: ... for cable guide 3 Detach multifunction switch 7 from brake fitting 1 Disconnect Bowden cable 2 at cam disc of grip tube 5 Take off Bowden cable guide 4 L Note Turn grip tube 5 fully forwards Pull grip tube 11 off handlebar tube 10 Option with heated grip Pull grip tube 5 with cable 6 off handlebar tube 6 Installation is the reverse of the removal proce dure Adjust the basic throttle cable setting...

Page 265: ...switch 6 from clutch lever fitting 1 Loosen fastener arrow for clutch lever fitting 1 on handlebar tube 3 Pull clutch lever fitting 1 off handlebar tube 3 Installation is the reverse of the removal proce dure Pay particular attention to the following eImportant Make sure that lines and cables are correctly routed L Note Note correct installed position of clutch switch 6 The marks on the clutch lev...

Page 266: ... from brake lever fitting 2 Loosen fastener arrow for brake lever fitting 2 at handlebar tube 7 Pull brake lever fitting 2 off handlebar tube 7 Installation is the reverse of the removal proce dure Pay particular attention to the following eImportant Make sure that lines and cables are correctly routed L Note Note correct installed position of brake light switch 6 Align the marks on brake lever fi...

Page 267: ...ause brake fluid destroys paint Set the clutch lever fitting 1 down securing it if necessary Remove handlebar tube 2 from handlebar holder 4 Installation is the reverse of the removal proce dure Pay particular attention to the following eImportant Check brake fluid if necessary bleed the clutch system Make sure that lines and cables are correctly routed The marks on the clutch lever fitting 1 and ...

Page 268: ...uid to come into contact with painted parts of the motorcycle because brake fluid destroys paint Set brake lever fitting 1 down and secure it if necessary Installation is the reverse of the removal proce dure Pay particular attention to the following eImportant Check brake fluid bleed if necessary Make sure that lines and cables are correctly routed Align the marks on brake lever fitting 1 and han...

Page 269: ...nt Screw is secured with a thread locking compound L Note When removing installing note springs 2 Remove fastener 1 from left right handlebar lever 3 When installing apply Loctite 243 to fastener 1 and tighten 32 72 Removing installing throttle cables a 00 36 KR320040 2 1 3 ...

Page 270: ...ng input bevel pinion 12 Removing crown wheel 14 Installing crown wheel 15 Checking adjusting backlash 16 Checking tooth contact pattern 17 Shimming housing cover 18 Installing housing cover 18 Installing rear drive shaft 19 Installing rear wheel drive 19 Removing disassembling reassembling and installing rear swinging arm 21 Removing rear swinging arm 21 Removing installing flexible gaiter 22 Rem...

Page 271: ...33 2 Contents Page Installing rear swinging arm 24 Removing installing suspension strut 25 ...

Page 272: ...e shaft Layout 2 section double drive shaft with integral torsional vibration damper in hollow swinging arm BMW PARALEVER universal joints at both ends with sliding joint at rear wheel drive end Swinging arm Type Paralever new swinging arm with spring strut at tached off centre kinematic progressive rate Swinging arm length mm in 320 12 5984 Rear suspension Spring strut Gas filled strut with varia...

Page 273: ...33 4 ...

Page 274: ...33 5 Rear wheel drive cutaway drawing KR330000 ...

Page 275: ...33 6 ...

Page 276: ...effect Unscrew the oil filler plug 5 Remove oil drain plug 4 and drain oil into a suit able vessel Loosen reaction link 3 at the rear wheel drive Release clamping strap 1 d Warning Note high release torques for locknut and fixed bearing stud Loosen floating bearing stud 6 and locknut 7 Loosen fixed bearing stud 2 Unscrew and remove free 6 and fixed 2 bear ing studs LWarning Note inner races of nee...

Page 277: ...ce circlip 3 if necessary Screw rear wheel drive centrally to holder BMW No 33 1 510 using bearing stud 6 Screw locking arm 7 on firmly Move threaded sockets 4 up to rear wheel drive Tighten with wheel studs 5 eImportant The grub screws must not project or the neck of the housing could be damaged Tighten grub screws 8 until they are sealed LT 33 043 2 KR330030 1 KR330390 3 KR330050 5 6 7 6 8 4 33 ...

Page 278: ...crew with a 36 mm 1 4173 in socket wrench insert and reducing adapter BMW No 33 1 720 Remove thrust ring 3 dWarning Threaded ring 2 requires a high torque to loosen it Heat the housing neck to 120 C 248 F and un screw threaded ring 2 with pin wrench BMW No 33 1 700 Remove outer bearing race 1 Remove locking arm 8 Take out screws 7 Remove housing cover 6 1 2 3 4 5 6 7 KR330140 KR330060 33 1 700 h 1...

Page 279: ...L Note If necessary release input bevel pinion 1 by strik ing lightly Take off thrust washer 2 33 12 Disassembling input bevel pinion Clamp input bevel pinion 1 into vise with pro tective jaws splines facing upwards Using puller BMW No 00 7 500 pull off both bearings at the same time Take off radial thrust bearing 6 roller bearing cage 5 outer race 4 and inner race 3 KR330070 h 120 w 33 1 510 1 2 ...

Page 280: ...r bearing for input bevel pinion Heat the needle roller bearing seat to 100 C 212 F Press in needle roller bearing using drift or the in put bevel pinion 33 12 Assembling input bevel pinion Heat the inner race 2 to 100 C 212 F and push onto input bevel pinion 1 until sealed Slide outer race 3 together with roller cage 4 onto inner race 2 Heat ball thrust bearing 5 to 100 C 212 F and push onto inpu...

Page 281: ... L Note When inserting input bevel pinion 1 make sure that it is not tilted Insert input bevel pinion 1 into housing Install housing cover 3 Tighten fasteners 4 in diagonally opposite se quence X Tightening torque Housing cover to housing 35 Nm Clean the threads in the neck of the housing and on threaded ring 6 eImportant Install shaft sealing ring 5 with the sealing lips fac ing the input bevel p...

Page 282: ...t ring Clean the threads of hex nut 6 and input bevel pinion Coat the thread of hex nut 6 with Loctite 2701 eImportant The nut must not damage shaft sealing ring 3 Tighten hex nut 6 with 36 mm 1 4173 in socket wrench insert and reducing adapter BMW No 33 1 720 X Tightening torque Threaded ring clean thread apply Loctite 577 118 Nm Nut for input bevel gear clean thread apply Loctite 2701 200 Nm Hou...

Page 283: ...m the inside out of housing cover 7 with a suitable drift Clamp crown wheel 3 into vise with soft jaws Insert thrust block arrow BMW No 33 1 307 Using puller BMW No 33 1 830 pull off grooved ball bearing 2 Pull taper roller bearing 5 off crown wheel 3 using puller BMW No 00 7 500 KR330170 7 8 h 100 w 5 3 2 4 6 1 33 1 830 KR330180 33 1 307 2 KR330190 00 7 500 5 3 ...

Page 284: ...3 4 670 and handle BMW No 00 5 500 Check that outer race is correctly fitted by strik ing it gently L Note If new parts were installed e g taper roller bearing check tooth backlash and adjust again if necessary b adjust tooth contact pattern Attach the original shim washer 4 to crown wheel 3 with grease Heat taper roller bearing 5 to 80 C 176 F and push it on Install crown wheel 3 Heat grooved bal...

Page 285: ...h backlash at three points 120 degrees apart turn the bevel pinion with the crown wheel Press the crown wheel 3 into the housing with the palm of the hand and turn to and fro to check tooth backlash Backlash Setting without oil 0 07 0 16 mm 0 0028 0 0063 in Compensate for excessive tooth backlash by in serting a thinner shim washer 5 or insert a thick er one if tooth backlash is insufficient 33 2 ...

Page 286: ...eel press into housing with the palm of the hands and turn to and fro eImportant Teeth should never make contact at the smaller di ameter If the correct spacer disc is installed the contact pattern shown here appears with no load ap plied L Note The contact point is central on front flank F The contact point is closer to the larger diameter on rear flank R If this contact pattern is obtained a thi...

Page 287: ...heel Preload 0 05 0 1 mm 0 0020 0 0039 in 33 11 Installing housing cover L Note Checking adjusting the ABS sensor gap is required after replacement of the following components Cover of rear wheel drive housing Crown wheel Oil the shaft sealing ring 31 slightly Using drift BMW No 33 1 860 and handle BMW No 00 5 500 drive in shaft sealing ring 1 eImportant Do not overheat shaft sealing ring and cord...

Page 288: ...of the rear universal shaft 1 with Never Seez eImportant Make sure that the inner race never presses against the ends of the needles Install the inner races arrows of the left right needle roller bearings with a small quantity of grease Push the flexible gaiter on to the neck of the housing and secure it with the clamping strap Offer up the rear wheel drive with flexible gaiter and push the rear d...

Page 289: ... Floating bearing stud 7 Nm Locknut 160 Nm Reaction link to rear wheel drive 43 Nm Oil drain plug oil filler plug 23 Nm Quantity Initial fill 0 25 l 0 44 Imp pint 0 26 US quart Oil change 0 23 l 0 40 Imp pint 0 24 US quart Oil grade Brand name hypoid gear oil SAE 90 API class GL 5 Install the brake disc a 34 8 Install brake caliper a 34 5 Without Integral ABS Install inductive signal transmitter a...

Page 290: ...ght threaded rings and bearing studs Remove circlip 1 and use socket wrench adapt er BMW No 33 6 643 to unscrew the right threaded ring 6 Remove circlip 1 and loosen lock ring 2 e Important Note high loosening torque for lock ring and for the threaded rings and the bearing studs on left and right Loosen the left threaded ring 3 with socket wrench insert BMW No 33 6 641 Loosen bearing studs 5 at le...

Page 291: ... ring bearings 33 17 Removing bearing from left right threaded ring Insert pressing out tool BMW No 33 6 644 with pins arrows in the holes in the threaded ring Press the left right bearing out of the threaded ring 33 17 Installing bearing in left right threaded ring eImportant Install with the open side of the bearing facing the threaded ring Lightly oil grease the bearing Press the bearing into t...

Page 292: ...te If necessary remove install the circlip in the joint el ement Checking universal joint for wear Determine endplay and radial play arrows 33 00 Installing drive shaft Coat splines of output shaft with Optimoly MP 3 Slide the front drive shaft 1 on to the output shaft Snap the circlip into position by striking the drive shaft lightly with a plastic faced hammer KR330350 1 KR330360 ...

Page 293: ... 7 until flexible gaiter 8 snaps into position at the gearbox neck Screw in left right bearing studs 5 Attach suspension strut with fastener 10 to swinging arm 11 Using socket wrench insert BMW No 33 6 643 tighten left and right bearing studs 5 KR330330 1 6 4 5 7 11 10 10 5 4 3 2 1 8 9 KR330410 33 6 643 ...

Page 294: ...e Install the rear wheel drive a 33 19 Install the brake disc a 34 8 Install brake caliper a 34 5 Without Integral ABS Install inductive signal transmitter a 61 15 Install the rear wheel a 36 8 33 53 Removing installing suspension strut Remove the seat a 52 5 Remove the right rear side section a 46 15 Remove the coolant expansion tank Unscrew the upper fastener arrow Press the suspension strut upw...

Page 295: ...S sensor 10 Integral ABS Marking rear ABS sensor ring 11 Integral ABS Checking and adjusting rear ABS sensor 11 Checking ABS sensor gap 11 Adjust ABS sensor gap 11 Integral ABS Removing installing rear master brake cylinder 12 Integral ABS Checking adjusting the blow by clearance of the piston rod 12 Checking blow by clearance at piston rod 12 Adjusting blow by clearance at piston rod 12 Integral ...

Page 296: ... Integral ABS Performing bleed test with BMW MoDiTeC a 00 35 24 Integral II Removing installing front brake lines hoses 25 Integral ABS Removing front brake lines hoses 25 Preparatory work 25 Integral ABS Removing installing rear brake lines hoses 27 Integral ABS Removing brake lines hoses 27 Preparatory work 27 Removing the brake lines from wheel circuit reservoir to the pressure modulator 28 Int...

Page 297: ...lever cylinder mm in 16 0 6299 Sensor gap front mm in 0 1 1 7 0 0039 0 0669 maintenance free Brake pad lining Sintered metal Identification mark White Rear wheel Rear brake 2 piston fixed caliper with fixed disc Brake disc dia mm in 285 11 2295 Brake disc thickness mm in 5 0 0 1968 Minimum thickness mm in 4 5 0 1771 Brake pad surface area cm2 sq in 20 3 1 Minimum pad thickness mm in 1 0 0 0394 Pis...

Page 298: ...34 4 ...

Page 299: ...21 X Tightening torque Brake caliper to fork tube 30 Nm Hollow union bolt for brake line 18 Nm Bleed screw to brake caliper 7 Nm 3400 Integral ABS Removing installing rear brake caliper Remove rear wheel a 36 8 eAttention Do not allow brake fluid to come into contact with painted parts of the motorcycle because brake fluid destroys paint Bleed rear wheel circuit a 34 16 Remove the ABS sensor a 34 ...

Page 300: ... from each brake cylinder bore Inspect the brake caliper piston for hairline cracks score marks and other damage Coat new sealing rings 3 4 with brake fluid and install Coat the brake pistons 5 with brake fluid and in stall force the pistons all the way back eAttention Keep the brake pistons parallel with their bores when installing Remove and install the other two brake pistons in the same way re...

Page 301: ...ith a com pressed air gun applied to the connecting bore work at low air pressure Remove sealing rings from left and right bores Inspect the brake caliper piston for hairline cracks score marks and other damage 3400 Assembling rear brake caliper Coat new sealing rings 4 5 with brake fluid and insert them into the left and right brake caliper bores Coat both brake pistons with brake fluid and in st...

Page 302: ...fully press back the pistons as you remove in stall the brake callipers as the wheel circuit reservoir must not overflow If fluid escapes proceed in accordance with In structions for filling reservoir a 00 50 Remove rear wheel a 36 8 Remove the brake caliper L Note Mark the installed position of brake disc 4 at rear wheel drive 5 so that vertical runout of the sensor wheel is not altered eAttentio...

Page 303: ...nect ABS sensor cable 1 from the tele scopic fork Disconnect the plug arrow for ABS sensor cable 1 in electronic equipment box 2 Release the fasteners arrows for ABS sensor 3 Take off ABS sensor 3 Installation is the reverse of the removal proce dure Pay particular attention to the following eAttention Carefully route the ABS cable and secure in position with cable ties a 34 10 X Tightening torque...

Page 304: ... 2 from brake caliper 1 Take off ABS sensor 2 with spacing plate 3 Remove all cable ties holding the ABS sensor cable 4 Disconnect plug connector arrow from ABS sensor cable 4 Installation is the reverse of the removal proce dure Pay particular attention to the following eAttention Carefully route the ABS cable and secure in position with cable ties If required check adjust ABS sensor gap a 34 11 ...

Page 305: ...he reverse of the removal proce dure Pay particular attention to the following Replace the fastener for retaining bracket 1 X Tightening torque Retaining bracket to brake caliper clean thread apply Loctite 243 8 Nm 3400 Integral ABS Checking and adjusting rear ABS sensor L Note Checking adjusting the ABS sensor gap is required after replacement of the following components ABS sensor ring brake dis...

Page 306: ...rest plate clean thread apply Loctite 243 9 Nm Brake hose line banjo bolt 18 Nm 3400 Integral ABS Checking adjust ing the blow by clearance of the piston rod dWarning Adjustments may only be made by a specialist work shop Checking blow by clearance at piston rod Insert a feeler gauge between the adjusting screw and the brake light switch plate arrow Feeler gauge 0 2 mm 0 0079 in Adjusting blow by ...

Page 307: ...ry with hose protector 2 a 00 69 Disconnect plug from power socket in mudguard Remove rear mudguard Slacken diagnosis plug eAttention Do not allow brake fluid to come into contact with painted parts of the motorcycle because brake fluid destroys paint Release hose clips arrows at wheel circuit reservoir 1 Open 3 cable ties arrows on rear frame Disconnect brake line 8 from distributor filler adapte...

Page 308: ...with the con nections upwards Installation is the reverse of the removal proce dure Pay particular attention to the following L Note Always replace the seals arrow between the brake lines and the pressure modulator when you replace the pressure modulator or brake lines dWarning Always replace the springs 10 Ensure correct positioning Install 3 new springs 10 Clip brake lines 1 4 into position Ensu...

Page 309: ...protective cap 9 Remove the springs 10 from the brake lines Remove the brake line 1 4 Unfasten the clips 5 6 Pull off the front and rear brake fluid hoses 7 8 L Note Prepare the old pressure modulator for transport by plugging all openings Install 7 new springs 10 Clip brake lines 1 4 into position Ensure that the springs 10 are correctly seated on both sides Replace the seals on the pressure modu...

Page 310: ... complete its self diagnosis Do not operate the brake lever until self diagnosis has completed Gently press the footbrake lever the pump starts up Open the bleed screw at the brake caliper Drain the wheel circuit with the pump Close the bleed screw Release the brake lever Draining front wheel circuit L Note Use the same procedure as for the rear wheel cir cuit Drain from the front brake calipers R...

Page 311: ...iper to en sure that the system is free of air bubbles dWarning On filling make sure no air bubbles enter the brake caliper via the injector and the silicon hose The brake caliper is fitted Filling the front wheel circuit Open the cap 2 Fill injector BMW No 34 2 551 and silicon hose with 80 ml 0 1407 Imp pint 0 0845 US quart of brake fluid L Note Press the plunger of the injector until the silicon...

Page 312: ...servoir filling instructions Follow the reservoir filling instructions a 00 47 Close cap 2 Filling rear wheel circuit Open the cap 3 Completely fill injector BMW No 34 2 551 and silicon hose with brake fluid Connect bubble free injector BMW No 34 2 551 to rear brake caliper Open the bleed screw at the brake caliper Inject brake fluid into the wheel circuit until the reservoir 4 is filled to above ...

Page 313: ...up the reservoir to the MAX mark eAttention During the filling process ensure that the return bore arrow is always covered with brake fluid as otherwise air is drawn into the brake system Bleed the control circuit again if this happens Connect the silicon hose with bleeding device to each of the 3 bleed screws in turn front dosing cylinder front integral circuit front control circuit Let the brake...

Page 314: ... dWarning If the brake fluid level in the reservoir does fall below hose level arrow the wheel circuit must be refilled at the brake calliper and bled once again a 34 17 Connect the silicon hose with bleeding unit to each of the 3 bleed screws in turn rear dosing cylinder rear integral circuit rear control circuit Let the brake fluid run out and at the same time continuously top up new brake fluid...

Page 315: ...ady for use L Note The control circuit must be filled with brake fluid Remove the cap from the front wheel circuit res ervoir 1 Force back the brake pistons a 00 45 Fill the front wheel circuit reservoir 1 with as much brake fluid as it will take Screw cap BMW No 34 2 541 onto front wheel circuit reservoir 1 Connect silicon hose BMW No 34 1 560 to bleed nipple of left brake caliper and to cap BMW ...

Page 316: ...cuit reservoir Connect silicon hose BMW No 34 1 560 to bleed nipple of right brake caliper The procedure for bleeding the right brake cali per is the same as that for the left caliper Close the bleed screw Release the handbrake lever Switch off the ignition Disconnect silicon hose BMW No 34 1 560 from bleed screw and drain its contents into wheel circuit reservoir Remove cap BMW No 34 2 541 e Atte...

Page 317: ...ed nipple of brake caliper and to cap BMW No 34 2 541 L Note If required secure bleed hose with cable tie L Note The bleed process runs via the pump in the pres sure modulator L Note After switching on the ignition always wait for the BMW Integral ABS to complete its self diagnosis Do not operate the brake lever until self diagnosis has completed If the brake pistons were forced back the general w...

Page 318: ...r Switch off the ignition Disconnect silicon hose BMW No 34 1 560 from bleed screw and drain its contents into wheel circuit reservoir Remove cap BMW No 34 2 541 eAttention After changing and or bleeding the brakes always top up the fluid in the wheel circuit reservoir to the correct level in accordance with the instructions Fill rear wheel circuit reservoir with brake fluid in accordance with ins...

Page 319: ... 10 dWarning Comply with safety precautions when handling or working with fuel note that the fuel lines are pressu rised Remove fuel tank a 16 5 e Attention Do not allow brake fluid to come into contact with painted parts of the motorcycle because brake fluid destroys paint Wrap cloths around the ends of the pressure lines to prevent residual brake fluid escap ing Open cable ties securing brake ho...

Page 320: ...ated on both sides eAttention Replace the sealing rings of the brake line hose Filling and bleeding the front brake system a 34 17 Check the operation of the brake system eAttention After all the work on the brake system has been completed run a bleed test using the BMW MoDiTeC Perform bleed test with BMW MoDiTeC a 00 35 Brake fluid DOT 4 X Tightening torque Brake hose line banjo bolt 18 Nm Brake ...

Page 321: ...e sections a 46 10 Remove the spring strut if necessary a 33 25 Slacken fasteners of return reservoir arrow if necessary e Attention Do not allow brake fluid to come into contact with painted parts of the motorcycle because brake fluid destroys paint Wrap cloths around the ends of the pressure lines to prevent residual brake fluid escap ing 41340020 ...

Page 322: ...nes d Warning Always replace the springs Ensure correct position ing Fit new springs Clip in brake lines Ensure that the springs are correctly seated on both sides eAttention Replace the sealing rings of the brake line hose Fill and bleed the rear brake system a 34 17 Check the operation of the brake system eAttention After all the work on the brake system has been completed run a bleed test using...

Page 323: ... to length in such a way as to ensure that the end of the hose is clear of the exhaust system Install the hose and route it downward in the same way as the battery breather hose Cut off the hose at an angle level with the swing ing triangle arrow Integral ABS Checking brake pads for wear replacing a 00 41 IntegralABS Checking brake fluid level at handlebar fitting a 00 43 Integral ABS Changing bra...

Page 324: ...lling left wheel bearing 7 Installing right wheel bearing 7 Removing installing rear wheel 8 Removing rear wheel 8 Installing rear wheel 8 Static balancing of front and rear wheels 9 Static balancing of front wheel 9 Static balancing of rear wheel 9 Checking front rear wheel rim for runout 10 Checking front wheel rim for runout 10 Checking rear wheel rim for run out 11 36 Wheels and tyres ...

Page 325: ...36 2 Contents Page ...

Page 326: ... 70 ZR 17 tubeless Rear 170 60 ZR 17 tubeless Option rear 180 55 ZR 17 tubeless Tyre pressures tyres cold One up front bar psi 2 5 36 26 One up rear bar psi 2 9 42 06 Two up front bar psi 2 5 36 26 Two up rear bar psi 2 9 42 06 Wheel bearing lubrication Brand name anti friction bearing grease operating temperature range 30 140 C 22 284 F drip point 150 230 C 302 446 F high corrosion protection lev...

Page 327: ...36 4 ...

Page 328: ...nd right 2 clamping screws in telescopic fork Pull the quick release axle 1 out to the right noting the right bearing cover 3 and the left spacing bushing 5 Remove the front wheel 4 Installation is the reverse of the removal proce dure Pay particular attention to the following Grease the quick release axle 1 and bearing cover 3 lightly with Shell Retinax EP2 L Note Tighten the quick release axle 1...

Page 329: ...Note There is no circlip at the right wheel bearing Lever out shaft seal 1 Remove circlip 2 with suitable pliers Place support ring BMW No 36 6 640 on wheel hub Heat bearing seat to 60 C 140 F Pull out wheel bearing 3 with puller BMW No 00 8 570 and internal puller 21 4 BMW No 00 8 573 Remove spacer sleeve 4 KR360020 3 3 4 2 1 KR360060 00 8 570 00 8 573 36 6 640 w h 60 ...

Page 330: ... with suitable pliers Grease shaft sealing ring 1 lightly with Shell Retinax EP2 and drive it in flush with the wheel hub using handle for drift BMW No 00 5 500 and drift BMW No 36 5 512 Installing right wheel bearing Insert spacing sleeve 4 eImportant When pressing in the right wheel bearing make sure that the left wheel bearing does not move away from its seat Cool the wheel bearing 3 Heat beari...

Page 331: ...eel hub must be free from grease and clean eImportant Only use wheel studs with length code 55 Offer up the rear wheel with spacing washer to the rear wheel drive and hand tighten all wheel studs Working in diagonally opposite sequence tight en the outer wheel studs to 50 Nm Fully tighten the screw in the centre Fully tighten the outer wheel studs in diagonally opposite sequence X Tightening torqu...

Page 332: ...g procedure as a check 36 30 Static balancing of rear wheel L Note The rear wheel can also be balanced dynamically Align the balancer BMW No 36 3 600 with knurled screws 2 level gauge 1 Attach mounting fixture BMW No 36 3 618 to the centering collar side of the rear wheel Pass the balancing shaft BMW No 36 3 607 through the rear wheel Screw the balancing shaft up handtight with knurled nut BMW No ...

Page 333: ...lancer BMW No 36 3 600 Lock the balancing shaft at the balancing stand with the pin arrow to prevent it from turning Install dial gauge BMW No 00 2 510 in the dial gauge holder on the balancer and adjust it to suit the measuring work to be performed L Note Apply the dial gauge BMW No 00 2 510 only to the machined inner surface of the wheel rim Measure vertical or horizontal runout as applica ble M...

Page 334: ... wheel on the balancing stand BMW No 36 3 600 Lock the balancing shaft at the balancing stand with the pin arrow to prevent it from turning Install dial gauge BMW No 00 2 510 in the dial gauge holder on the balancer and adjust it to suit the measuring work to be performed L Note Apply the dial gauge BMW No 00 2 510 only to the machined inner surface of the wheel rim Measure vertical or horizontal ...

Page 335: ...talling cover for windscreen holder 12 Removing installing windscreen holder 12 Removing installing instrument panel trim 13 Removing installing engine spoiler 14 Removing installing bracket for engine spoiler 14 Removing installing left right tail side section 15 Removing installing fairing carrier 16 Removing installing air guide 17 Removing installing intake air pipe 17 Removing installing disc...

Page 336: ... brake light switch 22 Removing installing left footrest system 22 Adjusting left right footrests 22 Adjusting gear shift lever 22 Removing installing rear left footrest holder 23 Removing installing rear right footrest holder 23 Removing installing rear frame 24 Removing installing frame 25 Removing installing cross tube 25 Removing installing left right cross member 25 Removing installing frame ...

Page 337: ...61 2203 Ground clearance in normal load position mm in 125 4 9212 Wheel offset rear wheel to right Rear wheel 5 x 17 mm in 4 5 0 1772 Rear wheel 5 5 x 17 mm in 0 0 Caster angle in normal load position mm in 124 4 8819 Steering head angle in normal load position 62 8 Steering lock angle min 30 Dynamic heel angle footrests up 44 Dynamic heel angle footrests down 41 Axle load distribution without rid...

Page 338: ...46 4 ...

Page 339: ...46 5 General view of body panels K41469010 ...

Page 340: ... Note To remove or install the rear section the front sec tion has to be removed first eImportant When installing the rear section of the front mud guard centre it relative to the wheel X Tightening torque Front section to rear section of front mudguard to slider tube top 9 Nm KR460010 ...

Page 341: ... rear Remove the spray guard from the tail section Remove the reflector Remove the number plate light Remove left and right flashing turn indicators and the cross member Remove the rear light Installation is the reverse of the removal proce dure 46 62 Removing installing rear carrier section Remove the seat a 52 5 Activated charcoal filter Undo the cable tie for the activated charcoal filter at th...

Page 342: ...side section 46 63 Removing installing left right inner trim Detach and remove left right inner trim 1 Installation is the reverse of the removal proce dure L Note When installing make sure that the lug arrow is correctly seated K41460050 1 ...

Page 343: ... Remove upper section of fairing 1 Remove left right lamp sockets 2 from upper section of fairing Installation is the reverse of the removal proce dure L Note When installing make sure the fairing upper section 1 is correctly located arrow in the instru ment panel trim 3 K41460040 1 3 2 4 ...

Page 344: ...ring bracket Release the fasteners for the left and right side sections of the fairing L Note The side sections of the fairing are attached at the tank cover and by the frame at the sides by retaining pins arrows Installation is the reverse of the removal proce dure eImportant Avoid scratching the paint when installing the side sections take special care not to cause damage at the upper section an...

Page 345: ... to two positi ons Raise the windscreen 1 Press out pins 2 towards the motorcycle s cen treline and take off the windscreen eImportant Do not re use the pins Press the bushings arrows out of the cutouts in windscreen 1 Installation is the reverse of the removal proce dure K41UB0020 2 1 ...

Page 346: ...d right windscreen hol ders Remove upper section of fairing a 46 9 Remove instrument panel trim a 46 13 Remove retaining rings 3 and remove top windscreen holders Remove tensioning springs 4 for left and right windscreen holders Unscrew mount 5 for left and right windscreen holders and remove windscreen holders Installation is the reverse of the removal proce dure L Note When installing grease lef...

Page 347: ...ers a 46 12 Remove upper section of fairing 1 a 46 9 Release instrument panel trim 3 Slacken screws 4 and push bottom windscreen holder up in direction indicated by arrow Remove the instrument panel trim Installation is the reverse of the removal proce dure L Note Centre the instrument panel trim relative to the headlight K41460040 1 3 2 4 ...

Page 348: ...46 63 Removing installing bracket for engine spoiler Remove engine spoiler Take out screws arrows at left and right and re move the engine spoiler bracket 2 downwards Remove rubber support 1 Detach the radiator from its bracket and press it forward Undo the screws arrows at the cross member and take off the front left engine spoiler bracket 2 Installation is the reverse of the removal proce dure X...

Page 349: ...ion pannier case carrier Detach the left right pannier case carrier at the front Detach the left right tail side section L Note The tail side section is a push fit at the front arrow Installation is the reverse of the removal proce dure X Tightening torque Case holder front 22 Nm KR460140 ...

Page 350: ...lder eImportant Comply with safety regulations fuel lines are pres surised Remove fuel tank a 16 5 Release the cable ties guide the instrument cluster with wiring harness through the fairing carrier and set it down on the frame Detach the radiators at left and right from their holders and press forwards Release the fairing carrier and pull off forwards Remove windscreen holder and horn Remove crui...

Page 351: ...g intake air pipe eImportant Comply with safety precautions when handling or working with fuel Release fasteners and pull back the fuel tank a 16 5 Remove fasteners securing intake to right radia tor 1 and to fairing carrier 2 Remove fastener 3 at intake air silencer Disconnect the intake from the right radiator and from the intake air silencer Installation is the reverse of the removal proce dure...

Page 352: ...at shield X Tightening torque Heat shield To gearbox 1 22 Nm To ignition coil 2 9 Nm 46 00 Removing installing tail com ponents 52 53 Removing installing grab handle Remove the seat a 52 5 Remove the left right tail side sections Remove the tail section Take out screws arrows for grab handle Installation is the reverse of the removal proce dure X Tightening torque Grab handle 9 Nm 46 54 Option Rem...

Page 353: ... luggage rack from the grab handle at bottom arrows Installation is the reverse of the removal proce dure 52 53 Removing installing lock carrier Remove the seat a 52 5 Remove screws arrows and pull the lock carrier to the right to remove Installation is the reverse of the removal proce dure X Tightening torque Lock carrier 9 Nm KR460220 KR460240 ...

Page 354: ...1 Nm Switch to side stand clean thread apply Loctite 243 9 Nm 46 52 Removing installing pivot mount with centre main and side stands Remove the seat a 52 5 Remove the engine spoiler a 46 14 Remove engine spoiler holder a 46 14 Secure lifter BMW No 00 1 510 to oil sump Raise the motorcycle until the centre stand can move freely Disconnect the cable tie disconnect the plug for the side stand switch ...

Page 355: ...nkage Detach the master cylinder from the footrest plate e Important Screw is secured with a thread locking compound Detach brake pedal 1 from the footrest plate and remove it with the torsion spring bearing bushing and washer eImportant When installing use a new screw L Note When installing the brake pedal pivot bushing grease with Staburags NBU 30 PTM Installation is the reverse of the removal p...

Page 356: ...el X Tightening torque Brake light switch 5 Nm 46 71 Removing installing left footrest system L Note When installing pin for footrest grease with Shell Retinax EP 2 Lubricant Shell Retinax EP 2 X Tightening torque Footrest to frame 20 Nm Footrest pad to footrest 4 Nm 46 71 Adjusting left right footrests Remove the right footrest system a 46 21 Remove the left footrest system Install the left right...

Page 357: ...ening torque Footrest holder rear to frame 21 Nm Battery carrier left to footrest holder 18 Nm 46 71 Removing installing rear right footrest holder Remove the retaining plate for the brake lines ar row at the footrest holder Take out the screws and remove the footrest holder Remove footrest L Note Note presence of ball and spring when installing grease footrest pin with Shell Retinax EP 2 Remove f...

Page 358: ...ining hoop for the exhaust sys tem Remove the support for the seat tray 1 Remove fastener securing fuse box 2 Remove the battery holder from the rear frame on the right Remove fastener 1 securing brake fluid reser voir to rear frame Remove fastener for spring strut adjuster from back of rear frame and disengage the hose from the clip Detach the rear frame from the main frame and lift it clear Remo...

Page 359: ...0 Nm Footrest assembly right 20 Nm Reaction link to cross tube 43 Nm 46 51 Removing installing left right cross member eImportant Comply with safety precautions when handling or working with fuel Remove fuel tank a 16 5 Remove the air inlet guide a 46 17 Remove the intake air pipe a 46 17 Detach the radiators at left and right from their holders and press forwards Remove the engine spoiler a 46 14...

Page 360: ...footrest assembly a 46 21 eImportant Do not allow brake fluid to come into contact with painted parts of the motorcycle because brake fluid destroys paint Drain the brake system a 34 16 a 34 16 Disconnect brake hose from brake cylinder Disconnect brake lines from retaining plate at rear right and seal the brake lines and hoses Disconnect the plugs for the rear ABS sensor and the brake light switch...

Page 361: ...r with multifunction switch together with the holder for the left radia tor the clutch line and the clutch slave cylinder Remove the right handlebar with multifunction switch Disconnect the plug of the front ABS sensor Detach the electronic equipment box and the wiring harness from the frame arrows and re move Remove the telescopic fork with the front wheel a 31 5 L Note Make sure that oil cannot ...

Page 362: ... 18 Nm Brake lines Brake hoses lines banjo bolts 18 Nm Swinging arm to frame Left and right bearing studs 160 Nm Right threaded ring 200 Nm Left threaded ring 10 Nm Counter ring left 160 Nm Spring strut to swinging arm 50 Nm Spring strut to frame 43 Nm Rear wheel drive to swinging arm Fixed bearing stud 160 Nm Floating bearing stud 7 Nm Locknut 160 Nm Reaction link To rear wheel drive 43 Nm To tra...

Page 363: ...ug for the immersion tube sen sor Disconnect the plug for the fuel pump dWarning Comply with safety precautions when handling or working with fuel Disconnect the fuel lines Release the tank cover fastener Release the fuel tank fasteners at the frame and take off the fuel tank Remove throttle valve rail complete with intake air silencer Disconnect the plug for the temperature sensor at the intake a...

Page 364: ...ht bearing studs and pull the swinging arm away from the gearbox Press off drive shaft Remove cross tube a 46 25 Open the retaining hoop and disconnect the gear shift lever Remove the left footrest assembly Remove the right footrest assembly and secure it to the frame together with the brake pipe and the master brake cylinder Release the cross tube and take it off with the strut Disconnecting plug...

Page 365: ...ne BMW No 46 5 640 Remove the fuel lines at the engine block Transferring the engine to the assembly stand Secure the engine mount BMW No 11 0 610 to the crankcase Lower the platform and transfer the engine to as sembly stand BMW No 00 1 490 Remove the lifter Remove the starter motor a 12 13 Remove the generator a 12 10 Remove the gearbox a 23 9 Remove the clutch a 21 5 46 00 Lowering the frame L ...

Page 366: ...ve cylinder Secure the cable tie Install the clutch bleed line and secure it to the frame Install the lower cross tube a 46 25 Tighten lower cross tube to frame Install left footrest assembly Install right footrest assembly with brake line and master cylinder Connect the gear shift lever and close the retain ing hoop Install drive shaft a 33 23 and swinging arm a 33 24 Install drive shaft Install ...

Page 367: ...ug for the throttle valve potenti ometer Install the fuel tank a 16 5 Place the fuel tank in position and secure it Attach the tank cover to the frame Connect the drain and vent hoses Connect the fuel lines Connect the plug for the fuel pump unit Connect the plug for the immersion tube sensor Secure the cable ties Secure the exhaust system Install retaining hoop at silencer Additional work for ins...

Page 368: ...m pivot Removing threaded bushes L Note The right and left threaded bushes are not identical Remove rear swinging arm a 33 21 dWarning Always wear protective gloves when handling heat ed parts in order to avoid burns eImportant When applying heat always take care not to dam age cables and lines and rubber and plastic compo nents Using a hot air gun heat the frame to approx 100 C 212 F Use BMW refr...

Page 369: ...care not to dam age cables and lines and rubber and plastic compo nents Heat frame to approx 100 C 212 F Use BMW refrigerant spray to chill the threaded bush Install threaded bush until sealed using puller BMW No 46 5 732 spindle BMW No 46 5 731 disc BMW No 46 5 733 and nut M14 BMW No 31 5 694 Remove M8 alignment pin BMW No 46 5 734 Coat grub screw with Loctite 2701 and install until flush with bu...

Page 370: ...auge must slide freely up to the motorcy cle Adjust measuring stops arrows until they con tact the rim not the tyre Connect hook 2 to a wheel spoke and use it to pull the gauge firmly up to the wheel Align front wheel parallel with the gauge Release tension in the track alignment gauge by raising it by approx 5 mm 0 1969 in at the front and lowering it again Using a depth gauge 3 or ruler measure ...

Page 371: ...itive sign track offset is to the left Negative sign track offset is to the right EXAMPLE B B A A Fv S Fh KR460480 Formula S Fixed value A length of measuring stops A 50 0 mm 1 9685 in Half of rear wheel rim width 72 5 mm 2 8543 in Measured value B average value B 70 0 mm 2 7559 in Half of front wheel rim width 54 5 mm 2 1457 in Track offset S S S 122 5 mm 4 8228 in 124 5 mm 4 9016 in Track offset...

Page 372: ...ge 51 Removing installing ignition switch steering lock 3 Removing installing lock barrel 3 Removing installing fuel tank lock barrel 4 Removing installing seat lock 5 Removing installing mirror a 00 22 5 51 Equipment ...

Page 373: ...51 2 Contents Page ...

Page 374: ... lock barrel Remove the lock barrel L Note The lock barrel can also be removed when the fork bridge is installed Turn the ignition key to the ON position Press in the safety catch by inserting a suitable tool through the opening arrow e g a piece of wire Pull the lock barrel out with the ignition key Removing lock barrel if ignition key has broken off eImportant When drilling without removing the ...

Page 375: ...he ignition key Grease new lock barrel with Shell Retinax EP2 Install lock barrel with key at a right angle to di rection of travel Further installation is the reverse of the removal procedure X Tightening torque Fuel filler pipe to fuel tank 5 Nm Drilling out lock barrel Using a 4 5 mm 0 1575 0 1969 in drill bit open up the entire length of the lock barrel Repeat with a drill bit of larger diamet...

Page 376: ... Remove lock carrier and press keeper into lock barrel through the small hole in the lock carrier Pull out lock barrel with key Grease new lock barrel with Shell Retinax EP 2 Insert the lock barrel until the keeper engages Option case carrier Install the left case carrier with the seat lock Lubricant Shell Retinax EP 2 51 16 Removing installing mirror a 00 22 KR460230 ...

Page 377: ...52 1 Contents Page 52 Technical Data 3 Removing seat 5 Installing seat 5 Adjusting seat 5 Removing installing seat lock a 51 5 5 52 Dualseat ...

Page 378: ...52 2 Contents Page ...

Page 379: ...52 3 52 Technical Data K 1200 RS Height of seat at unladen weight Seat top mm in 800 31 4960 bottom mm in 770 30 3149 Comfort seat top mm in 820 32 2834 bottom mm in 790 31 1023 ...

Page 380: ...52 4 ...

Page 381: ...e seat into the lower or upper guide depending on the rider s height Press down on the rear end of the seat to engage the second detent position of the catch 52 53 Adjusting seat eImportant When installing make sure that the seat is retained firmly Turn the key in the seat lock anti clockwise and hold it there Pull the seat upwards and to the rear out of its catch as far as the first detent positi...

Page 382: ...tion switch 13 Removing installing fuse box 14 Removing installing power socket 14 Without Integral ABS Removing installing inductive signal transmitter for speedometer 15 Renewing ABS sensor at front rear 15 Removing installing water temperature sensor 15 Replacing side stand switch 16 Removing installing side stand switch 16 Check operation of side stand switch a 00 71 16 Renewing adjusting foot...

Page 383: ...61 2 Contents Page Removing installing gear indicator 20 ...

Page 384: ...61 3 61 Technical Data K 1200 RS Circuit voltage V 12 Battery Amp h 19 ...

Page 385: ...61 4 ...

Page 386: ...air guide from the right hand radiator a 46 18 Remove the right hand air intake pipe a 46 17 Release the nine fasteners arrows Take off both covers Pull out relay holder 1 and plug holder 2 Remove fastener arrow for plug strip of Motronic control unit Take off the seal and push the plug strip through to the inside Disconnect the earth ground lead arrow Open the cable tie 1 Remove screws 2 Remove b...

Page 387: ...61 6 Wiring harness View from right ...

Page 388: ...61 7 View from left ...

Page 389: ...61 8 View from front K41610010 ...

Page 390: ...ectronic equip ment box Control unit for fuel level warning light 1 Flasher relay 2 Motronic relay 3 Horn relay 4 Fan relay 5 Starter module 6 ABS warning relay 7 Load relief relay 8 Fuel pump relay 9 KR610081 2 6 4 5 3 1 7 8 9 ...

Page 391: ...ve the discharge air guide from the right hand radiator a 46 18 Press radiator out of holder Remove the right hand air intake pipe a 46 17 Release the fasteners arrows and take off the cover Open the cable ties arrows Open the cable ties arrows KR610090 KR610100 KR610110 ...

Page 392: ...Remove clutch switch 2 with cable Installation is the reverse of the removal proce dure 61 31 Removing left multifunction switch Disconnect plug for multifunction switch 8 in electronic equipment box Release the fastener 4 Take off multifunction switch 3 with cable Installation is the reverse of the removal proce dure K41320010 6 5 1 2 4 3 KR610130 7 8 ...

Page 393: ...Remove the air output from the right hand radia tor a 46 18 Press radiator out of holder Remove the right hand air intake pipe a 46 17 Release the fasteners arrows and take off the cover Open the cable ties arrows Open the cable ties arrows KR610090 KR610100 KR610170 ...

Page 394: ...ith cable Installation is the reverse of the removal proce dure 61 31 Removing installing right multifunction switch Separate the plug connector 7 at the multifunc tion switch Disconnect plug 9 Release the fastener 1 Take off multifunction switch 2 with cable Installation is the reverse of the removal proce dure K41320020 3 4 5 6 1 2 KR610130 7 8 KR620020 9 ...

Page 395: ... box with wiring harness Turn the holder and take it off Installation is the reverse of the removal proce dure 61 13 Removing installing power socket Remove the left rear side section a 46 15 Disconnect plug 2 Release the fastener 1 and take off the power socket Installation is the reverse of the removal proce dure K41610020 KR610250 KR610260 KR610300 1 2 ...

Page 396: ...o rear wheel drive 4 Nm 34 52 Renewing ABS sensor at front rear Remove install front ABS sensor a 34 9 Remove install rear ABS sensor a 34 10 61 31 Removing installing water tem perature sensor Remove the left side section of the fairing a 46 8 and the left rear section a 46 15 Drain coolant a 00 67 Disconnect plug 1 Open the cable ties Remove temperature sensor 2 with washer Installation is the r...

Page 397: ... arrow Remove side stand switch with cable Installation is the reverse of the removal proce dure Pay particular attention to the following L Note When installing note correct position of cable ties X Tightening torque Fastener for side stand switch clean thread apply Loctite 243 5 Nm Check operation of side stand switch a 00 71 KR610350 KR610360 ...

Page 398: ... Tightening torque Brake light switch to footrest plate 5 Nm eImportant Make sure that the cable is routed correctly at the cutout arrow in the footrest plate X Tightening torque Footrest to frame 20 Nm L Note When installing note the correct positions of the ca ble ties To adjust the brake light switch loosen locknut 2 Turn adjusting screw 1 to set distance A Tighten the locknut dWarning Check pi...

Page 399: ...screw Pull the ignition light switch housing 2 with ca ble off downwards Release the cable tie arrow Open the lid of the electronic equipment box Disconnect plug arrow Installation is the reverse of the removal proce dure Pay particular attention to the following L Note Seal the tapped hole for grub screw 1 with lacquer When installing note correct position of cable ties KR610340 1 2 KR610100 KR61...

Page 400: ...ug of oil pressure switch 2 Disconnect the plug for the oil pressure switch 4 in the electronic equipment box Disconnect the cable Removing installing temperature sensor at water pump Pull off protective cap and plug at temperature sensor 1 Disconnect the plug for the temperature sensor 3 in the electronic equipment box Disconnect the cable Route the cable at the Hall effect transmitter as illustr...

Page 401: ... the horn Installation is the reverse of the removal proce dure X Tightening torque Horn to fairing bracket 6 Nm 23 14 Removing installing gear indicator Disconnect plug arrow Open the cable ties Press the clip arrow together and pull the gear indicator out to the rear Installation is the reverse of the removal proce dure K41610030 2 3 1 KR610150 KR610190 ...

Page 402: ...ts Page 62 Technical Data 3 Removing installing instrument panel 5 Wiring colours 5 Removing installing instrument cluster 6 Replacing telltale warning lights 7 Removing installing wiring harness 8 62 Instruments ...

Page 403: ...62 2 Contents Page ...

Page 404: ...62 3 62 Technical Data K 1200 RS Instrument cluster Turn indicator repeaters 12V 1 7W DIN 72 601 Other telltale lights instrument lighting 12V 1 7W DIN 72 601 ABS warning light 12V 3W DIN 72 601 ...

Page 405: ...62 4 ...

Page 406: ...t 8 blue black brown blue 9 violet yellow green black 10 brown green black 11 white black green black 12 green yellow brown blue 13 blue red brown blue 14 brown black green black 15 blue green black 16 white brown blue 17 brown green green black 18 white green green black 19 violet white 20 KR620071 7 1 2 3 4 4 8 16 15 1 3 3 1 19 18 17 4 4 20 9 10 11 12 13 14 3 5 4 6 ...

Page 407: ...out the telltale warning lights Release the contacts Disconnect the plug for the digital display Install the contacts and telltale warning lights in the new instrument cluster according to the cor rect colours Reconnect the digital display plug Press the instrument cluster into its holder Secure the fasteners X Tightening torque Instrument cluster to fairing carrier 9 Nm KR620040 ...

Page 408: ...ry charge warning light 12 High beam telltale 13 Engine oil pressure warning light 14 Low fuel level warning light 15 Clock light 16 Disassemble the instrument cluster to the point at which the telltale warning lights are accessi ble L Note The telltale warning lights may if necessary be re moved by pulling on the cables Pull out the appropriate holder with telltale warn ing light Replace the tell...

Page 409: ...onnectors arrow in the elec tronic equipment box by swinging the hoop over L Note The telltale warning lights may if necessary be re moved by pulling on the cables Remove telltale light and contacts from instru ment cluster Disconnect the plug for the digital display Take off the wiring harness Install the new wiring harness in the correct po sitions Install contacts and telltale warning lights in...

Page 410: ...adlight a 00 26 5 Replacing bulbs in headlight 6 Renewing front turn indicators 6 Removing installing front turn indicator 6 Changing the bulb 6 Renewing rear lights 7 Removing installing rear brake light housing 7 Removing installing turn indicator housing 7 Renewing bulb 7 63 Lights ...

Page 411: ...63 2 Contents Page ...

Page 412: ... beam headlight H3 halogen bulb 12V 55W asymmetric Low dipped beam headlight H7 halogen bulb 12V 55W asymmetric Parking light 12V 5W DIN 72 601 Standard designation W 10 5 Brake rear light 12V 21 5W DIN 72 601 Standard designation P 25 2 Flashing turn indicators 12V 21W DIN 72 601 Number plate light 12V 5W DIN 72 601 Standard designation C 11 ...

Page 413: ...63 4 ...

Page 414: ...om fairing carrier Take off the headlight L Note Do not touch inside of reflector and glass of bulbs with bare hands Installation is the reverse of the removal proce dure Pay particular attention to the following Centre the headlight relative to the instrument panel trim X Tightening torque Headlight to fairing carrier 3 Nm 63 10 Adjusting headlight a 00 26 K41630011 3 1 2 ...

Page 415: ...age the retaining loop 63 13 Renewing front turn indicators 63 13 Removing installing front turn indicator Release the fastener 1 and remove the turn in dicator Installation is the reverse of the removal proce dure L Note When installing make sure that the lug arrow is correctly seated 63 12 Changing the bulb L Note Never touch the glass of the bulb with the fingers Remove the appropriate turn ind...

Page 416: ...take off the turn in dicator glass 3 Pull off the cable connectors Release fastener 6 and remove cover 7 Release the fastener 8 Pull off the flashing turn indicator 4 Installation is the reverse of the removal proce dure 63 99 Renewing bulb L Note Never touch the glass of the bulb with the fingers Take off the appropriate housing Change the bulb e Important When changing the rear and brake light b...

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BMW K 1200RS, Repair Manual

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