BMW K100 LT Repair Manual Download

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Summary of Contents for K100 LT

Page 1: ...ual K75 K100 LT All 2V Models BMW Motorrad GmbH Co Service Department dated 4 1988 scann 12 2011 Order No 01 51 9 798 791 b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r...

Page 2: ...rinting Take a modern laser printer duplex and print each chapter seperatly Org size is A5 printing in A4 is possible The file only shows the K Models up to 1988 Not shown is ABS 1 for that you ve to...

Page 3: ...Radiator 17 01 0 18 Exhaust system 18 01 0 21 Clutch 21 01 0 23 Gearbox 23 01 0 31 Frontfork 31 01 0 32 Steering 32 01 0 33 Rear wheel drive 33 01 0 34 Brakes 34 01 0 36 Wheels and tyres 36 01 0 46 Fr...

Page 4: ...ca CI c CI C c c ca c ca c CI c ca EC b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 5: ...ngine from spark plug appearance Spark plugs renewing Clutch cable nipple greasing Clutch play checking adjusting Valve play checking adjusting Air cleaner element removing and installing Cable play t...

Page 6: ...tenance inspection and adjustment procedures together with the technical data required lorthese tasks The tasks involved in a motorcycle inspection are listed in a maintenance and inspection chart The...

Page 7: ...0 0 9 8 1 2 16 0 19 17 8 2 1 21 4 2 6 30 3 3 6 35 6 4 3 M10 23 0 36 0 40 0 47 0 66 0 79 0 20 5 2 5 32 0 3 8 35 6 4 3 41 8 5 0 58 7 7 1 70 3 8 4 M8 x 1 12 0 19 5 22 0 25 0 36 0 44 0 10 7 1 3 17 4 2 1 1...

Page 8: ...l N m 1 N m 1 Pa stress kp mm Pa 1 kp mm 9 81 Nimm N mm Energy work quantity kpm J 1J 1Nm 1 kWh 3 6MJ 1 kpm 9 81 J hp s of heat cal kWh 1cal 4 1868J Torque kpm Nm 1 kmp 9 81 Nm hp kW 1 kW 1000W 1W 1 N...

Page 9: ...unds Ib 12 205 Pressure Bar bar Pounds force square inch psi lb f in2 114 504 Power Kilowatts kW Horsepower hp 11 341 Torque New10n metres Nm IFoot pounds ft lb 10 723 Speed Kilometres hour km h IMile...

Page 10: ...ounds force square inch psi lb l in2 Bar bar 0 069 Power Horsepower hp Kilowatts kW 0 746 Torque Foot pounds ft lb Newton metres Nm 1 383 Speed Miles hour mile h mph Kilometres hour km h 1 610 Feetlse...

Page 11: ...derthe lid atthe points where it is nailed on and lever up the lid working Irom the cross struts to the centre 01 the crate Cut open the sheeting with a knile vertically at the ends and horizontally a...

Page 12: ...ve the side sections Note Do not operate the handbrake lever on the K 100 RS and K 100 RT The front wheel is not fitted Only applicable to motorcycles packed with front wheel fitted Release retaining...

Page 13: ...rget the spacing sleeve 2 on the left hand side Insert machine screw 1 with shim 3 and tighten Only tighten the retaining screws arrows on the left hand side Tightening torque Machine screw Retaining...

Page 14: ...ycle toolkit Breakdown repair kit Rider s Handbook List 01 dealers First aid instructions 3wrenches 1 10lding 2 rigid Special equipment options 00 14 0 8 87 b y a k i n d a p p r o v a l o f t h e B M...

Page 15: ...ress in the lowerfront journal first then the lower rear one and finally the top journal Battery trims installing 1 1 Introduce battery trim into rear section with pin arrow Fix both hooks to weathers...

Page 16: ...eet metal nuts attop and base Assemble the lett hand and right hand halves 01 the spoiler with M 5 x 15 cheese head screws and plastic washers Mount the top mounting bracket AHix the sealing strips lo...

Page 17: ...t front left of oil sump and front right of crankcase base using a screwdriver Fit the two M 5 sheet metal nuts 1 on holder 2 Screw on the holder with machine screws and spring washers M 10 x 20 on cr...

Page 18: ...m gap between trim and bracket with 20 mm 0 plastic washer 3 and 4 mm thick Secure with M 6 machine screw and spring washer Push tongue of rear bracket into engine spoiler grommel Screw on bracket 1 w...

Page 19: ...reader rivets Press in pins with riveter BMW 00 9 51 0 grease the pins slightly K75s Screw on the windshield with retaining screws 1 and rubber washers Note 00 nottighten the screws excessively orthe...

Page 20: ...o max 80 C Dissolve cleaning agent protective coating remover in water app 5 7 solution See current Service Information for recommended protective coating removers Hold steam jet at least 30 cm from s...

Page 21: ...t plug by pushing a screwdriver through the hole in the toolbox Pull plug at cable input end out ofthe control uni Lift out taoItray and tuel injection control uni Disconnect battery mounting arrows a...

Page 22: ...e essential 00 22 0 Battery charging Warning Max charging currentmustnotexceed 10 o the baffery capacity Example 25 Amp h battery max 2 5 Amp charging curren Charging time 5 10 hours Battery charge ca...

Page 23: ...ssure teIltales Horn Check functioning of any special equipment features Final functional check Check that clutch gear shift steering footbrake and handbrake are functioning properly e g by test ridin...

Page 24: ...0 Check valve play I adjust if necessary at 10 15 0 2 mm max 35 C X X X E 0 25 0 3 mm 035 0 Renew intake air cleaner X3 036 0 Check cable play for throttle and increased X X 040 0 I starting speed cho...

Page 25: ...heck coolant concen X X 60 water 049 0 tration adjust if 40 antifr necessary Change coolant 28 C at least every two 50 50 years 36 C Check footbrake pedal play adjust if neces X app 25mm 051 0 sary dr...

Page 26: ...ng surfaces Metal sealing surfaces on gearbox and final drive Adhesives and locking agents Loctite242 Damper pistons on piston Screw connections rod telescopic fork medium torque Loctite270 Spring str...

Page 27: ...Sports settings Tightening torques Oil filter Oil drain plug engine Oil filler drain plug gearbox Oil drain plug final drive Oil filler plug final drive Inductive transmitter final drive Rocker cover...

Page 28: ...oil with the engine at operating temperature Renew the filter element Add fresh oil to the engine Ride the motorcycle in normal conditions until the oillevel has fallen to the lower mark on the inspe...

Page 29: ...ew for cover oil filter Oil filling capacity Oil grades see Service Data page 00 29 0 Gear oil changing 11 111 6 1Nm 3 751 Remove oil drain plug on gearbox arrows and allow oil to drain out Two versio...

Page 30: ...ng torque Oil Iiller plug 20 2Nm Final drive inductive transmitter cleaning 1 111 Remove retaining screw arrow and pull out inductive transmitter carefully lever out with screwdriver il necessary Clea...

Page 31: ...uses mixture too rich air filter contaminated spark plug too cold wrang thermal value Light white Electrade and insulator a snowy white colour Potential causes mixture too lean incorrect ignition timi...

Page 32: ...d then at the lever Grease the nipple e g with Shell RetinaxA Clutch play checking adjusting 1 111 To ensure perfect lunctioning ofthe ciutch and its operating mechanism the basic setting and lever pl...

Page 33: ...w on the release arm 1 1 A 2 0 5mm 1 1 A 4 0 5mm Valve clearance checking adjusting 1 11 111 K 100 RT remove lowerfairing on left as forremoving and installing air cleaner page 00 36 0 The cam ein the...

Page 34: ...d remove the holding down tool Insert special pliers BMW 11 1 730 through the groove in the bucket type tappet grip the adjusting plate Irom beneath and remove it sideways Note Whenever the valve clea...

Page 35: ...f the radiator trim K 100 RS Remove retaining screw arrow on engine block mounting crankshall end The illustration shows the cylinder head end K 100RS Remove the retaining screws arrows for lower fair...

Page 36: ...nt cover and remove retaining screws arrows take off knee pad K 100 RT Remove retaining screws on storage compartment arrows and take out storage compartment K100RT Remove retaining screw arrow for si...

Page 37: ...1 and 1 1 Pull out intake air line on air cleaner housiilg and pull off intake pipe When installing To simplify installation grease the intake air line slightly at the base Remove retaining clips arr...

Page 38: ...d marked TOP is at the top the leUering must point towards the rear rear wheel Install in the same order but according to the reverse procedure Cable play throttle increased starting speed checking ad...

Page 39: ...11 K 100 RS and RT remove lower fairing section on left same procedure as when removing and installing air cleaner page 00 36 0 Only adjust idle speed with the engine at operating temperature 85 C Pul...

Page 40: ...n telescopic fork changing 1 111 Remove stop cap with screwdriver Remove liller screw with Allen key preventfrom turning with open ended wrench il necessary Note K 75 c K 75 sand K 100 RS remove retai...

Page 41: ...el again air cushion in fork Tightening torque Oil filler plug 15 2Nm Steering head bearing play checking adjusting if necessary 111 Place motorcycle on supports and raise with BMW hoist 00 1 510 unti...

Page 42: ...ake fluid attacks paintwork Slacken off hex nut 1 and locking pipe arrow Adjust steering with circular nut Tighten the circular nut if play is excessive slacken the circular nut if steering is too sti...

Page 43: ...ut Fuelfilter renewing 111 74 5 Nm 10 1 Nm Remove retaining screws arrows forfuel filler stub pipe and take out pipe Remove hose connector arrow on pressure line illustration shows cutaway model Take...

Page 44: ...posed to high thermal loads fluctuating loads as a result of which the natural ageing process is accelerated Due to its hygroseopie properties moisture is absorbed from the atmosphere and the boiling...

Page 45: ...ake out the piston setting back device and substitute with spacer BMW 34 1 510 to holdthe piston back in the brake caliper On twin disc brakes insert the piston setting back device in the second calip...

Page 46: ...elief Swing the handlebar between the left and right lock limits applying the handbrake several times Any air will escape via the main brake ram and the pressure point will be achieved Pull hose off a...

Page 47: ...s with acid protection grease e g Bosch FT 40 V1 Coolant concentration checking 1 111 Remave battery trim on right as illustrated He Remave batterytrim on right as illustrated FromframeNo K100 0008131...

Page 48: ...e is cold the cooling system is under a slight vacuum to ensure that coolant Ilows lram the equalizer tank into the radiator The equalizer tank must be lilled to between MIN and MAX Neverlill toabove...

Page 49: ...Correct play 01 app 25 mm is obtained by unscrewing the wing nuts again by 3 4 turns Screwsand nuts taking up slack 1 111 All screw connections with are vital to the motorcycle s salety must regularly...

Page 50: ...eed setting page 00 41 0 Idlespeed 950 50 min 1 Checkengine gearbox final drive brake lines and fuel system for leaks Check tyre pressures at front and rear Tyre pressure bar tyres cold Speed K75 K75c...

Page 51: ...CD c C c w b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 52: ...h strainer and oilfilter cartridge removing Crankcase lower section removing Output shaft removing Rockercover removing Crankcase end cover removing Hall effect transmitter removing Rotor mask removin...

Page 53: ...ton installing Output shaft installing Bottom section of crankcase installing Oilsump installing Cylinder head installing Camshafts installing Timing chain installing Camshaft wheels installing Chain...

Page 54: ...g harness installing Ignition coils connecting up Cable for increased starting speed installing Radiator installing Connections on frame wiring harness Battery installing Coolant adding Rear mudguard...

Page 55: ...0 Displacement effective cm3 740 987 Compression ratio 11 0 1 10 2 1 Max output nominal kW 55 66 bhp 75 90 at engine speed min 1 8500 8000 Max continuous speed min 1 8600 8500 Max permissible speed mi...

Page 56: ...steady 90 km h 1 100km 4 2 4 2 4 0 5 0 4 3 4 4 4 4 at steady 120 km h 1 1100 km 5 6 5 6 5 4 6 3 5 7 5 9 5 9 Engine lubrication Lubricating system Pressurized oil circuit Oilfilter Full flow Bypass val...

Page 57: ...before TOG Valves Overaillengths inlet mm 111 exhaust mm 110 71 0 1 Valve head dia inlet mm 34 exhaust mm 30 Valve stem dia inlet mm 6 975 0 015 exhaust mm 6 960 0 015 Wearlimit inlet mm 6 950 exhaust...

Page 58: ...ersize mm 13 2H 7 018 Valve stem clearance inlet mm 0 025 0 050 exhaust mm 0 040 0 070 Wearlimit inlet mm 0 150 exhaust mm 0 165 Valvegear Valve actuation Direct by bucket type tappets Camshaft drive...

Page 59: ...Radial operating c1earance guide bearing mm 0 027 0 061 base bearing mm 0 027 0 061 Wearlimit guide bearing mm 0 150 base bearing mm 0 150 Cam pitch circle mm 30 Camlift inlet mm 39 3927 0 031 exhaus...

Page 60: ...9 0 006 mm 0 024 green 37 992 37 984 1 483 0 006 white 37 984 37 976 1 487 0 006 Crankshaft main bearing dia mm Basic bore 49H6 16 Main bearing journals radial clearance mm 0 020 0 056 Wearlimit mm 0...

Page 61: ...A 66 92 B 66 93 Piston dia mm Make Mahle A 66 970 0 007 B 66 980 0 007 Wearlimit mm A 66 92 B 66 93 Piston installed ciearance mm 0 015 0 039 Wear limit mm 0 130 Piston installed direction Arrow on c...

Page 62: ...t mm 30 0 010 0 025 Wearlimit mm 2 90 Ringgap mm 0 20 0 45 Wearlimit mm 1 50 Ring flank clearance mm 0 020 0 055 Wearlimit mm 0 30 Ring installed direction with TOP marking uppermost ring grooves 1 an...

Page 63: ...aft timing gears to camshafts Chain tensionerto engine block Slider rail to camshaft bearing mounts Timing case coverto engine block cylinder head Hall effecttransmitter cover to timing case cover Clu...

Page 64: ...o 0 CI c O e c w b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 65: ...b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 66: ...s o Q c e c Ul b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 67: ...b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 68: ...ngine 1 Output shaft 2 Crankshaft 3 Starter shaft arrangement 1 1 4 Freewheel 5 Auxiliary shaft 6 Countershaft 11 17 0 b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c...

Page 69: ...n 5 1 Crankshaft 2 Connecting rod 3 Big end bolt 4 Small end bearing 5 Big end bearing shell 1 6 Nut 7 Piston 8 Piston bolt 9 Circlip 10 Piston rings 7 9 G 8 87 b y a k i n d a p p r o v a l o f t h e...

Page 70: ...cu J o b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 71: ...pring 10 Tensioning gear 11 20 0 Output shaft 16 1 1 2 17 8 7 19 20 18 6 11 Cup spring 12 Bearing innerring 13 Snapring 14 Snapring 15 Needle roller race 16 Deep groove ball bearing 17 Snapring 18 O r...

Page 72: ...CI C c tU CI tU C CI E CI c b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 73: ...shaft 4 Freewheel cage 5 Freewheel outer ring 6 Cup spring 7 Coverplate 11 12 9 8 Relaining boll 9 Freewheelgear 10 Needle roller bearing 11 Washer 12 O ring 8 87 b y a k i n d a p p r o v a l o f t h...

Page 74: ...10 O ring 11 Shaft 12 Oil pressure switch 13 Nut 14 Water pump impeller 2 9 10 I I 2J U 25 15 O ring 16 Drain screw 17 Sealing ring 18 Retaining bolt 19 Cover 20 Retaining bolt 21 O ring 22 Pipe 23 B...

Page 75: ...hen disengage it at the front Take outthe storage tray with fuel injection control unit to the rear and top Note Note the rubber plug Battery removing Remove the battery holder retaining screws arrows...

Page 76: ...t ofthe radiator and pull offthe hose Release the hose clip 1 atthe top right ofthe radiator and pull ofthe hose Pull out the intake air line on the lower section ofthe air cleaner housing and pUIi of...

Page 77: ...the nipple Detach the throttle cable from the reaction bearing Warning 00 not bend the throttfe cable Clutch cable detaching Disconnectthe choke cable at the operating lever arrow and pull it outthro...

Page 78: ...gnition coil Pull off spark plug cap Pull off cap arrow on alternator Detach cable 1 on starter Disconnect cable connector 3 on frame Plug connections uncoupling Detach the cable connector at the fram...

Page 79: ...box switch brake light switch and inductive sensor Separate cable connector 2 Exhaust system removing Slacken offthe nuts arrows tor securing the exhaust pipes to the cylinder head Loosen the silencer...

Page 80: ...ove the retaining screws arrows Remove the nuts in the storage compartment and take off the licence plate holder Note Note the protective caps Release the retaining screws arrows and take off the rear...

Page 81: ...to the engine behind the bearing mount and secure bearing mount to the gearbox again Slacken offthe starter motor retaining bolts at the gearbox Slacken off the gearbox retaining bolts arrows atthe e...

Page 82: ...and right ofthe engine and also atthe right ofthe intermediate flange Note Note the shims Lift off the frame complete with telescopic fork and place it on the workshop floor Detach the hose clip 1 at...

Page 83: ...m section ofthe air cleaner housing Attach BMW engine lifting fixture 11 0 610 to the crankcase arrows Lower the lifting fixture until the engine mount can be joined to the assembly stand Detach the l...

Page 84: ...screw 1 the ignition coils lold lorwards Slacken off the retaining screws at the bottom and take off the ignition coil holder with ignition coils Butterfly valve stub pipe assembly with air collector...

Page 85: ...etaining screw 1 and pull of driver with BMW puller 00 8 400 Note Note O ring Clutch removing Slacken offthe retaining screws arrows forthe housing cover and take it off with the clutch plate and pres...

Page 86: ...output shaft Intermediate flange removing Slacken off the screws holding the intermediate flange with BMWTorx insert 002600 and pull offthe intermediate flange Countershaft removing Pull the counters...

Page 87: ...ressure line and insert it in the hole in the pump housing Slacken off the pump housing retaining screws arrows and pull off the pump Note Note the O ring water passage Oil sump removing Remove the sc...

Page 88: ...se lower section removing Remove the bolts arrows retaining the lower section of the crankcase Slacken off retaining bolts 1 and 2 Take offthe bottom section ofthe crankcase Output shaft removing Take...

Page 89: ...nd camshafts attop Hall effect transmitter removing Slacken offthe retaining screws circles and take offthe cover for the Hall effect transmitter with seal Slacken off the retaining screws arrows and...

Page 90: ...removing Slacken offthe retaining screws arrows lorthe slider rail with BMWTorx insert 00 2 600 and take offthe slider rail Chain tensioner removing Slacken off the retaining screws arrows lorthe cha...

Page 91: ...de rail and take offthe guide rail with the timing chain I el Remove the chain guide rail first then the timing chain Camshaft removing Rotate the camshaft app 45 beyond TDC to prevent the valves from...

Page 92: ...emoving Cover for water pump removing Rockercover removing Cover for Hall effect transmitter removing Timing case cover removing Timing chain removing Spark plugs removing Camshaft removing see page 1...

Page 93: ...ng cap Coverthe threads 01 the big end bearing bolt e g with a short piece 01 rubber hose to avoid damaging the big end bearings when removing the connecting rods Push the piston with connecting rod o...

Page 94: ...g end bearing cap Note Observe the instruetions below 16 07 0 11 26 0 11 37 0 1 1 39 0 11 39 0 11 39 0 11 40 0 11 41 0 11 41 0 Coverthe threads ofthe big end bearing bolt e g with a piece of rubber ho...

Page 95: ...ss is gained to the valve cone Take outthe valve cone Turn the spindie back to slacken offthe coil spring Take out the cup spring at the top and the valve spring and spring plate at the bottom Examine...

Page 96: ...s essential to maintain the valve seat width when regrinding Regrind valve seats with the correct tool BMW No 00 3 520 Seats must not exhibit any chatter marks To check valves for leaks fill the inlet...

Page 97: ...l the cup spring at the bottom and the valve spring and spring plate at the top Compress the spring with th spindie 01 BMW valve spring tensioner 11 1 740 until the grooves on the valve stem are revea...

Page 98: ...l 9 Output shaft 10 O ring 11 Shaft 12 Oil pressure switch 13 Nut 14 Water impeller v 1 17 16 10 I 23 1 2 l F 132 15 O ring 16 Drain plug 17 Sealing ring 25 18 Retaining screw 19 Cover 20 Retaining sc...

Page 99: ...ut the shaft Take outthe shaft and impeller Pull the sliding ring seal out ofthe pump housing with special pliers 11 1 250 Carefully drive the shaft oil sealing ring out ofthe pump housing using a 5 m...

Page 100: ...core marks caused by the oil pumpgears Check free movement of the valve plunger and examine the spring for signs of damage Combined water oil pump assembling Screw in the pressure relief valve Slightl...

Page 101: ...lar as the seat with a suitable piece oftubing Note Make sure that the sliding sealing ring is always Iree 01 grease Warning Use only Genuine Part No 11 51 1264 466 manufactured by Goetze Fit the impe...

Page 102: ...I U1 o w b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 103: ...with a screwdriverthat has been ground to a round end Pull out the spacer sleeves Drive in the new spacer sleeves 1 with a suitable arbor When installing Note projecting dimension X 7 0 5 mm Insert c...

Page 104: ...ft 4 Freewheel cage 5 Freewheel outer ring 6 Cup spring 7 Cover plate 7 8 9 10 8 Retaining screw 9 Freewheel gear 11 12 10 Needle roller bearing 11 Washer 12 O ring 8 87 b y a k i n d a p p r o v a l...

Page 105: ...ing screws arrows Strip the freewheel down to its individual components Components 1 Auxiliary shaft 2 Cup spring 3 Freewheel cage 4 Freewheel outer ring 5 Cover plate Pull out the needle roller beari...

Page 106: ...e Tightening torque Retaining screws 9 1Nm Push the freewheel gear arrow on to the auxiliary shaft by rotating it in a clockwise direction Install the washer and O ring Needle roller bearing for auxil...

Page 107: ...ve 4 Housing Hold the chain tensioner together with BMW tensioner 11 5500 Tensioning rail removing Liftthe tensioning rail atthe lugs arrows with a small screwdriver Push the tensioning rail outof the...

Page 108: ...loth or sirnilar underneath II splinters should lall into the crankcase detach the oil sump and rernove the splinters Belore installing the new sight glass apply HD engine oil to the external thread D...

Page 109: ...led position Carefully scrape off any carbon deposits also cleaning out the valve pockets Measure the piston diameter atthe piston skirt with a micrometer see illustration Make KS Mahle Dimension A 12...

Page 110: ...ection and at right angles to the travel direction 1 Piston assembling Carelully install the piston rings using piston ring pliers Reler to the illustration lor the correct direction 01 installation R...

Page 111: ...he measured difference along test lest length P must not be greaterthan 0 06 mm Piston and connecting rod assembling Note the connecting rod weighttolerance For values see Specilications page 11 09 0...

Page 112: ...ugh 30 Wipe off oil Irom the bearing journal and bearing shell Place the Plastigage thread arrow over the entire width ofthe bearing 6 8 mm lrom the centre Fit bearing cap and tighten to the specilied...

Page 113: ...dard grade 0 is available as areplacement Crankshaft installing Installthe crankshaft with bearing shells Iightly lubricated groove to groove See illustration lor sequence 1 1 Cylinder 1 and 2 are mar...

Page 114: ...torque to the big end bearing shells and tighten with BMW tightening angle indicator 11 2 110 Note The crankshaft must not be rotated now Tightening torque Connecting rod bearing cap nut Angle 30 3Nm...

Page 115: ...ot marked Once the crankshaft has been installed the following procedures must be carried out Timing chain installing Chain tensioners installing Timing case cover installing Cover for water pump inst...

Page 116: ...9 Spring 10 Tensioning gear Output shaft 16 1 1 17 11 7 9 10 8 b 0 __ DJ t2 6 11 Cup spring 12 Bearing inner ring 13 Snapring 14 Snapring 15 Needle roller race 16 Deep groove ball bearing 17 Snapring...

Page 117: ...block Tap shaft out of damper inner section 2 with plastic faced mallet Tensioning gear stripping down 1 1 Pull the output shaft out ofthe damper until thrust piece BMW31 1 307 makes contact Remove c...

Page 118: ...groove and circlip the ring must be atthe bottom bearing version with shoulder shoulder must be at the top Press on the bearing until it makes contacl Insert Seeger ring into the groove using pliers E...

Page 119: ...I i 1 6 b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 120: ...ll off the ball bearing with puller BMW 00 8 400 and thrust section BMW 33 1 307 arrow Insert holder 12 4 600 in the tensioning gear Turn the holder clockwise pulling the holder up atthe same time Out...

Page 121: ...76 1 90 mm 1 91 2 05 mm 2 06 2 15 mm Ball bearing with shoulder installing Shim 1 60mm 1 75mm 1 90mm 2 05mm Heat the ball bearing to app 80 C and press it against the stop with the shoulder at the top...

Page 122: ...rooves are offset by app 120 Move the relevant crankpin to bottom dead centre Note Coverthe threadsofthe big end bearing bolt e g with a short piece of rubber hose to avoid damaging the crankshaft bea...

Page 123: ...n both gears are aligned Note The position of the crankshaft relative to the output shaft mustnot be altered as this will result in imbalance 1 1 Identifying feature ball bearing with circlip The gap...

Page 124: ...with O ring in the rubber bushing on the bottom section ofthe crankcase Wetthe seal althe oil filter with oil Note Screw in the oil filter as far as the stop and then tighten further by max 1 2 turn T...

Page 125: ...ecting up Cable for increased starting speed installing Hose on thermostat housing connecting up Coolant adding Exhaust system installing Ignition coil cover installing Frame fixation on driving devic...

Page 126: ...nder 3 face inwards Ofter up the bearing mounts Note The numbers on the cylinder head must agree with the bearing mount numbers Tighten the remaining bearing mounts uniformly from the inside to the ou...

Page 127: ...the tension side taut Secure the camshaft gears to the camshaft Hold the hexagon on the camshaft to prevent it lrom turning Tighten the retaining screws Tightening torque Camshaft gear retaining scre...

Page 128: ...im plates turn the tappets until the groove taces inwards at app 45 arrows Press the tappet down with BMW holding down tool 11 1 720 Note Ofter up and press the holding down tool outwards in such a wa...

Page 129: ...chronized see page 13 07 0 Timing chain cover installing The sealing faces must befree of oil and and grease Apply a thin coat of Three Bond 1207 B to the sealing faces Ofter up the timing chain cover...

Page 130: ...ure switch pass it through the opening in the pump housing and connect itto the switch The joint lace must be Iree 01 oil and grease Apply a thin coat ofThree bond 1207 Bto the jointface an tighten th...

Page 131: ...stalling a newpart always clean offthe corrosion protection material and applya generous coatofengine oil Insertthe countershaft Intermediate flange installing Note Ensure thatall adaptersleeves are p...

Page 132: ...termediate flange Install the clutch housing with BMW hOider 11 2 800 Install the new O ring and thrust washer arrow and secure the hex nut Tightening torque Hex nut 140 5Nm Hex nut 140 5Nm Tighten lo...

Page 133: ...g screws 22 3Nm Crankcase cover installing Turn the engine round until crankshafton top The joint laces between the crankcase intermediate Ilange and crankcase cover and the crankcase timing case cove...

Page 134: ...Cylinder head cover retaining screws 8 1Nm Turn the engine round instalied position Placethe coolantstub arrow with O ring on the cylinder head and tighten the retaining screws Install the intake stub...

Page 135: ...rear 1 1 Note instructions on ignition coils Conneclthe hose crankcase breather to Ihe crankcase wilh hose clip arrow Injectors installing Install the injector rail with injectors Moisten the injeclor...

Page 136: ...gine retaining bolts Install and secure the starter motor Tightening torque Starter on gearbox 7 1Nm Mounting tor centre stand removing and installing Slacken offthe retaining screws arrow forthe moun...

Page 137: ...for the throttle butterfly switch injector nozzles and temperature sensor Secure the lead to the injector rail circle with adhesive tape Locating frame on driveline Remove the frame support BMW No 46...

Page 138: ...n the frame Secure the earth cable arrow to the frame Connectthe engine wiring harness to the frame wiring harness Connect the plug for the increased starting speed to the frame wiring harness Secure...

Page 139: ...are installed above the electric wiring Radiator installing Attach the radiator with the plates at the bottom to the rubber bushings on the frame Make the plug connection for the fan Push the radiato...

Page 140: ...to the bottom section ofthe air cleaner housing Note Moisten the rubber seal before installing Connections on frame wiring harness Connect the plugs for the Hall effect transmitter 1 and the oil press...

Page 141: ...r is clamped firmly in place Coolant adding Add coolant at the filler pipe Note Use only recommended grades see Specifications page 17 03 0 Capacitiy 1 1 1 1 2 51 2 81 0 41 in reservoir Normal concent...

Page 142: ...ver Rear mudguard and licence plate holder installing Install the rear mudguard and insert the hoop with threaded pins through the holes in the mudguard from the bottom Screw on the nuts arrows Clamp...

Page 143: ...rew then secure the exhaust pipe 10 the cylinder head with a new seal and tighten Attach asecond screw forthe silencer mounting and tighten both screws Tightening torque Exhaust pipe on cylinder head...

Page 144: ...en the frame and eye on the intermediate flange and fill with shims leaving a gap of no more than 0 25 mm Insert screw 3 and tighten Insert screw 5 tighten 4 and 5 Tighten torque K 100 RS RT Fuel tank...

Page 145: ...IC Cl c C cC wO b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 146: ...ing Ignition coils connecting up Alternator removing and installing Alternatordriver rernoving and installing Starter removing and installing Starter stripping down Carbon brushes renewing Starter ass...

Page 147: ...X5DC X5DC Beru 12 5DU 12 5DU Champion A85YC Electrode gap mm 0 6 0 1 when new wear limit 0 9 Ignition system AII electronic breakerless microprocessur controlled digital system Ignition trigger Two m...

Page 148: ...T jK 100LT Average contral range es 22 18 at low engine speeds min 1 3530 3940 3011 3530 Ignition control begins min 1 1300 1500 Ignition contral ends min 1 8777 8650 12 04 0 B B7 b y a k i n d a p p...

Page 149: ...ing to alternator Magnetic gate plate to timing chain cover Adjusting plate for TDC Cover for Hall effect transmitter Sparkplug Ignition coils to intermediate flange Tightening torques Nm 6 1 4t06 21...

Page 150: ...ltank 5 Fuelpump 6 Ignition control unit 7 Fuel pump relay 6 8 H 9 8 Starter relay 9 Fuel injection control unit 10 Ignition coils 11 Battery 12 Starter motor 13 Spark plug 14 Hall effecttransmitter 1...

Page 151: ...1 Retaining screw M 5x 12 2 Underlaywasher 3 Magnetic gate with board and cable 4 Retaining screw M4 x 10 5 Underlaywasher 6 Rotor 7 Shim for top dead centre 7 8 87 b y a k i n d a p p r o v a l o f...

Page 152: ...ine bolt 6 Drive end bearing 7 Repair kit starter motor 1v 2 10 11 9 Shim 10 Exciter winding 11 Carbon brush set 12 12 Commutator bearing 13 Brush mounting plate 14 Spring washer 15 Hexnut 15 14 11 12...

Page 153: ...ew 12 Machine bolt 13 Drive end bearing Alternator 17 20 16 23 14 Deep groove ball bearing 15 Cover 16 Rotor 17 Slipring 18 Deep groove ball bearing 19 O ring 20 Ring winding 21 Screw 22 Diode plate 2...

Page 154: ...nnectors and take offthe magnetic gate board Installation sequence Secure the magnetic gate board with 2 retaining screws When installing To achieve the basic magnetic gate setting the recesses in the...

Page 155: ...ve the ignition trigger cover Removing engine spoiler see Group 46 Separate the plug connector between the Hall effect transmitter and the ignition control unit arrow at the top right frame tube Conne...

Page 156: ...king the ceramic insulator 1 1 Screw the dial gauge extension BMW 00 2 580 with dial gauge in cylinder 3 reuel Screw the dial gauge extension BMW 00 2 580 with dial gauge in cylinder 1 Turn the cranks...

Page 157: ...e After loosening the two clamp screws arrows turn the magnetic gate board slowly to the left or right ignition retard or advance until the diode on the ignition timer goesout Tighten the clamp screws...

Page 158: ...nitto the left or right Ignition coils removing and installing le e Slacken off and remove the three retaining screws on the ignition coil cover and take off the cover Pull off the two pin plug on the...

Page 159: ...r removing and installing Remove control unit forfuel injection system see page 13 14 0 Remove battery Group 61 Take the coolant header tank out of the battery mounting plate Remove the three retainin...

Page 160: ...p starter motor in vice with protective jaws as illustrated Slacken off and remove the retaining screws arrows Pull off drive end bearing 6 Pull off housing with stand 10 Pull rotor 8 out of commutato...

Page 161: ...plate Insert rotor 8 in the commutator bearing illustration right Insert housing with stqnd 10 in such a waythatthe large lug fits in the notches arrows illustration on lett Fit the O rings 7 on the d...

Page 162: ...b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 163: ...assembly removing and instaliing Air cleaner element checking removing and instaliihg Pressure regulator removing and instaliing Fuel injection control unit removing and instaliing Air flowmeter remov...

Page 164: ...relay 10 Thrattle butterfly switch 11 Fuel injection contraIunit 12 Ignition coils 13 Air cOllector 14 Airflowmeter 15 Idle mixture adjusting screw 11 20 16 Injectors 17 Throttle butterfly 18 Bypass p...

Page 165: ...18 YIlI i _ I _ hr 21 I 13 Air collector 14 Air flowmeter 15 Bypass air screw 17 Throttle butterfly 18 Idle speed adjusting screw 10 1t 1 I 19 13 05 0 b y a k i n d a p p r o v a l o f t h e B M W A...

Page 166: ...ect Synchrotester BMW 130700 with adapters BMW 13 0 702 arrows to the vacuum unions tor cylinders 1to 3 Connect adapter BMW 130703 1 to cylinder4 and push hose 2 trom the pressure regulator on to the...

Page 167: ...hand lairing RS removing and installing knee pads see Group 46 Set up the CO value test equipment according to the manulacturer s instructions The ignition timing must be correct Increased starting sp...

Page 168: ...butterfly switch removing and installing Slacken off the retaining screws arrows for the throttle butterfly switch Pull the throttle butterfly switch off the throttle butterfly shaft Pull off the mul...

Page 169: ...ion K100 K75 c s Pull intake tube off lower section of air cleaner housing and intake pipe K 100 unscrew intake pipe on radiator Removefuel tank see page 16 07 0 Loosen hose connectors on air line at...

Page 170: ...starting speed indicator 1 and pressure regulator 2 to change the throttle butterfly stub pipe assembly r r On K 100 up to frame number 0 008 130 K 100 RS up to frame number 0 084 624 K 100 RT up to...

Page 171: ...ad off the COvalue Remove the air cleaner element and repeat the above procedure II the CO value is now signilicantly lower the air cleaner element must be renewed K 100 RS RT LT Remove and instalilow...

Page 172: ...page 13 12 0 Detach the hose connector 1 on the air collector Take out the upper section ofthe air cleaner housing The picture was taken with the engine removed to provide a better illustration Slacke...

Page 173: ...r 1 Fuel tank with bridge mounting 1 Carefully pull away from frame 2 Carefully pull away from frame 3 Carefully pull back from arbor on frame ree e Fuel tank without bridge mounting 1 Carefully pull...

Page 174: ...e it at the front Pull offthe keeper peg arrow for the contral unitto the top using flat pliers Pull the fuel injection control unit out ofthe storage tray to the lett Install by following the same pr...

Page 175: ...s taken with the engine removed to provide a bener illustration Take out the upper section olthe air cleaner housing Remove retaining screws arrows on air Ilowmeter and loosen hose connectors 1 on air...

Page 176: ...CI 1 LL b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 177: ...emoving and installing Fuel pump pressure testing Fuel filter removing and installing Fuellevel sensor lever sensor removing and installing Page 16 03 0 16 05 0 16 07 0 16 11 0 16 13 0 16 14 0 16 15 0...

Page 178: ...ank Tank capacity 21 22 Reserve included in above capacity Visual warning signal at app 5 Fuelpump Type Roller cell pump Manufacturer Bosch Operating voltage V 12 Pump pressure bar 2 5 Output I h 45 8...

Page 179: ...87 Fuelsystem 2 Fueltank 3 Fuel filter 4 Fuelpump 6 Injector rail 21 7 Pressure regulator 15 Injector 10 19 16 05 0 b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k...

Page 180: ...I o 6 b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 181: ...Cl E s o s ca Cl J LL I I I _ ii LV I I ___ _ j Q b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 182: ...off frame 3 Carefully pull back from arbor on frame r r Fuel tank without bridge mounting 1 Carefully pull off frame 2 Carefully pull down slightly 3 Pull arbor forward and out of dualseatframe r r K...

Page 183: ...ghty and pull the breather hose off the tank base When installing 00 not bend the breather line when fitting the fuel tank or else the breather function will be rendered inoperative 1 1 and 1 1 Fuelta...

Page 184: ...hen take off to side Place cloth on injector rail to soak up seepage as a certain amount of fuel will spill when the pressure line 1 is pulied off Detach fuellines on fuel tank K 75 s pull fuelline of...

Page 185: ...and lever off the hose Impartant Ta avaiddamaging the paintwark fit a plastic tube 1 aver the screwdrivershaft Take off the tuel tank Install the tuel tank by tollowing the same procedure but in the...

Page 186: ...tive connection M 4 nut Negative connection M 5 nut The picture shows a sectioned model Squeeze the retaining clips arrows atthe retaining ring tirmly and pull out the tuel pump Pull the tuel tilter o...

Page 187: ...until it is feltto engage When installing The positive connection on the fuel pump arrow must be located opposite the plus mark arrow on the retaining ring Both marks must be located in the fuel tank...

Page 188: ...ssure test gauge 16 1 500 on to the left handlebar assembly Puli the luelleed line off either the luel tank or injector rail and connect the test pressure gauge between the two connections For correct...

Page 189: ...rrow atthe pressure line The picture shows a sectioned model Pull the filter element with pressure line out of the filler pipe and set it down Remove the filter element When installing Note the correc...

Page 190: ...ive connection black cable M 5 thread Release the base insulation trom the underside ofthe tuel tank Slacken offthe tuellevel sensor relaining screws 1 Take outthe tuellevel sensorwith seal Install Ih...

Page 191: ...o ca c ca a b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 192: ...alling Fan motor renewing Filler cap checking Coolant renewing Thermostat removing and installing 17 Radiator Page 17 03 0 17 05 0 17 07 0 17 11 0 17 12 0 17 12 0 17 13 0 17 14 0 17 01 0 b y a k i n d...

Page 193: ...freeze 0071CI Glycoshell P 300 Glysantin G04 Genantin VP 17 19 ICI012 Glysantin G 41 23 Thermostat insert Starts to open at C 85 Fan Cuts in at C 103 Coolant temperature Warning lights comes on at C 1...

Page 194: ...0 Cl c E c z CI l Cl j c 0 0 TI Q ftI c S c ftI 0 a u 1 ltl CO Q E ro 2 Ci 1ii ro er ltl 0 1 0 0 c in J 0 1ii Ci 0 E Q b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i...

Page 195: ...nt circuit 1 Radiator cap 2 Equalizing tank 3 Cross flow radiator 4 Thermostatvalve 5 Temperature sensor 6 Waterpump 17 07 0 b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b...

Page 196: ...bolt 6 Equalizing tank 7 Cap 8 Hoseclip 9 Hose 10 Filler inlet 11 Spacer 12 Hex nut 13 Cap 17 Q 14 Sealing ring 15 Sealing ring 16 Buffer 17 Support 18 Rubber bushing 19 Spacer sleeve 20 Machine screw...

Page 197: ...he system more quickly Release the hose clip 1 on the top right of the radiator and pull offthe hose Pull out the air intake line from the bottom section ofthe air cleaner housing and pull it off the...

Page 198: ...he motor InstaJl by foJlowing the same procedure but in the reverse sequence Filler cap checking Check operation of the pressure relief valve in the fiJler cap with BMW tester 17 0 500 and the interme...

Page 199: ...51 0 41 in the equalizing tank 1 1 2 81 0 41 in the equalizing tank Add eoolant at the filler pipe up to the bottom edge of the overflow arrow Note To bleed the eooling system turn the overengine with...

Page 200: ...thermostat housing cover arrow and take off the cover Pull the thermostat arrow out ofthe housing See illustration for correct installed position Heat the thermostat in water and check compliance wit...

Page 201: ...b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 202: ...system removing and installing Exhaust pipes removing and installing Silencers removing and installing Shield panel renewing Page 18 03 0 18 03 0 18 05 0 18 05 0 18 05 0 18 06 0 18 01 0 b y a k i n d...

Page 203: ...cer removing and installing r Slacken offthe retaining screws on the footrest plate see above Tightening torque Retaining clip Release the retaining clip on the silencer Pull off silencer Note Use the...

Page 204: ...d panel Note When slackening off and tightening the front retaining nut forthe shield panel it is essential to preventthe hex arrow on the vibration proof mounting from turning with an open ended wren...

Page 205: ...b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 206: ...thrust bearing removing Clutch thrust rod removing 21 Clutch Output shaft sealing ring removing and installing Clutch thrust rod installing Clutch thrust bearing installing Page 21 03 0 21 04 0 21 05...

Page 207: ...ring Extl dia of clutch plate mm 165 1 180 1 Total thickness of clutch plate with lining mm 5 3 0 25 Min thickness of clutch plate mm 4 5 Free travel at handlebar lever mm 2 0 0 5 4 0 0 5 Length 01 ca...

Page 208: ...utput shaft 1 1 reue Housing coverto clutch housing 21 04 0 Tightening torques and tighten again to Nm 140 5 140 5 then release 100 14 10 19 2 8 87 b y a k i n d a p p r o v a l o f t h e B M W A G f...

Page 209: ...4 Pressure plate 5 Clutch plate 6 Housing cover Clutch 4 6 12 7 Thrustrod 8 Bearing reaction ring 9 Ball bearing 10 Thrust piston 11 Spring 12 Clamp 13 Sieeve 21 05 0 b y a k i n d a p p r o v a l o f...

Page 210: ...ygreased wilh app 49 lubricanl CIUlch seclion al 120 Table of approved lubricants Lubricating paste OPT MOLY PASTE PL Lubricating agent STABURAGS NBU 30 PTM Acheson lubricating mixture Lubricating age...

Page 211: ...gm spring 4 Take outthe wire ring Clutch housing removing Attach BMW holder 11 2800 in the position illustrated Unscrew and remove the hex nut Take out the thrust washer arrow Move the clutch housing...

Page 212: ...ee diagrams page 21 06 0 Insertthe wire ring and diaphragm spring 4 in the clutch housing Insertthe pressure plate 3 clutch plate 2 and housing cover 1 in such a way that the colour marks are offset b...

Page 213: ...he rubber gaiter 1 back slightly and adjust dimension B 75 1mm with the adjuster at the clutch lever using BMW adjusting gauge 21 3 500 see illustration below Loosen the knurled adjusting nut 1 at the...

Page 214: ...b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 215: ...and lock with the knurled nut Important Take up excessive clearance causedby wearonlyat the adjusting screwon the withdrawalarm 1 1 A 2 0 5mm 1 1 A 2 0 5mm Clutch thrust bearing removing Remove the si...

Page 216: ...er engine until it is flush When installing The spring washer faces outwards Clutch thrust rod installing Install the clutch thrust rod with BMW assembly sleeve 231 800 Press the bearing reaction ring...

Page 217: ...o c ca CD b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 218: ...gment assembling Bearing shell tor input shafttaper roller bearings removing and installing Intermediate shaft ball bearings removing and installing Input shaft stripping down and assembling Output sh...

Page 219: ...4th 1 88 5th 1 67 Oil grade above 5 C SAE 90 brand name hypoid gear oil below 5 C SAE 80 brand name hypoid gear oil API classification GL 5 all year round SAE 80 W 90 brand name hypoid gear oil Oilqu...

Page 220: ...nal drive 10 swinging arm Spring slrul 10 frame final drive Slarter molor10 gearbox Brake caliper 10 final drive Wheel sluds rear wheel Exhausl manifold pressure plale 10 cylinder head Silencerlo fool...

Page 221: ...b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 222: ...6 Washer 7 Coil spring 8 Thrust piece Inputshaft 7 8 9 Spurgear 10 Taper roller bearing 11 Circlip 12 Shaft sealing ring 13 Spacer 14 Deep groove ball bearing 15 Intermediate shaft complete I 10 11 1...

Page 223: ...Deep groove ball bearing 5 Spacer 6 Spurgear 1stgear 7 Bushing 8 Spacer 9 Sp urgear 4th gear 16 18 10 Needle roller cage 11 Spur gear 2nd gear 12 Supporting ring 13 Circlip 14 Spur gear 3rd gear 15 B...

Page 224: ...ctorlork 5th gear 4 Selectorlork 3rd and 4th gears 5 Roller 6 Selectordrum 7 Roller 4 5 6 10 8 Dowelpin 9 Stepped disc 10 Shaft sealing ring 11 Ball 12 Coil spring 13 Machine screw 8 87 b y a k i n d...

Page 225: ...5 Shaft sealing ring 6 Selector shaft 7 Spacer 8 Headless screw 9 Stop 10 Circlip 11 Segment 13 Roller 10 9 6 14 Circlip 15 Leg spring 16 Stop lever 17 Roller 18 Circlip 19 Spring 20 Pawl 21 Pawl mou...

Page 226: ...eeve on tank 1 lit out of rubber mounting at base 2 pull the cover out ofthe dualseat frame to the front 3 1 1 Fuel tank bridge mounting Take off the let and right battery covers pull out of rubber mo...

Page 227: ...heel Mode s with rear disc brake Note the washer Left footrest plate removing Slacken offthe three footrest plate retaining screws arrows and take off the footrest plate Right footrest plate removing...

Page 228: ...on the footrest plate Remove the footrest plate with brake linkage Models with rear disc brake Slacken off both retaining nuts 1 for the brake fluid reservoir Slacken off the two brake caliper retaini...

Page 229: ...ws arrows for the ignition coil cover Take off the cover r r Slacken off the four retaining screws arrows for the ignition coil cover Take off the cover Rear mudguard removing Take the protective caps...

Page 230: ...e rear and take it out of the front guide Lift out the storage tray with control uni Note Note the rubber stoppers Battery removing Detach the battery negative cable 1 at the gearbox Disconnectthe pos...

Page 231: ...aining screws arrows and remove the alternator cover Slacken offthe wo retaining screws arrows atthe starter motor Pull the starter motor out of the intermediate flange Detach the c1utch cable arrow a...

Page 232: ...ecl Ihe plug conneclion for Ihe speedomeler sensor Apply Iighl blows 10Ihe final drive 10 dislodge il and lake il off Rear swinging arm removing Slacken offIhe bearing journailocknul arrow Unscrewlhe...

Page 233: ...ect pul rod from lever for side stand return mechanism on automatie side stand special equipment option Slacken offthe retaining screws arrows for mounting bracket on the underside ofthe gearbox Remov...

Page 234: ...2 Loosen retaining screws arrows on clutch housing cover if necessary Centre the clutch and tighten the retaining screws evenly in a crosswise pattern Remove the centering device Tightening torque Re...

Page 235: ...Nm Secure the ignition coil holder on the intermediate Ilange Secure the mounting with centre stand and side support to the gearbox with lour retaining screws II special equipment option automatie sid...

Page 236: ...ournals 11 with NeverSeez Insert the lixed swinging arm bearing in the swinging arm mounting with a slight turning movement with the aid 01 BMW puller 26 1 660 and secure with a slight turning movemen...

Page 237: ...tening torque Final drive 10 swinging arm 40 3Nm Install the spring strut Install the spring strut with the preload bushing at the top Tightening torques Spring strut to frame Spring strut 10 final dr...

Page 238: ...late before tightening the nuts Right footrest plate installing Model with rear disc brake Screw on footrest plate with three retaining screws Attach the tension spring for the brake lever Insert the...

Page 239: ...eel installing The wheel centering surface and wheel hub contact faces must be absolutely clean and free of all traces of grease Note Use only55 mm lang wheel studs ar rear drum brakes and60 mm lang w...

Page 240: ...each case Tighten the silencer retaining bolts Tightening torque Pressure plate to cylinder head 21 2 Nrn Install the alternator cover Install the lett and right battery covers 8 87 23 27 0 b y a k i...

Page 241: ...stop spring bearing 1 and the gearbox cover retaining screws Heatthe gearbox coverto app 1000 e check with a thermochrome pin and push it off with a screwdriver at the three points indicated Note Not...

Page 242: ...sioner 11 5 500 Pull selector drum up and twist to remove Note Note the rollers on the selector lork guide journals Selector forks removing Take out selector lork lor 1st and 2nd gear Take out selecto...

Page 243: ...is secured with Loctite Shift segment removing Remove circlip rings arrows for stop 2 Take out segment 1 with torsion spring and stop 2 Note Note washer between torsion spring and housing Stop lever r...

Page 244: ...that the spring arm makes contact with the indentation circle 2 on the pawl holder Fit circlip 24 Shift segment stripping down Removetorsion spring 15 and stop 9 Removecirclip 14 and take off pulley...

Page 245: ...manner Bearing shell tor input shaft taper roller bearings installing Heat up bearing seat for taper roller bearings in the housing and coverto app 80 C check with thermochrome pin and insert bearing...

Page 246: ...spring 7 Fit the thrust piece 8 and spur gear 9 overthe toothed shaft profile Compress the coil spring at the thrust piece in the position shown with universal puller BMW 00 7 500 and pressure head c...

Page 247: ...auge Spurgear 1stspeed max 0 30 mm Spur gear 2nd speed max 0 60 mm Spur gear 5th speed max 0 40 mm Adjust end play at shims 8 Shim ticknesses available 1 6 1 7 1 8 1 9 2 0 mm 23 35 0 b y a k i n d a p...

Page 248: ...rrows tor 1st and 5th off the bushings 1 Heat the short spur gear bushing 1 st gear 1 to app 80 C and pull it off together with the spur gear tor 4th and the supporting ring 3 Heatthe long spurgear bu...

Page 249: ...in such a waythatthe dogs point upwards Fitthe shim 8 Heat up the ball bearing 17 to app 800 eand install Turn round the output shaft and clamp in the vice with protective jaws at the hub profile to...

Page 250: ...ctor shaft bore in the threaded bore ofthe segment is visible Secure headless screw 8 with Loctite 242 Fix the stop 9 with circlips 1 0 Tightening torque Headless screw 17 2Nm Selector pawl installing...

Page 251: ...selector lork guide journals Insert the selector drum 2 in such a way that the idle position stop points towards the segment dptled line Pivot the selector lork lor 5th gear 3 inwards and introduce th...

Page 252: ...asure through the window arrow in the measuring plate up to the bearing shoulder on the shaft and note the value Record this value preceded by a negative sign in the table see page 23 41 0 Mab App dim...

Page 253: ...diate shaft Dan Cover dimension input shaft Permitted endplay lor intermediate and output shafts Endplay 0 05 0 15 mm Permitted input shaft preloading Preloading 0 03 0 08 mm Sampie measurements All d...

Page 254: ...over Tighten the retaining screws Tightening torque Cover retaining screws 9 1 Nm Check the taper roller bearing friction value with BMW adapter 23 6 670 and friction value gauge BMW No 00 2 570 at 1...

Page 255: ...500 until the arbor is in full contacl Pedal switch removing and installing Slacken off and remove retaining screw 3 and pull shift lever off selector shaft Install the new pedal switch in such a way...

Page 256: ...b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 257: ...1 Frontfork Taper roller bearings in steering head removing and installing Telescopic lork measuring Telescopic fork installing Steering head tube installing Page 31 03 0 31 04 0 31 05 0 31 11 0 31 15...

Page 258: ...ber oil approved oil grades Aral1 01 0 shock absorber oil Bel Ray Fork oil with Seal Swell SAE 5 PB Aero Hydraulic BP Olex HLP 2849 Castrol shock absorber oil1 318 Castrol DB hydraulic Iluid CastrolAW...

Page 259: ...ase axle Clamping screw lor quick release axle Hollow screw for brake line to distributor pipe Brake caliper to sliding tube Handlebar clamps to lork bridge Tapered screw in steering head Circular nut...

Page 260: ...nescrew 11 Cover I 4 3 Telescopic fork 1 1 K 75 c upto Frame No 0 113 804 l 1 l _ 4 15 10 t 9 8 6 7 17 6 fi 5 9 2 12 Upperlork bridge 13 Bolt 14 Washer 15 Hexbolt 16 Round nut 17 Roller bearing 18 Rin...

Page 261: ...2 Snapring 3 Upper lork bridge 4 Locking tube 5 Nut 6 Washer 7 Retaining bolt 9 f 10 _ i _13 e1 2 8 Adjusting ring 9 Taper roller bearing 10 Ring 11 Shim 12 Retaining bolt 13 Fluidbloc 8 87 b y a k i...

Page 262: ...ated disc 8 Valvedisc 9 Valve housing 10 Girclip Telescopic fork 11 Bushing 12 Sealing ring 13 Sliding tube 14 Sealing ring 15 Hex bolt 16 Machine screw 17 Washer 18 Sealing ring 19 Machine screw 31 0...

Page 263: ...dering 5 Damper tube 6 Goil spring 7 Perforated disc 8 O ring 9 Goi spring soft 10 Valve 11 Valve housing 5 1 6 I i S lO 11 12 13 I I 1 I 1 I I 12 Spacer ring 13 Circlip 14 Gap bushing 15 Shaft sealin...

Page 264: ...4 IS 15 9 17 1 Spacing tube 2 GoiIspring 3 Coil spring 4 Piston 5 Guidering 6 Tube right 7 Goil spring 8 Valvedisc 9 Bushing U 16 10 11 t J 17 10 Spacer ring 11 Girclip 12 Tube lett 13 Sealing ring 14...

Page 265: ...m Guide bushes in the stanchion and in the forkslider Not like all the other worn out Fichtel Sachs and Brembo type forks The Showa fork can be repaired For detailes you ve to refer realoem and to the...

Page 266: ...all screwdriver Push retaining hooks on either side for ignition lock inwards with a small screwdriver and push the ignition lock down to remove Release the retaining screws arrows and take off the im...

Page 267: ...screw arrows for handlebar clamps Set down handlebars with fittings on frame r r K 75cfrom Frame No 0113805 Slacken ofelamping seres arrows remove hex nut 1 and pull off upper fork bridge r r and K75c...

Page 268: ...is exposed Take outthe bearing 1 1 Pull down the telescopic fork to remove K75c upto Frame No 0113804 In order 10 avoid damaging Ihe fluidbloc mask overthe thread on the steering head tube with 1 1 21...

Page 269: ...Open drain plug 1 to drain off oil in telescopic lork Remove retaining screw lor damper in sliding tube Use the quick release axle to counter lock Note 00 not re use the sealing ring Remove the cover...

Page 270: ...piclork Damper with valve disc 1 Spacer tube 2 Goil spring 3 Damper 1 Piston with guide ring 2 Goil spring 3 Perforated disc 4 Valve disc 5 Valve housing 6 Dampertube Adjustment dimension 258 0 5Nm Te...

Page 271: ...Piston 3 Goil spring 4 Perforated disc 5 O ring 6 Goil spring soft 7 Valve with assembled O ring 5 fitted at base 8 Valve housing 9 Dampertube Adjustment dimension x 260 5 0 3 mm Sports telescopic fo...

Page 272: ...d to the damper tube with Loctite Ta remove heatthe piston over agentie Ilame untilthe Loctite begins to burn Unscrew the piston out ofthe damper tube When installing Thread must be Iree 01 grease App...

Page 273: ...arefully lever out the seal ring in the sliding tube with a screwdriver Drive in new sealing ring with BMW arbor 31 4 660 arrow and handle 00 5 500 until flush with the upper edge of the sliding tube...

Page 274: ...luidbloc chambers 1 with silicone grease and insert in steering head tube 2 until the mark appears in the threaded holes lnserttapered screws 3 Pull in bearing outerrace 4 attop Adjust the steering he...

Page 275: ...Insert steering head tube again immediately Note Mark the installed posilion of Ihe sleering head lube on the fork bridge Siol is for sleering lock Heal up laper roller bearing 10 80 C before inslalli...

Page 276: ...o check the lowerlork bridge push two new lixed tubes in the lork bridge Note Note control installed length 01 app 180 mm Irom upper edge offixed tube to upper edge 01 lower lork bridge Place BMW stra...

Page 277: ...rk bridge Screw in clamping screw When installing Note adjustment dimension x 01 app 180 mm Tighten clamping screws finally after fitting the upper fork bridge Set down handlebar to the front Push on...

Page 278: ...Tighten retaining screws forlork stabiliser in a crosswise pattern Tightening torque Clamping screws Retaining screws for fork stabiliser 14 2Nm 21 2Nm Quick release axle must slide easily into the lo...

Page 279: ...mping screw boltom Note When off load the telescopic fork mustfall evenly to the lett or right from the cEl 1tre position Ensure that the wire cables and electric cables are located properly 1 1 Tight...

Page 280: ...tall the luel tank see group 16 Install headlights instrument cluster and lairing sections Check the headlight beam setting Note Compress the motorcycle suspension and check the lunctioning 01 the tel...

Page 281: ...CI CI cn b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 282: ...Wire throttle cable installing Steering Wire cable for increased starting speed removing and installing Increased starting speed adjusting Wire clutch cable removing and installing Clutch play adjust...

Page 283: ...ng block clamp halves Steering block to upper lork bridge Mirrorto housing 8 87 K75 IK75C 40 665 22 K75s 35 610 Specifications K 100 K 100 RS K 100 RTIK 100 LT 40 35 730 610 Tightening torques Nm 22 2...

Page 284: ...Siotted Screw 4 Washer 5 Lever 6 Detent plate 7 Housing 8 Headless screw 9 Spring washer 10 Hex nut 11 Machine screw 12 Hand lever 13 Bushing 14 Grip 15 Switch with cable 15 32 05 0 b y a k i n d a p...

Page 285: ...11 26 13 1 6 I Throttle twistgrip 5 Handlebartube 6 Grip 7 Countersunk screw 8 Cover 9 Carn 10 Housing 11 Support block 12 Switch with cable 13 Machine screw 5 8 87 b y a k i n d a p p r o v a l o f...

Page 286: ...impactpad Right handlebar fitting removing Remove the cover trom the throttle operating mechanism Using actuating cam 1 pull the chain through until the cable can be disconnected atthe end ofthe chain...

Page 287: ...the handlebar Allow the brake fluid reservoirto hang down Left handlebar fitting removing Lever off plastic cap on increased idle speed actuator lever with a screwdriver and remove the slotted screw...

Page 288: ...rrow Pull the clutch lever Push nipple mounting 1 down out ofthe clutch lever with an arbor Push back the nipple mounting in the direction of the arrow until it is above the clutch cable and disconnec...

Page 289: ...bber handgrip to handlebar with Loctite 496 Slacken off clamp screw arrow on fitting housing and pull fitting off handlebar Remove handlebar mounting clamp screw and take off handlebar Install followi...

Page 290: ...move lower left fairing see Group 46 Remove fuel tank see Group 16 Remove impact pad Turn carn disc inwards inthe direction ofthe arrow Disconnectthe cable Liftthe cable out ofthe reaction bearing Rem...

Page 291: ...to air collector Note 00 not kink the cable as kinks will be subject to abrasion and the cable could fray as a result 32 12 0 Connect cable to end of chain When assembling ensure thatthe mark on the t...

Page 292: ...g section and the knee pads on left and right Increased starting speed cable removing and installing r r Remove fuel tank see Group 16 Remove impact pad r r K 100 RS RT LT remove knee pads on left and...

Page 293: ...et arrow on lever and disconnect When instal ing Connect cable up to lever with the aid of pointed pliers Release the cable connector at the front right comerof the frame triangle K75 c s K 100 Pull c...

Page 294: ...eJ Dimension a 1 5 mm Dimension b 3 5 mm eHe Dimension a 1 0 mm Dimension b 2 5 mm Clutch cable removing and installing Remove fuel tank see Group 16 Remove impact pad 1 1 K 100 RS RT LT remove knee p...

Page 295: ...able up through frame triangle to remove K100RS RT LT Pull cable down between upper radiator edge and frame to remove Install foliowing the same procedure but in the reverse order 00 not connectthe cl...

Page 296: ...revolutions slowly screw in until pressure point is feit then secure with lock nut 1 Afterthe basic adjustment procedure adjust play at clutch lever to dimension A with adjuster screw and secure with...

Page 297: ...Cl I c Cl Cl c I ca Cl a b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 298: ...rown wheel shimming tooth backlash wear pattern Taper roller bearing preload calculating Housing cover installing Rear swinging arm removing Drive shaft removing Universal joint checking forwear Drive...

Page 299: ...s mm 0 18 0 28 0 38 0 50 0 63 0 75 0 88 Oilgrade above5 C Brand name hypoid gear oil SAE 90 below5 C Brand name hypoid gear oil SAE 80 API class GL 5 all year Brand name hypoid gear oil SAE 80 W 90 Fi...

Page 300: ...ng bearings Rear wheel drive 10 swinging arm Spring slrul 10 frame rear wheel drive Brake caliper 10 rear wheel drive Wheel sluds rear Oil drain plug rear wheel drive housing Oil filler plug rear whee...

Page 301: ...bearings 1 Nut 2 Thrust ring 3 Threaded ring 4 Shaft sealing ring 5 Ball thrust bearing 6 Spacer 7 Needle roller bearing 7 33 05 0 b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y...

Page 302: ...w w I o C1l Cl _ U b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 303: ...Coverdisc 6 Taper roller bearing 7 Machine screw 8 Washer 9 Bearing journal 10 Hexnut 0 5 6 11 Bearing journal 12 Machine screw 13 Spring washer 14 Spring strut 15 Hexnut 16 Washer 17 Hex bolt 18 Spr...

Page 304: ...er slacken off wheel studs pull off rear wheel and take out Models with rear disc brake Noteshim Remove inductive transmitter Remove retaining screw arrow ler inductive transmitter and pull out transm...

Page 305: ...s allowed to lall the rubber drive shaft sleeve will become damaged allowing contamination and moisture to penetrate and resulting in long term damage Remove the hex nut arrow on the lower spring stru...

Page 306: ...own wheel in retaining fixture BMW 33 1 500 Tighten bolts to 100 Nm torque Remove the input bevelpinion Heatthe hex nut on the input bevel pinion to approx 100 C and unscrew it Never use a hammer to l...

Page 307: ...ng 21nner race ball bearing 3 Thrust ring 4 Outer race roller bearing 5 Roller bearing cage 6 Ball bearing cage 7 Outer race ball bearing 8 Bearing balls Remove the housing cover To dismantle the hous...

Page 308: ...nd pull ollthe crown wheel Remove andinstall shaftsealing ring in gearhousing cover Drive the shaft sealing ring out ofthe cover with an arbor Drive in the new sealing ring with arbor BMW 33 1 860 and...

Page 309: ...page 33 20 0 Removing crown wheel bearing Secure crown wheel in vice with protective jaws Insert pressure head BMW 33 1 307 Attach three arm puller BMW 33 1 830 to the deep groove ball bearing and pul...

Page 310: ...eel shaft The standard size is not stamped on the housing If the size ofthe housing is not standard two digits representing the deviation in one hundredths 01 a millimetre are stamped on the inside of...

Page 311: ...earing for input bevelpinion Clamp rear wheel drive in vice with BMW holder 33 1 630 as illustrated Heat up bearing seat in housing to app 120 C and insert needle roller bearing with the letlering fac...

Page 312: ...OO C Threads must be free from oil and grease Apply Hylomar SO 37 to threaded ring Screw in threaded ring with journal key BMW 33 1 700 Note Ensure that the sealing lip of the shaft sealing ring is c...

Page 313: ...the crown wheel installed place measuring ring 1 with dial gauge holder 2 on the rearwheel drive housing For accurate tooth backlash measurement the pinion must be prevented from moving with the locki...

Page 314: ...ight coloured oilbound paint to a lew teeth Insert the crown wheel in the housing and turn it a lewtimes to and Iro while exerting strong pressure on the wheel Ifthe resulting contact face pattern is...

Page 315: ...act face at centre of leading flank V Gontactface nearer the large diameter on trailing flank R The teeth must never make contact at the small diameter in any circumstances The following pattern is th...

Page 316: ...thicker spacing ring must be fitted See Technical Data page 33 03 0fortable ofspacer sizes Taper roller bearing preload 0 05 0 1 mm app 600 1600 N preloadforce m measure h measure d 9 measure play wi...

Page 317: ...e out of withdrawal arm Remove left hand swinging arm bearing Remove bearing journallocking nut arrow Unscrew bearing journal 1 with 6 mm Allen key Remove three retaining screws for swinging arm fixed...

Page 318: ...groove with small screwdriver and press down towards the universal joint Take out the snap ring through the universal joint Ieft picture lntroduce a new snap ring in the universal joint and press up...

Page 319: ...34 mm Drive in cover ring Sealing sleeve between swinging arm and gearbox removing and installing Pull gaiter out 01 swinging arm and remove circlip Apply Staburags NBU 30 PTM or Optimoly Paste PL to...

Page 320: ...ng BMW puller 26 1 660 and tighten the three retaining screws Tightening torque Swinging arm fixed bearing 9 1 Nm Goat swinging arm moving bearing journal 11 with Never Seez Pull swinging arm towards...

Page 321: ...ring strut mounting at top and bottom 51 3Nm Models with rear drum brake Introduce pull rod through brake backplate Screw on wing nut Turn rear wheel screwing in pull rod wing nut until the rear wheel...

Page 322: ...5Nm Add oil to rear wheel drive Filling capacity 0 261 Install rearwheel The centre hub and wheel hub contact surfaces must be scrupulously clean and free from grease Warning Models with rear drum bra...

Page 323: ...b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 324: ...locks removing Brake blocks installing Rear drum brake installing Rear brake disc removing and installing Front brake disc removing and installing Footbrake pedal removing and installing Footbrake lig...

Page 325: ...der Brake disc 10 front wheel Relaining screw on quick release axle Clamping screw on quick release axle Brake disc 10 rearwheel drive Wheel sluds rear Foolbrake lever10 foolresl plate Main brake cyli...

Page 326: ...Front brake lines 12 t I 13 24 15 14 L j 3 2 I 1 11 Brake hose 12 Hollow screw 13 Sealing ring 14 Distributor pipe 15 Plastic nut 16 Toothed washer 17 Mounting bracket 18 Brake pipe 19 Bake hose r 16...

Page 327: ...screw 9 j fl 11 26 13 14 Cylinder with piston 15 Countersunk screw 16 Countersunk screw 17 Cover 18 Spacer 19 Rubber gaiter 20 Reservoir 21 O ring 22 Cylinder 23 Screw 24 Piston 25 Circlip 26 Machine...

Page 328: ...djusting screw 7 Flexible gaiter 8 Machine screw 9 Mounting plate 10 Washer 8 J 2 12 11 10 1 9 1 9 r 16 11 Hex nut 12 Washer 13 Reservoir 14 Brake hose 15 Brake pipe 16 Sieeve 17 Hose 18 Hoseclip 19 M...

Page 329: ...Pin 12 Wing nut 13 Brake backplate Reardrum brake 1 1 14 Washer 15 Machine screw 16 Tab 17 Lower brake shoe 18 Upper brake shoe 19 Coil spring 20 Circlip 21 Sealing ring 22 O ring 23 Sealing ring 24...

Page 330: ...ibed The rear disc brake fluid is changed according to a similar procedure using the appropriate reservoir adapter Take off the lid ofthe brake fluid reservoir atthe front and remove diaphragm Connect...

Page 331: ...the brake fluid emerges free from bubbles carry out procedure at both brake calipers Remove piston setting back device and spacer again Install brake pads see page 34 12 0 Setthe leveron the bleeding...

Page 332: ...pads are inserted push back the piston into the brake cylinder Ensure thatthe spring and pin are properly located Drive in retaining pins with an arbor until they engage in position Front brake calipe...

Page 333: ...ining pins with arbor until they engage in position Rear brake caliper removing and installing Remove the rear wheel Unscrewthe brake pipe from the caliper arrow Tie up the brake pipe and stop up with...

Page 334: ...d unscrew ootbrake lever trom threaded rod on brake cylinder Detach brake tluid supply pipe 1 and brake hose 2 rom the brake master cylinder Assemble tollowing the same procedure but in the reverse or...

Page 335: ...s on brake linkage Remove rearwheel see page 36 07 0 Lever off retainer arrow on brake mounting with a screwdriver Grasp each brake shoe in one hand and pull off in the direction ofthe arrows Brake sh...

Page 336: ...g nut through 3 4 revolutions equivalent to app 25 mm footbrake pedal play Set pointer 1 to MAX when the brake shoes are making contact Rear brake disc removing and installing Remove rearwheel see pag...

Page 337: ...quick release axle Pull out quick release axle noting spacer 2 Pull front wheel forward to remove Remove four retaining screws for brake dises take off brake dises Assemble following the same procedur...

Page 338: ...n removed here Take off the locking nut arrow and unscrew the brake pedal Irom the threaded rod on the brake cylinder Assemble lollowing the same procedure but in the reverse order Models with rear dr...

Page 339: ...screw switch with 11 mm open ended wrench Assemble following the same procedure but in the reverse order When inslalling microswilch The switch mounting plate must be in contact with the cast rib ofth...

Page 340: ...ank Cable coding Yellow Yellow Green black Grey red Detach cable connector on handlebar and pull up cable to remove Remove switch from handlebarfitting with 11 mm open ended wrench Assemble following...

Page 341: ...b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 342: ...s Front wheel removing and installing Front wheel bearing removing and installing Rear wheel removing and installing Page 36 03 0 36 04 0 36 05 0 36 06 0 36 06 0 36 07 0 36 01 0 b y a k i n d a p p r...

Page 343: ...yres cold Htyres Vtyres VRtyres 1 1 Solo Withpillion Solo Withpillion Solo Withpillion Speed Front Rear Front Rear Front Rear Front Rear Front Rear Front Rear no limit 2 0 2 50 2 30 2 90 2 25 2 50 2 5...

Page 344: ...liper to sliding tube Clamping screw on quick release axle Retaining screw on quick release axle Wheel stud rear 36 04 0 Tightening torques Nm 29 3 32 2 14 2 33 4 105 4 8 87 b y a k i n d a p p r o v...

Page 345: ...Cast wheel front 2 Spacer sleeve 3 Deep groove ball bearing 4 Quick release axle 5 Bushing 6 Bushing 7 Spacer 8 Machine screw 9 Cap 36 05 0 b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w...

Page 346: ...he reverse order When installing Insert spacer bus ings 5 and 6 in the appropriate place 5 right hand bushing narrow 6left hand bushing wide Warning Ensure that the dust cap is firm y on the va ve Tig...

Page 347: ...but in the reverse order When installing Contact surfaces between rear wheel and rear wheel drive must be free from grease Models with rear drum brake Wheel studs 55 mm long marked on stud head Models...

Page 348: ..._ _ b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 349: ...ing and installing Radiator trim removing and installing Windshield and innerfairing removing and installing Upper fairing removing and installing Fairing mounting removing and installing Storage comp...

Page 350: ...djusting Distributor pipe installing Divider installing Rear mudguard installing Rear section installing Radiator installing Coolant topping up Dualseat installing Centre stand removing and installing...

Page 351: ...ber Motorcycle dimensions andweight Maximum width across mirrors mm 850 1 830 1 930 1 820 1 920 Seat height off load mm 810 Overalilength mm 2220 Wheelbase off load mm 1516 Wheel offset mm max 5 Unlad...

Page 352: ...pivot block Side stand 10 pivot block Footrest plate to gearbox Pivot block to lootrest plate Fairing holderto engine Fairing rear panel to K 75 c K 100 lork bridge Tightening torques Nm 45 6 41 5 41...

Page 353: ...Rubber bushing 9 Bushing 10 Abrasion protector 11 Sheet metal nut 2 f 7 I 21 20 2 16 1 5 14 11 _ 13 12 12 Retaining screw 13 Washer 14 Fairing holder 15 Retaining screw 16 Square nut 17 Sieeve 18 She...

Page 354: ...t 5 Retaining screw 6 Inner cover 7 Butler 8 Butler 9 Retaining screw 3 4 1J 4 i J 17 10 Shim 11 Radiator trim 12 Radiator grille 13 Retaining screw 14 Washer 15 Washer 16 Retaining screw 17 Cover 18...

Page 355: ...eader nut 9 Washer 10 Cover 11 Inscription 12 Grab recess 13 Tool box 5 6 14 Cover 15 Side cover 16 Rubber stopper 17 Buffer 18 Buffer 19 Pin 20 Grab handle 1A 2 21 Retaining screw 22 Nut 23 Seal 24 A...

Page 356: ...her 4 Front lett footrest 5 Footrest rubber 6 Pin 7 Torsion spring 8 Sieeve 9 Splint 10 Pivot block 11 Pin 12 Support plate 13 Washer 14 Retaining screw 15 Washer 16 Nut 17 Rear lett footrest 17 12 46...

Page 357: ...Gap 5 Sieeve 6 Machine screw 7 Spring 8 Rubber bushing 12 13 9 10 11 4 16 1 14 5 6 3 4 6 9 Side stand 10 Bushing 11 Retaining screw 12 Plate 13 Spring 14 Buffer 15 Gap 16 Blind rivet 17 Snapring 15 0...

Page 358: ...51 r J l J b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 359: ...off the headlight Remove retaining screws on left and right arrows for headlight housing and take offthe housing Remove headlight fairing retaining screws 1 Remove retaining screws in the rear panel o...

Page 360: ...pin plug Remove retaining screws lor rear panel attop and base 01 the lork bridge Take off the rear panel together with instrument cluster Install lollowing the same procedure but in the reverse orde...

Page 361: ...ockpitfairing Remove plugs on headlight Slacken off retaining screws for headlight and take off headlight When installing The marks arrow on the holder must be aligned when assembling Disconnect elect...

Page 362: ...ment cluster Note Note the angle between the base of the fork bridge and the rear panel Remove the retaining screws arrows on left and right for cockpit holder Take offthe cockpit holder Install follo...

Page 363: ...ll the fairing forwards to remove and allow to hang down freely Slaeken offthe headlight mounting at let and right Pull the headlight forwards out of holder Pull eleetrie eable off refleetor arrows 8...

Page 364: ...ti pin plug in instrument housing and pull out multi pin plug Remove the four Allen screws arrows and take offthe rear panel together with the instrument cluster Install following the same procedure b...

Page 365: ...eve on right and left atthe fuel tank with BMW lever 46 5 700 Pull radiatortrim slightly forward lower and take offto one side Install following the same procedure but in the reverse order B B7 Q _ P...

Page 366: ...section of radiator trim then pull out of rubber sleeve on fuel tank arrow Pull right hand side of radiatortrim out of rubber sleeve on fuel tank arrow and take off radiator grille with side section I...

Page 367: ...screws 1 tor windshield Take off windshield Radiator trim removing and installing Remove the tour retaining screws arrows tor radiator trim Take offthe radiatortrim Remove centre retaining screw 1 8...

Page 368: ...turn indicator housing Take turn indicator housing outoftrim Pull off plug connections 1 2 Remove top retaining screw arrow Remove retaining screw arrow on fairing inner cover Remove lower retaining s...

Page 369: ...J C f b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 370: ...asher 3 Rubber bushing 4 Plastic sleeve Take off centrefairing Disconnect the following leads arrows Combination plug for H4 bulb 1 brown yellow white Parking light bulb 2 grey white brown Horn 3 gree...

Page 371: ...1 for instrument cluster plug connection Pull out plugs 2 and 3 Remove jour retaining screws arrows for instrument cluster Take off the instrument cluster 8 87 46 25 0 b y a k i n d a p p r o v a l o...

Page 372: ...o provide a beller picture Remove cable strap lor wiring harness on inner cover Lift out the inner cover Slacken off the lairing mounting retaining screws il necessary Remove the two retaining screws...

Page 373: ...J I o b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 374: ...holder on radiator trim Note Note plastic shim between the holder and radiator trim Remove both retaining screws arrows on underside of engine spoiler Pull the engine spoiler slightly down atthe rear...

Page 375: ...s for holder on oil sump and take off the holder Install following the same procedure but in the reverse order 8 87 546004 Ansicht Z 46 29 0 b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w...

Page 376: ...emoving and installing Remove retaining screw arrow at base 01 side section and take out retaining screws in upperlairing arrows take out the knee pad 8 87 46 31 0 b y a k i n d a p p r o v a l o f t...

Page 377: ...Cl c S c 0 E Ci GI I e Cl cn 0 tJ cn Cl c c 0 e 0 Cl c Q 0 GI E g Ol iii 0 Ol c l c Ol c 0 Ol 0 5 c c 0 e tJ cn Cl c e Ol o EZl 010 0 0 b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f...

Page 378: ...tre section Remove retaining screws lor sealing gaiterson radiatortrim Take offthe radiatortrim When installing When installing ensure thatthe air duct on the radiatortrim is correctiy lixed to the in...

Page 379: ...ecessary push Ihe mirror up unlil Iree al all Ihree holders Pull electric cables off Ihe mirror and lake off Ihe mirror Innerfairing removing and installing Fold up Ihe cover arrow atthe lower edge en...

Page 380: ...outside the horn has been removed to provide a better picture Remove the innerfairing on either side ofthe windshield arrows and pull outto the side 8 87 46 35 0 b y a k i n d a p p r o v a l o f t h...

Page 381: ...l off electric cables on the horns and headlight Remove retaining screws arrows on either side on the fairing mounting and frame and take offthe upperfairing The horn has been removed to provide a bet...

Page 382: ...er on lett and right Disconnect cable straps arrows on fairing holder Remove retaining screws arrows on lett and right and take offthe fairing mounting Install following the same procedure but in the...

Page 383: ...ing and installing Open the storage compartment and remove the retaining screws arrows tor the storage compartment and knee pads on either side Remove retaining screws at base on either side arrow 8 8...

Page 384: ...a 6 Cl Q e J S l 0 I Q e C e C Cl e Q o E GI C c I e Cl e GI 3 c b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 385: ...e also illustration on next page Remove retaining screws arrows in the vicinity 01 the cylinder head crankshaft cover and take off the lower sections 8 87 24946030 24946032 46 41 0 b y a k i n d a p p...

Page 386: ...g ensure that the air duct on the radiator trim is correctly lixed to the intake pipe slacken off the intake pipe on the radiator il necessary Windshield and innerfairing removing and installing Remov...

Page 387: ...b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 388: ...cables off turn indicators and horn arrows on either side and pull off headlight cables Remove side retaining screws on upper section of cockpit on either side arrow 8 87 b y a k i n d a p p r o v a...

Page 389: ...ide and take off the plastic covers on either side Disconnectthe cable straps arrows on the fairing mounting Remove the retaining screws arrows on either side Take off the fairing mounting on either s...

Page 390: ...ing screws arrows for fairing mounting on either side Remove handlebar and fittings Lever out marker disc for ignition lock with a small screwdriver Push in ignition lock retaining hook with a small s...

Page 391: ...r arm on gearbox and pull out as far as the handlebar Disconnectthe clutch switch 1 and lett fitting 2 and pull outthe leads as far as the handlebar Remove retaining screw arrow for central earth on f...

Page 392: ...ews arrows for handlebar clamp blocks and take off complete handlebar together with fittings Telescopic lork with front wheel removing 1 1 Slacken offthe retaining screws arrows remove hex nut 1 and p...

Page 393: ...erthe thread on the steering head tube with 1 1 2layers 01 adhesive tape 1 1 Secure locking tube arrow unscrew adjusting ring 1 and taper roller bearings on steering head tube Secure BMW hoist 00 1 51...

Page 394: ...Note Slacken off liller pipe cap to speed up draining process Pull air intake line out 01 lower section 01 air cleaner housing and pull off intake pipe Remove retaining screws arrows on Irame lor coo...

Page 395: ...take out the radiator to the front Dualseat removing Pull circlip arrow off pin on frame Fold up dualseat remove retainer arrow on dualseat hinge and pull out pin Remove retainer arrow from base of du...

Page 396: ...e off the rear light cluster to the rear Pull the multi pin plug 01 the rear wiring harness out 01 the plug socket Remove the two recessed head screws and two Allen screws on the bridge arrows Remove...

Page 397: ...om multi pin plug in the direction of arrow First pull the multi pin plug back then disengage at the front Lever out the storage compartment complete with fuel injection control unit Remove frame moun...

Page 398: ...arrow at starter motor Disconnect engine frame wiring harness plug connection Disconnect plug for Hall eHecttransmitter 1 and oil pressure switch 2 Disconnect plugs at rear right of frame Speedometer...

Page 399: ...ting on right pul out headertank and secure to the engine with wire Lift frame off drive uni and set down on workbench Steering lock removing Break plastic cover on steering lock and remove Lever notc...

Page 400: ...ug arrow projects completely out ofthe steering head Take outthe ignition control unit to the right or lett Frame wiring harness removing Disconnect all cable straps pull out all luses and take out th...

Page 401: ...hells Rubber bearing on frame removing Pull all rubber bearings off frame Remove rubber support for fuel tank at front and rear rubber bearing for ignition contral unit rubber bearing for radiator rub...

Page 402: ...er and hex nut 3 00 not mix up the upper and lower bearing outer races Affix the sheet metal and cage nuts and fit the rubber bearing Rubber bearings for Ignition control unit radiator central electri...

Page 403: ...aged Note The spring bearings must engage in grooves K 100 RS RT LTand K75s Drive notched pins for steering lock limiting into the welded on stop on the steering head Frame wiring harness installing I...

Page 404: ...t and right 8 Connection for oil pressure switch 9 Connection for magnetic gate 10 Connection for handbrake light switch 8 87 10 I 9 2 cU 1 Central earth 2 Connection for rear light rear indicators 3...

Page 405: ...Oil pressure switch wire 1 Magnetic gate wire 2 Oil pressure switch wire 3 Passage in divider 46 64 0 K100 K 100 RS RT 1 2 4 3 1 2 8 87 b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f...

Page 406: ...nd 5 pin plug housing 1 1 1 4 1 Connection for footbrake light switch 2 Connection for fuellevel sensor lever sensor and fuel pump 3 Connection for inductive sensor 4 Connection tor gear indicator 46...

Page 407: ...gate wire 2 Oil pressure switch wire 1 Right hand indicator 2 Left hand indicator 3 Headlights 46 66 0 1 1 1 K75s 2 8 87 b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r...

Page 408: ...and 4 and tighten 1 and 2 Calculate gap between frame and eye on intermediate flange and shim out Remaining gap must not exceed 0 25 Insert screw 3 and tighten Insert screw 5 and tighten 4 and 5 Tight...

Page 409: ...ged 1 1 Note Only fill the fluidbloc chambers with grade 300 silicone grease other lubricants will alterthe specified frictional value 1 1 Gently heat up the taper roller bearing to app 60 C and fit E...

Page 410: ...ndlebar When installing The centre punch mark arrow must lie between the two clamping block halves when assembled Tighten clamping block retaining screws Tightening torque Retaining screw 22 2 Nm Stee...

Page 411: ...cables on the inside abovethem 1 1 Tighten fluidbloc taper screws Tighten torque Taper screws 9 1Nm Wire cables adjusting Connect up throttle cable to throttle butterfly system connect up clutch cabl...

Page 412: ...Fit clamp arrow on distributor pipe with a suitable tube with spring lugs pointing upwards Secure brake hose to distributor pipe with hollow screw arrow Renew sealing rings Tightening torque Hollow s...

Page 413: ...tery and secure with battery holder arrow Engage the multi pin plug first at the front and then press in atthe rear until the securing loop 1 is heard to engage Insertthe storage tray with fuel inject...

Page 414: ...not become displaced and secure to the loop with recessed head screws and Allen screws Push multi pin plug into socket on rear section and secure rear lightto rear section with knurled nuts arrows Pus...

Page 415: ...e starter motor and massage the coolant hose between the water pump and thermostat housing simultaneously Add coolant if necessary Coolant mixture 40 60 40 antifreeze to 60 water for antifreeze protec...

Page 416: ...at lock slacken off locking nut arrow Setthe locking pin in such a way thatthe dualseat lies on the frame and the locking pin engages in the dualseat lock Tighten the locking nut again Installing fair...

Page 417: ...d cutter and apply Loctite 242 Tightening torque Retaining screw for centre stand to pivot block 41 5Nm Pivot block removing and installing Remove centre stand and bearing bushings as described above...

Page 418: ...ift handle on the greased tube on frame Grease the spring and push into upper spring bearing in tube Push out spring with a screwdriver far enough to engage the lower spring bearing Note Spring bearin...

Page 419: ...measuring plane as elose to the wheel centre as possible and so that the gauge can slide freely along the motorcycle The measuring stops must only make contact with the outer edge ofthe rim and notthe...

Page 420: ...alue B 46 mm Calculation SO 46 4 mm wheel offset S EXAMPLE2 Front and rear wheels of differing rim widths Formula E g Reference value halfwheel rim Measured value halfwheel rim A F 2 h B v S A SOmm 94...

Page 421: ...oving cockpit see page 46 15 0 K 75 s removing fairing see page 46 21 0 Telescopicfork removing see page 31 11 0 The taper roller bearing outer races remain in the steering head Screwon BMW adapter 46...

Page 422: ...side when the measuring points are gentlytouching the measuring discs The frame is in good order iithe measuring points are at approximately the same position on either side within the tolerance circi...

Page 423: ...c Cl E c s tT W b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 424: ...t Q E c C W lt 00 i i 00 I I lOlO Q Cl a b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 425: ...tall the lock in the reverse order Always replace the grooved pin 1 Spring washer 2 Cover 3 Steering lock 4 Coil spring 5 Semi circular grooved pin 3 x 9 Dualseat lock removing and installing Remove r...

Page 426: ...N rI b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 427: ...ca CI tn ca l C b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 428: ...ca CI tn ca j C N Ln 00 M t 00 1 1 NN 1 01 0 a 0 tU Il cti Cii C 0 C tU 0 C 0 E I Ec tUa 0 tU tU _ J 00 b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 429: ...Q E ca I t o ca Q rn ca C j b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 430: ...aise the dualseat at the rear and pull forward to remove from pin on frame Dualseat installing Assemble following the same procedure but in the reverse order To adjustthe dualseat lock slacken off the...

Page 431: ...E CI tn tn ca CJ CJ CI CI b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 432: ...moving Headlight removing K75 horn removing and installing K75 s horn removing and installing Lell or right horn K 100 RT LT removing and installing Lell or right horn K 100 RS removing and installing...

Page 433: ...mp h 12130 Alternator Three phase with fully electronic regulator direct drive ratio 1 1 5 Output W 460 Starter Permanent magnet version with four stage reduction gears 27 1 and freewheel Output kW 0...

Page 434: ...Q E c o c Q E Q C c ca o Q s s o Q c ca o J C E b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 435: ...tor and hazard warning flasher relay 3 Starterrelay 4 Temperature switch 5 Load shedding relay 6 Horn relay 7 Electric fuel pump relay 8 Minifuse fuses 9 Fusecover 10 Left hand fitting 11 Right hand f...

Page 436: ...nting 1 Carefully pull off frame 2 Carefully pull off frame 3 Carefully pull back from arbor on frame to remove 1 1 Fuel tank without bridge mounting 1 Carefully pull off frame 2 Carefully pull off fr...

Page 437: ...up storage tray with control unit to remove Take out the screws for the battery carrier arrows take off the battery cover and detach the leads Irom the positive and negative posts Lift outthe battery...

Page 438: ...turn indicator housing Disconnect turn indicator lead plug and take off the ockpit fairing Headlight removing Disconnect headlight plug Slacken off headlight retaining screw and take off headlight Wh...

Page 439: ...emove and pull off cable shoes Note To provide a beller picture the side tairing has been removed here K 100 RT LT right or left horn removing and installing Remove knee pad and storage compartment on...

Page 440: ...tor interior cover holder Lift up interior cover slightly and slacken off retaining screw behind tairing holder do not remove nut Take out holder Pull cable shoes tor horn and remove retaining nut ar...

Page 441: ...b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 442: ...ng and installing Quartz clock removing and installing TeIltale lightframe removing and installing Fuel gauge board removing and installing Revolution counter removing and installing Revolution counte...

Page 443: ...t 9 Cap 10 Retaining screw 11 Covercap 12 Retaining screw 21 20 3 4 2 13 3 13 Fuel gauge board 14 Gasket 15 Retaining screw 16 Green glass large 17 Blue glass 18 Redglass 19 Green glass 20 Redglass 21...

Page 444: ...7 2 I I I I I I 1 Instrument cluster 2 Speedometer 3 Revolution counter 4 Housing 5 Reset button 1 6 Rearpanel 7 Gasket 8 Retaining screw 15 Retaining screw 8 87 b y a k i n d a p p r o v a l o f t h...

Page 445: ...fairing together with turn indicator housing Disconnect turn indicator lead plug and take off the cockpitfairing Headlight removing Disconnect headlight plug Slacken off headlight retaining screw and...

Page 446: ...and installing Remove retaining screws arrows with angled Phillips head screwdriver Remove retaining screws on right arrow and left of rear panel Take off cap 1 for instrument combination plug Pull o...

Page 447: ...uster Assemble tollowing the same procedure but in the reverse order K 100 RT and LT instrument cluster removing and installing Remove knee pads and storage compartment see Group 46 Remove retaining s...

Page 448: ...retaining nuts on lelt and right arrows Pull mounting bracket up to remove Raise instrument cluster slightly Remove cap and disconnect plug Take outthe instrument cluster Assemble tollowing the same...

Page 449: ...ing and installing Remove retaining screw arrow on lower left 01 circuit board Remove retaining screw arrow on lower right 01 circuit board Remove retaining screws arrows at centre 01 circuit board ba...

Page 450: ...g Pull up quartzclock frame 1 to remove Carefully press out the four quartz clock retaining hooks then pull the clock up to remove Note Release first the front two hooks then the rear two When install...

Page 451: ...ution counter Revolution counter dial removing and installing Carefully pull needle off mounting Remove retaining screws and take off dial Gear indicator board removing and installing Turn over revolu...

Page 452: ...corder as far as possible in the direction ofthe arrow and take outthe speedometer TeIltale light renewing Grip bulb socket diagonally with BMW relay pliers 61 1 250 turning the pliers to and fro take...

Page 453: ...tn c C J b y a k i n d a p p r o v a l o f t h e B M W A G f o r w w w f l y i n g b r i c k d e...

Page 454: ...K75c K 100headlight removing K75 c K 100 headlight installing K75 s headlight removing and installing 63 Lights K 100 RS RT LT headlight removing and installing Rear light cluster removing and install...

Page 455: ...light DIN72601 12V 10W standard designation R 19 1 0 Brake light DIN72601 12V 21 W standard designation P 25 1 Turn indieators DIN72601 12V 21 W 4 x standard designation P25 1 Instrument cluster Turn...

Page 456: ...elow the first Switch on the low dipped headlight beam and align the headlight so that the light dark boundary 01 the beam runs to the left of the lower cross rises to the height of the upper cross to...

Page 457: ...RT LT headlight adjusting The beam throw adjustment mechanism is located in front of the right hand telescopic fork fixed tube The 3 stage lever 1 should be in thetop position screw 2 is forfine adju...

Page 458: ...rrow and take headlight out 01 housing Pull plugs 1 2 3 off headlight and take off headlight Remove retaining screws on left and right arrows lor headlight housing and take off housing 8 87 b y a k i...

Page 459: ...on left and right Tiltforward cockpitfairing together with turn indicator housing Disconnectturn indicator lead plug arrow and take off the cockpit tairing Slacken off retaining nuts for headlight pul...

Page 460: ...centre sections see Group 46 Pull off plugs for H4bulb 1 Parking light bulb 2 and Horn 3 Remove headlight ring retaining screws 4 Take off headlight ring together with headlight and horn Lever headlig...

Page 461: ...nurled screws in the storage compartment arrows take out rear light cluster to the rear Push in the bulb holder clamp arrow and take out the socket Assemble following the same procedure but in the rev...

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BMW K100 LT, Repair Manual

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Summary of Contents for K100 LT

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