BMW K100RS 16V Repair Manual Download Page 1

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Repair Manual

K1 – K100RS 16V

BMW Motorrad GmbH + Co.
Service Department

Summary of Contents for K100RS 16V

Page 1: ...Repair Manual K1 K100RS 16V BMW Motorrad GmbH Co Service Department...

Page 2: ...ty but usable Must be an early edition because the K100 16V models are not included Nevertheless It can be used for all K100 16V models as well The PDF file is made with Acrobat 9 0 Pro Printing Print...

Page 3: ...ff I f I p t I I I J I j INTRO OU CTIO N 1 I ff I I t I fir _ I r t b 1 I J...

Page 4: ...le and p de i y hcok I 0 Operating rTu dia rind setvioing data Eleotri os Brake system Running gear Frame attao hments Exhaust t yst m I Gearb x I Clutoli J j Eflgine t FU ls itPIY ari d ixture i fu 1...

Page 5: ...The cG mt nIG am dLvlded Iilp ln l Glp rate Cl1aplers Tho page numb lflrlng means 11 of 10 J 1 Page number wlthlh cl1 pler Tl e work 10 be PQr o rmod durlng an Inspocllon ls slaled In an Insp cllo l 8...

Page 6: ...g h also e anged l Slnc6tthe co ntents pr Indlvlduai maln grou s are elosely related they have r low i een g oupe d t6ge her l lto chaP te IS kes easler to loeate the requlred InfonJ1atlon ar l l gall...

Page 7: ...f 1 Jt l y It 90M P ETINGTJi MO TORGVCLE ANO u f PR E DELIVERY CHECK f J h f t J J I l J i...

Page 8: ...OMPLETENES S 1 4 J P8E DELIVERV CHECIt 1 5 rREMOVING BAnERY 1 5 g LlNG BAlTER Y WITH A ID 1 3 HARGING BAnERY I i 1 7 I HECKING T H fNES OF R r AR WHEEL STUDS 1 7 I CHECKING CORRECTING T YI E PRESSURES...

Page 9: ...lftiout lifting 11 Inst I i Ihe gUlck r lease xle fram Ihe rlght Note Ihe SPClcln w hers atleft ari rlght Screw themaCI 11r l strew wlth spacer In o the qulcK release aXle Tlghten the clamp screws ori...

Page 10: ...torqu J Forl s Bl lIlzor 21 J 2 Nm It JS ALLlN G t N INi UNDE TRA 2 Insan Ihe anglne undeJrlnilY Inlo lhe falrlng ard scraw 11 on Iighl NOTE Insert Phlillps head screws al Iha raar left and rlght CLg...

Page 11: ...he dualsaat Re ve the reta nln r s 1 Take off Ihe duai seat lock holder Release 111e kee per on Ih cG ntrol nlt plug C nd pull the plug out of the con roi unI on Ihe ca ble entryslde arrow Remawe the...

Page 12: ...whon cl1arglng 1 4 J 1 1 r Qt tJ a J 0 1 I Rertiove n e 1IIIer P8 O dad P letce mLJIOlor grodoBulpllurlbaoldtoVDIiQ5iO st nd rd or equlvalenl 10 tl1e b Oltory up 10 Ihr Mo m rk Spci elfle grevlty 1 28...

Page 13: ...osilive lood flrsl Ihon Ihe ne galive lead NOTE Make sure lhnl lheNenl lube Is run corr eei Iy CHECKING TIGHTNESS OFREARWHEEL o STUDS Q hte 9 torque Re he Istuds 3 Nm 105 4 Nm I CHECKING CORRECTING TV...

Page 14: ...t tB I cor r c t ond 94 itJf I If 950 11 50 mitl Inspeo gembox rom wl1801 I drive b rol ell nos 011 1 lIL I system fOrl 0 qr fj m It by a slomp onu In 1118 rum 1Il 8 U1e IHft pr888ir o lI e covoriown...

Page 15: ...J 1 f t I _ J _ _ I tJ r I...

Page 16: ...10VI G AN INSTALLING AIR CLEANER ELEMENT 111 2 15 Remo lng englne falrl ng 2 15 Remov ng rlght slde seeIIon of falrlng 2 15 ADjUSTING THAOTILE GABLE PLAY I 111 2 16 ADJUSTING IDLE SPEED I 11 1 2 16 O...

Page 17: ...elearances ad Just If necessary X rlj Every 30000 km 0 15 0 20 E 0 25 0 30 2 11 1 5 Renew air cleaner element Check throttle cable play ad Just11 necessary Check Idle speed andCO 00t f lent 01 e haust...

Page 18: ...20 21 2 23 Check coolont concentratlon X 60 woter c9rrecllf neces ry 2 o nlllr 223 Renew cool ant at least every I I 50 50 two years n 36 0C Chepk for play In swlnglng arlJ1 Md rear wheel drive bearl...

Page 19: ...models Order l1umbor _ 07 55 0 056902 07 55 9 050 900 18211 387498 11 21 9 056 999 07 58 9 058 193 0758 9 056 193 HVVB 0122 9 407 302 HVVB 81 22 9407 303 HWB 81 200 400 208 07 589 62 3 16 I I Curll K2...

Page 20: ......

Page 21: ...cold T Jghtenlng torque Oll filter Englne oll draIn PIUQ End ph g In tl lng ease cover Cqmshaft bei lng td cyllm ler head Chaln spracket to camshaft Gearbox olr filier dr aln plug Rear wh el drive bll...

Page 22: ...8nd r8rnOV Hl j lrlr lq In llO qlrec J If neGo aICHY ron V d 0 ring In 111Gi co vpr I Tlglltpr ng tprqud Oll drain plug c o r toSUfTlP 18 1 2 N 11 Nm Oll c nlonl wllOn flilor 11 rOn wQd _ I r r oll Qf...

Page 23: ...NDUCTIVE TRANSMrnER ON REAR WHEEL DRIVi I 11 e rak out the retplnlng screw a d pult out JhB inquttlve trans ltier If necessary ver it out carefully wlth a screwdrfver Cleia the Inductlve transmitter w...

Page 24: ...ly tlglltm 1 aOdln untll the pressure point I fal Secu e Ihe adju tlng sor w In 1I11sp oltion wl1l1 tho locl nuL WMn 1110 btWIG settino la carroet t 1dJ lsl play al tl1o l1nndlobil lover FIO 11 AdjLls...

Page 25: ...lrlng Take oUI1I10 reloll1lng ser ws 1 01 loft and rlgll Swing1119 falrlngoulalll1e rem p ulIll back silgtlllyond lal 8 II off Romovlng loft sldo 900tlO ot tolrlnu Take out 11113 relalnlng serows In 1...

Page 26: ......

Page 27: ...are provlded wlth jentlfl catlon marks Inlet one groove after the thrust bearlng Exhaust no groo e Tha camshaft Qearlng oaps are also mar ed In let slde 9 9d nl lmbers Exhau st slde even numbers The n...

Page 28: ...sorl Il1e cylindor Iload cover g081 81 wllll 1110 1101f moor1s Irsl T11 r nprkt r rows on lIlP cG ver end lila gask i l u sl be 011 gned al front lInd rEwr Press llle rem t Qlf moons In flrsl georbox...

Page 29: ...ClUI1I1Q rotolnlng serows In thG ro Glr1 Ier SlJrround and for 1118 upper soc llo anLl tl18 falrl rQ t older Puil lu t the 81 dtJct 1 Iurhlng It Slighily al the same time J Heleasecllps 2 on the air S...

Page 30: ...wIll lI e onglno 0 118 correcl ofj8rotlng temperaturEl 1 150q Pul Oul Ula plug arrow oll IhG 18 Cuuhl f onnectloris enddel ach ttlO v cuuril Ilose al qYllnd 1 w t 2 16 I BMW No 1 3 0 700 to cYl nders...

Page 31: ...lidor lub81 i and ollow Ilgllton 1118 ttl tork oll 10 drain out rIghtenlng torquo J W lGlI1 10 more oll drain oul J tor soveral llmQs 10 torce out Iho r19r 0 111 I 20 2 r N f or p ug t J 111 11 I I e...

Page 32: ...ng boatln Corry oul lila proparl llory w rk 1 l B f r chocklng stearing baarlng play Bl cken off the hex nul 1 ond locklng tu be 2 1 Release bearlng preload by loc klng tube several tlmes wllll a plos...

Page 33: ...wlth seal 2 SI Cken the hose clip prrow at the pipe end and push It on to the plpe Pull 1he fle lble hose wlth fuel filter out of the fuel tank Renew the fuel filter note Its correct Instl l I dpositi...

Page 34: ...s Insped the brake plpes and unions agaln far sl9l1s of leaka ge CHECKINGBRAKE PADS FOR WEAR RE NEWING IF NECESSARY 11 111 2 20 Front brake Remove the mudguard as jve Remove the retalnlng screws 3 fro...

Page 35: ...the tluld s bolllng point WARNING Th 3 motorcycle s palnlwork Will be darila gec l If bral e fluid Is allowed to contact It e enew the brake fluid th a brake fIIllng and blE edlng devlce Recommen ded...

Page 36: ...mudgunrd to galher will 5 AI Em cr Qws Md tlgl1len 11 0 ft5rl stEiblllz er I Tlgl lterllng torque FOl k stablllzer 2 2 Nm AO f wlng fluid In rear broko clroult 119 reE brake callper dMSn0111ave 10 b...

Page 37: ...1ch conleln no nitrides Renew the coorant al le sl every Iwo years 4 1 I l 1 I I Cbnte 8 L I f L ri 11eJodar Wnl ll r tI CHEO KINGPhA V IN SWIN61t JG RMAND I l REAR WHei l DRIVEI JEARINGS ADJ U f I rl...

Page 38: ...8rako anp lIetmqlilplulo l lgIlIS und lurnln dloal rs I Hlgl1 boall l telltoblo Qbllory cl mgo and onglne oll pr s suro warhlrlg IIg1118 nElulrul I ndlcolor i oll e RQW Ilg 11 rnonllor I e Horn Ch o k...

Page 39: ...I v I 3 10 1 w I OPERATING vI EDIA A N P SERVICI NG DATA 11 u I l t 1 I I I...

Page 40: ...I 1 1 I I I I COhtents 1 Page OPE ATING MEDIA K M bELS I I 3 j BMW MAINTeNANOI AND IN91 ECTION SCHr DUI E 3 4 Drlvallno 3 4 RUr1nlng geor 3 5 t t 1 I 3 1...

Page 41: ...lng faces K m deIS Ordor 07 659 080 092 07 5p 0 056 903 1821 1337 408 11 21 9 OM909 07 5 1 058 193 IWB 81 229407302 Hw e 81 22 e 407 303 HWB 81 2 9 400 208 07 589 062376 MetEil sea ng f ces on HWB 81...

Page 42: ...y I X A 4 0 5mrn 13 75 1mm 2 9 10 Check valve clearances ap just If necessary j I X Every 30 006 km I 0 15 0 20 E 0 25 0 80 2 11 1G I ReneW air cleaner eleme fit X Every 60000 km X 2 15 Recomn erttfat...

Page 43: ...11 I Il 1 4 f I 4 Ij 4 I r J r I...

Page 44: ...5 4 16 GENI RAL MOTORCYC LE ELECTRICS 4 17 RI MOVING AND INSTALLING MOTRONIC CONTROL UNIT 4 17 REMOVING ND INSTALLING ASS C ONTROL UNIT 4 18 R EMOVING AND INSrAL ING BATI ERY WITH U T WITIi AJ3f 4 19...

Page 45: ...G ANO INS ALLING ClENTRAL I LECTRIC C MPONENT B ex 4 4 t LAYOUT OP WIRING HARNESS CABLE STRAJ S WITHOUT WITH ABS 4 45 REMOVING AND INSTALLING AaS WIAING HARNESS 4 4 6 AGMOVINC3 AND I LLlN FRAME WIRING...

Page 46: ...e radlalor surround PulI off Ihe pl g eonneelors f0r the flas hing Il Irn Indlcal0rs the three pln pluQ tbe rubber sleeve and Ihe parking light plug conneelors Unscrew the2 retalnlng nuts wlth washers...

Page 47: ...ulb holder 7 Remove bulb 6 Take out bulb holder 11 Remove bulb 12 1 I Components 1 2 3 4 5 6 7 8 4 9 10 t1 12 13 14 15 I 8 5 Asym m elrlo gl8ss Seal Aet ector f efleC oi Retalnlng spring H4 60 55 Wasy...

Page 48: ...If necessarf r Set the raar sprlngQst 0 pOSIII n Ille orcy a 5 metres from a I NOTE fI Tile b 1ndary mU8t rlse 10 Ihe helght 01 tlle upper 08 t o the rlghl 01 th cenlr811 13 moIQ yelos fQr countries...

Page 49: ...f D i t y L r I If j 1...

Page 50: ...ng J rings 1 2 tram the flashlng turn Indlcator cover Take off the rlashlng lt Jrn lndlcaLor cover seal V4 I Take theflashlngturn Ipdlcator hou 3lng 5 Qut Qf the upper sectlon oure Yalrlng lUrn the pu...

Page 51: ...Take O I th flashlng turn Indlcator hdu Ing _ TS1ke oft th e seal 3 PuII Gf1 tl le plug80nnectl ms 4 RereaS t e b ib hi q rt lurnl l lt t6 the left arrow 4 e Tak out the bulb nstallatl 2 Ililthe reve...

Page 52: ...ar light Take out the bulb holder 3 4 Release the brake rear light bulb holder by turnlng It fa the left arrow Take out the bl Jlbs I11staHa tIon 18 In the reverse order of work I NOTE Wheh IMertlng a...

Page 53: ...g DlsGonneCI the pllJgs for the 8uxlilary In strur Tl hts Take o ff the upper secNon of the falrlng Remove 1 le 2 retalnlngs rews wash8rs 1 2 from the retalnl1l9 ptate Take off Ihe retalnlng plate 3 L...

Page 54: ...uster NOTE Avold dama g9 to the houslng er I 9 ess Take the 4 I retalnlng rument ca ler screws 1 out tii a elM 9 retalnlng houslng co crews 2 0 t Tak ver U of Ihe e effthe he Asse b uslng cover 3 I m...

Page 55: ...clrcults _ Make Eiure thai Ihe seals are correclly po sltloned TeIltale lamp bUlbs Instrumem IIghtlng 12 V 3 W 11 ot 4 1 2 Romovlng ond Instolllng tlla prlntod clrcult boord WI1en removlng ovoid damag...

Page 56: ...pairs In Ihe prder 2 3 4 5 Pull 1 1Ei quartz clock 6 oul upwards lrislall atlElch In IM opp slle order of work NOTE When Inslalllng make sure Ihal Ihe hooks and plug oonlacls are poSltioned corracl Iy...

Page 57: ...pposIte order of work NOTE Avold damage 0 the oomponenl boord as 1I I m ved or I tfllled 0 14 J I omovlllg ond 1119tollll1g oornponontbdpfd f r spod dOlll tor I I I I Not 1 1 Av ld darnogo 10 prlntod...

Page 58: ...I1 qIlQcll Ir UlO worl I o J li 0 ll J Ii t 1 0 ob 4 Ro ovlng ond 1 stO IJ1g spoodomotor Removo 1110 2 rettllnhlg screW8 3 e Pu11 Ille mso l knob 4 fuliV oullo lI lq rlglll tlrrow I oe JokO 1 ut 5 111...

Page 59: ...QJird I I I f I i I _ Ftemave the c ounter i Pull scre 2 tak off Jak 4 Ta ke of lhe 5 lhsta ll ttac irr p r qer Of orK NOTE f 1 YVhan Installlng yaldd lIn g tQ lhe comparient bqard 6te the spaCj3r 6 D...

Page 60: ...eat cover dualse t Unscrew the dualseat lock mountlng 1 Release the snap fastener 2 on the mul tl pln plug and press It to ODe Side I Remove the fuel Injectlon control uni 5 to the rear andlJPwards At...

Page 61: ...n trol uoll tI DeIach the multl pln plug 2 from Its lock arrows Bnd puliit off e Hamove the 2 retalnlng screws wlthwas hers end Hexh ts 314 5 fram tlie cOntrol unlt hQuslng e Take out th houslng 6 wlt...

Page 62: ...ips Y Remove the 2retalnlng screws from the battery holder Unscrew the retalnlng nut wlth washers 2 3 at the negative lead Unscrew the retalnlng nut wl 4 5 at the positive lead P ull the t allery vent...

Page 63: ...e holder In the 1alrlng Take out 11 9 retalnlng screw wlth washer 5 6 on the brake light sWlt6h Take atUhe brake light swlfch InstaU In the pposlte 6rd er ot work NOTE WMn In talllng secure the br ke...

Page 64: ...embve Ihe lefl rlgllt Inner falrlng Separate the plug connectqrs far t le 1 lIary Inslruments j t f j Take off the Separate Ihe far t le _ I J J brake llghl swllch r t 1 Open the 5 cable slraps I jr 1...

Page 65: ...r the swlt lI Pull fhe cablEbthrough under the battery hOld r 4 22 Rembve the 2 retplnl ng screws wlth lock washen 6 aUhe s w ttQh Pulllf fl the swltch 7 Note seal 8 Pres the rubber grammet 9 out d wn...

Page 66: ...1 work NOTE Wllen lnslalllng make sure 1I10t 1110 cable Is cofreclly localed Tlgf1fenlnr torque I Inductlve sensor to rear wheel drive 2 5 I 0 5 Nm f 1 REMOVING ANb INSTALLING HORN Remove ll1e duolsoo...

Page 67: ...truments the englnacOver Remove the left rlght centre sectlon of the falrlng Re move the radiator surround T ke offlhe fu 1 tank Open the 2 cable straps I A move the 5 relainlng screws wltt l wa hers...

Page 68: ...Q1 tM f lrlrlg Remove tM radlator surrpund take off the fl lel IElnk A move lh g sersws tram IM cover Qf th trans r Tak e off lhe eover h seal Aemove the two retalnlngscrews Tak 6U t the ba el Jale Se...

Page 69: ...n Ih thls CYl lnder to top de ad cenlra tDe by 1urhlng Ihe crC1hkshafl ar m Seltl1e laXgl 1uge scale rlh to 0 1Urn Il1e crankshattbaCklt 1 the dlrectlon QPpOsite 10 norm al rOlallqn arrow 1 111111 the...

Page 70: ...smll ter t p1u gS NOTE Tl Jrnlng to lsft Ignltlon retarded i Tl Jrnlng to rlght Ignl lon advance d r l r J Retlghtari the clamp screws CheCk that lgnltlon timing has not alte d r NOTE Check by turnlng...

Page 71: ...ns on colls AUach Ihe coll holders sI top and boUorn Make the plug connections for terminals 1 Remove Ihe eogl rie qover I Remove Ihe left c nlre secllon of the fal and 15 Push on Ihe earth le ads rin...

Page 72: ...J 1I l 2 I I I t f lf I j t 1 bV W...

Page 73: ...01ls II rl Relea e the k eper IOop 1 on Ihe multi plnplug Pu lIlhe u IU Plri plug 2 offthe Ignltl l oytpul Slage nsc e w t e retalnlng nut Vfllh Vfas ers P 4 frdm the8Eirih lead rake offthe earth lead...

Page 74: ...ntlng r __ _ Remove tl 1 IMO tIilQt liC contraI unlt I ASS COnlr J unll I _ i Y I th baltery V l i o fL I J J _ retalnlng screws wlth I the alternator cover J Ir r r 1 r 3 i tl r Pull twln plug 4 1 I...

Page 75: ...e alternator Retaln the tlousing in position wlth locking 124 600 1 lunsc1evU i I fake r up hghO 1 n thing 4 5 t J r pull off the fan 6 I I Pull key 7 out of Its groove wh 1 pllers Remove the 3 raJal...

Page 76: ...ctions from the diode board Take off tM ring wlndlng Rem vethe 4 retalnlngscrews 8 tram the diode board Tak e diode board 9 out of the sllprlhg bearlng Inst il ln the opposlte order of Work 11 I 1 2 N...

Page 77: ...In 1I1a drawlng Take Ihe readlng NOTE If O Is dlsplayed tM rotor Is defectlve Tlgf1tenlng torque NOinlria res stance 6 9 q 69 n OhoCklnll rotor fof shart t e trlh J oUnd NOT Befon aooh ohmmeier reqdln...

Page 78: ...e n buttqn untll tha digital display Shows 0 09 1 Check raslstance betweeneach pair of outputs 1 2 1 3 2 3 NOTE The reslstance Inehmsbetween two pha se outputs la aIWays low Temperature dlfferer ces o...

Page 79: ...eadlng zero wlth the BMW diagnosis test r Zerolng cormect he positive yelloW and negE ltlve green leadS together Press tM n putton untll the digital display shows 0 00 0 Measure between aach JJtPUI an...

Page 80: ...tach tl1e pratectlve cap 1 from the po sitive lead Unscrew the retalnlng nut Mth lock was ber 2 3 from the positive lead 41 PJ l1I off the lead 4 Remove the 2 retalnlng nuts locklng rings 5 6 at the s...

Page 81: ...nlngscrews wlth spring wa hers 2 32 fram the Input slde bea ring PulI off the InpLi slde b arlng 4 Note s aal and O rlng 5 6 P 1I1he exclter wlndlnglrotor l 8 out Of the C ommutator bearlng Note spacl...

Page 82: ...le nut 1 for 1118 br sh assembly Take off I le 4 Take IIle carbon and b u h h61der plale 3 4 out Of bearlng 5 T ke off IIle O rlng I Take Ihe IGckil lg plale 7 off brush holder 0 Inslali in Ihe oppqsl...

Page 83: ...he holder plate J Uslng a screwdrlver press out the spiral spring 1 1 Pu the cRrbon brU I1 2 o t of brush K holder 3 Install ln the of work NOTE I I i l I i When Installlng the splrpl sprl1 19 press o...

Page 84: ...Ol QtQf 4 and Run th startermoto earth es m ot r 4 Corn cr fOT 2 p re the eadln 3 vlouslynoted 9 wlt he ilal NOTE 11 the dlf1ere tMn 0 5 V c ce In the 2 values bl9 Ilelw en k Ihe conneCllon lS greoler...

Page 85: ...of thecentral electrl dai equipment bb Make sure that the saallng strlp 2 ls undamaged Pu offthe plugconneeto 3 arthe starter relay 4 0 Remove Ihe ralalnlng screw wlll1lock ring and washer 5 6 7 at t...

Page 86: ...ng startor itlotorrouiy Wlthoflm o tor NOTE 8erom eoch ohtnrllQtef readlng re Will tl1 J BMW dlognosls est r ZerQlng cennect IhepoSllivo yalll jW tJnd Mgotlve lead tog II r Press the bullon Untll the...

Page 87: ...ntral electrl cal component box e Detach the po llIve cable from the starter motor Pull off the plug at the alteinator Pull off the mul l plnplug attheCO pote tlometer I I I 2 I Pull off the mull l pl...

Page 88: ...ori ar row Open all cable straps for theABS wlrlhg han 1ess 1 1 Detachthe wlrlng harnessfrom ttframe iOdnhectI6ns 1 Connectlon toABS contra unlt 2 Cbntiectlbn toABS pulse transmltter S Earth ground co...

Page 89: ...taU In he opposlteorder of work lMPORTA r 1 The wlrlng hamess must be Installep wl thout any klnks or potential abrasion pohits Never allow plug conne orsto touch the frame Note correGt positions of c...

Page 90: ...ator conr 1ectlon 8 Connectlon to h zar f warnlng flasher Q swlic h optlonsl extra 9 H orn tonnc ctlon 10 Fan connectlon 11 Front teft flashlng turn Indlcator connectlon 12 Headllgl lt connoclion 13 p...

Page 91: ...1 6 Wlre tar oil r _ 8 Cable s rap t 10 ConQeotlon el Indlcator fram 1I Not coneet positions of ca Jelstraps N TE r f When tns alllng there should be no palnt j 00 the con ecllon pdlnl It a thln eoat...

Page 92: ...ck cable connections Poer contacl SI connernlons Check vollage tegul lor Is regulator defectlve Chec k carbon brusbes No No Are carbonbru hes defectlve No Oheck reCllfier Is rectlflerdlode defeCllve o...

Page 93: ...arect va Oh lCk cable D 61 hort to earth ground No W rnlnp laI DP not come on wherl englne Is t pped a nd Oheck warillng lamp bulb Has bUlb bl wn CMckbattety 18 batt ery flaVdafectlve Check wires Wlr...

Page 94: ...Cheok carb0 1 brushSs Are ombon brushes worn Check rotor wlndlng Cortoslon Ioyer 011 slIprings Check rotor wlndlng Inlerrupted No 1 1 I ols6ohMd wlr e Immedlotely preist bal WI II wl1l1e rtlolorcycle...

Page 95: ...amo on Ves Bridge termlnols 30 end 00 Inconno lon The star tor motor runs Ves Che ck Ignltlon starter swl tch and supply aable DefectivEllgnlti on starter swltch Vas Check carbon brushes Are they too...

Page 96: ...ts andtermlnlli t Ilndlllgl1ton flrm ly J f No Check con nections Are con neotlons 10 ose Ch dkCbO lmutatbr Ia commutator dldy NO I I No connections I l I t doe not 1 lf motor runs at high spe d oU lo...

Page 97: ...evel Is II below Ihe nominal level C heCl slate ofbattery chtlrge Is lhe baUery overcharged Check sta e of batlery charge 1 thebattery flat Check pattery aClq concenlratlon Is 1I t od low No Check ele...

Page 98: ...cbrroded Che ck state of b tterY char e Is It loo low Battery permanently overcharged Check charglng syster n Is there a fault In the charglng system No Check far short clrcult In cells Is there a ce...

Page 99: ...I I rJ l I t J oIJ O 0 5 BRAKES Ii 4 f t...

Page 100: ...ANDBRAKE LEVER 5 21 REMOVING AND INS1A LLlNG R AR BRAKg WI1HABS 5 22 REMOVING AND INSiAC LlNG REAR BRAKE PADS I 5 22 Rt MOVING REAR SRAKE bALIP R 5 23 STRIPPING REAR BRAKE CALIPER I iI I 5 24 ASSEMBLI...

Page 101: ...fter II has be eh d alned cr oft DIspose of l cordan Ce environmental proteetlon laws I I 1 emove the front mudguard Mask off the lefVrlght brake callper on 111e Vo Inside wllh adl1eslve tape Take out...

Page 102: ...r Take I out the hollow i2 al Ihe I t vr r W k lth sealtng the left rl ht a e caltper Carefulty press th9 brake IIne 3 a parallel move lk e callper Inwards ulde the brake arrows the retalnlng lug call...

Page 103: ...the retalnlng pln 1 Take the brake pads out downwardS WARNIN 00 not fall short of the mInimum of bfake pad thlckness arrows Br ke 0 padS remove and InstalI onlyby pairs M lImdrn rak pad thlck ass on...

Page 104: ...n the sorew wlth a steel wlre brush Separate hetwohalvesofthe brakecall per Take the O rlng 3 out of the connectlng bore Seal the bleed screw and the brake IIne union arrows Hold a cloth over the brak...

Page 105: ...tons wlth weat care avoldlhg th use of force Insert newO rlng 4 Intot11econnecttng bore arrQw FastElnfhe twohalvasof the brakecallper togetherwlth 2 reta lnlng scre s 5 Tlght n the retalnln rewstothas...

Page 106: ...ov 0 II Vl1D Hlj 111 111Ok i Cm ILiIIY sll j 1 lIl 1 l lJ OkO 1 1 pel OVAl 1110 Sl7ClHP 111 1 I utJe w1111 lork sl J 1 1 1010 vO l Ci0 eI olnlflq IHilCk 1 1 l Vs S 11111 om Scre 2 3 I I1I1P 4 0 Will...

Page 107: ...1lll1kl dlscs I carollilly L101oro tll y 1 IP 11 lHlrull j POJlUl 1I111 le lHake nllp is wt eI1IJlSlal lif lg or1I1e brakH pads f11ilylle dallaqmj I IMPORTANT Q 11eck sensor gap and lJjLlst II Always...

Page 108: ...C 11 Placethe mOlorcy le onI t s centre sland Measure brake dlsc Ihlckn ess wllh a rT Il crometer al varl ous pOlnls on Ihe dlsc Renevf Ihe brake dl sc Ifthe minimum Ihlckness Is not pre senl M fil mu...

Page 109: ...fluid attacks palnted surfaces 00 not allow It to contact palnted parts 01 the motorcycle If br ke fluid Is dralr 1ed off trap II Is a sLilta ble vesseJ Screw Joma adapterNo 0 80 W arrow ta the brake...

Page 110: ...IIne 9 Unscrew the retalnlng nut wlth westler 10111 at the dlsttlblJlor p lpe PuJi thEl dl Slrl butor 12 downWards out of thEl fork bridge t In stall Jn the oPPo lie der f 00rk WARNING The br kasyste...

Page 111: ...the threaded lfnl r 1 t r the ASS IIne at lhe co nnectlng plece trom the retalning angle pull the connectlng piece oLlt of the grbm met 2 I I 11 I I I I screw the ti reOdEld union 3 10 r 1I1ID BS Il...

Page 112: ...fluid attac s painted su rtaces Do not allow II to c nfact palnted parts of the motorcycle tf brake fluid Is dralr led off trap lt IS 8 sulta ble vessel I Drain the brake clrcult wlth a sultable e bl...

Page 113: ...the earth grol l modul tor tHe pressure I nl n n t wl tli loCk w s UrisGrew he reta 9 d I lor I pressure r rio U a her 4 5 al 119 wl w l th lock Take out t e re al nll g scre washer 6 S lIe prd r Of...

Page 114: ...olCler Take out the ret alnlng wllll lock 21 al 1I1e tlalder Take 0 holder wlth rubber ommet Un erew le 3 nu s washers 5 6 al der Take off the holder Unserew the 3 retaln ng nuls Wil oe k t waShers 8...

Page 115: ...J J Ir l t l t YV1f 1 tu Note Wh 1 installing run rIle cable and n te correct positior s of Tlghtening torqye rorx strews J r I f 050 055 mm I...

Page 116: ...instaifed Markthe point af mi nimum runout ScreWl e measl Jringshae BMWNO 342 l l lothe dlal gauge 5 18 Ofll3r LlfJ ttln 1110fJSLHIIl SIH to 1I1U IIllpul Ji Wll8 I tHI1SI Jll n1B 1ll0 lSlIrIlH FlllfJ...

Page 117: ...a sulta bis vessel Drain the brake clrcult wlth a sultable ble dlng devlc9 l g Jame 3 L Take _ tha retal ln s9rew 1 outot he handbrake lever cover Takeof thEr c ver 2 NotE The hand brake leverr etaln...

Page 118: ...Ifnecessary lnSlaliln the opp oslte order cf work 5 20 I 0 T writii lnsta lllng 111 brake cyllnder an cj s Elllng rll1gs mus orlly l1e rel lElwed as 0 I j j single uni Rub I thln layer 01 brake fll ll...

Page 119: ...e lever cover Take dU tM Cover NOT The h ridm3ke lever etalnlng screw 3 18 SEfCurliltJ wlth rUFLOK BLU and canbe uS d moreJhan o ce fHe sc r ew tapP d hbl de l h ve to be cl aned Tak out the braka lev...

Page 120: ...ards WA RNING Renew pads if the minimum thickness tar rciws is not present Always Umew brake pads In pairs I I I M 1711l1limv alw poct 1 1 clmess IIlclu fll g CI pl I i tnl7 I I 111 tiill 11 tl1U Df P...

Page 121: ...le Never re use brake flulda r It has been dralned OT slphoned off DIspose of I1 ac cordance wlth environmenlal protectlon laws pr ln Ihe brake clr cult wlth a sultable bteeding devlta e g Joma 3 L ra...

Page 122: ...rake callper Separate the two haJves 01 the brake call per RemQve the 2 O rlngs 7 lram the con nectlng bores Take out he I rlght dust se ls 8 Plug the bleed screw and the brake IIne unl on rioldAa ove...

Page 123: ...bo es talnlng pln end Ihe curo d spring 7 8 i IMPORTANT 1 Drivt the r t lnlng p ln In fUlly unlll It IQ r E1 c Into po sltlon Ia I It Is easy o tlll the pisIon Install wlth gre al the clamplng pln 9 f...

Page 124: ...ake callper into pOSllion wlth 2 retalnlng screws washersand retalrilhg brackel 5 6 7 usirg nie specilled 1ight e nlng lorque Screw IHe bra ke Ifne 8 to the tJrake cali p8r wlth the hollow screw and s...

Page 125: ...ake callper WARNING Naver opera1e the brake pedal when Ihe rear wheel has been re ved Remove IM rear wheel NOTE The retalnlng screws 1 are otUie rplcro encapsulated type Take Ih 2 relalnlli1g crews 1...

Page 126: ...d ligllten 0 1I1e speCified lorque Install 1I1 ii cence plale hOlder 0 Mlach the dualsl3al c ju lseat cover I 5 28 I I tf lgI IIO 1 I1 lorqu 1J1 JI o cl sc lOleJor 10 GIN WIJ wl cinvo lieEl w lool siL...

Page 127: ...1110 s Hlno f ltrut 8crew 1118 dlol qnuqu Wl1l1 adl lrlf H MW No 364 BOO nil 10 t l slucJ MB08Ur8 laternl rUfloul Ron j w Il1el1rak 3 rJlsr Ir 1110 I1l lXll1llIIl1I1l10 rrill rLllloul 18 BXU HJn l 4t...

Page 128: ...pter rde r No 0 22 Vv arrow n 10 brake fluld reservoir Qralrl the brake system wltH a u 1tab le ble ctlng devlca e g Jbm 3 L Det aqhth9r rear f llrlng from ItS mblm llng Remoye Ihe bi akeflul reservol...

Page 129: ...return line at the pressur I I t C r Brakefluld wlll dama ge Ptlll1ted SLlrfaCes l y Remove the hollow screw wlth seals rt K9ep It away fromall palnted ereas of th8 1 0 from the brake return Une at t...

Page 130: ...t v J Push Ihe brake line 0r la IM m ster eylin TIgh enfng t rqt1e der slub PIPet I Ho ow sCrG to p essure moaV t or 7 t J Nrtl Secure Ihe ItnEJi y lh hos clip 3 Hof low scre w t o bral e caflper fNrr...

Page 131: ...he p llug 1 BS j riflQ 8 911 11 trom t e f rake f 9 9d qd i h o l13turn lInes at he Remove tre el tank j T ke Of the pressur con TE ke Gffthe tuel tank lJr neetlng lirl I CAUr N f Brake fluid III r p...

Page 132: ...ut tl1 pressure mOdulator holder 5 Remave he etalnlng screw wlth washer 6 7 frOr rithe holder on the footrlilst piste Take off the holder Unscrew the retainlng nuts wlth washers 8 9L O elach the retal...

Page 133: ...e the prassure m dulator in the holder Sec re the pressure mOdl JJator an dearth cable 5 to the hdlder at the flght wlth re talnlng scrt lw and lock washe r 6 7 Insert the spacJog bushtng 8 between th...

Page 134: ...he WO I clips 3 on t e rem t wlngl g rm Take out the two Torx screws Wftl11QCk W a 11ers 4 5 at thesedsor uslng Torx In sert BMW No 34 2500 TElke off thEi sensor and sensor cable Instail in the opposI...

Page 135: ...e slaled cJlmensions NOTE The mark arr o l on t e edge Of lhEl pulse gener 3ting rlfl9 is the maximum d is ance II no mark is visible determlne Ihe maxi mum oistance This iS neo 8pary II Ihe bra ke di...

Page 136: ...sulfable bleedlng devlce e g onia 3 L Open the 4cable straps 1 or l the frame SeparatE the plug connecter 2 for tbe brake llght swltCh Take the 3 reta inlng s rews wlth lock was he s 6 out of the foot...

Page 137: ...ew at the ma ster from the foo In the bp posite order of ork Whe instaiUri g makEi sure the ea h gro nd c9bie ls 9f1d thebrake light switch cablEiprOP erly 10c ted Make sure that the bJ9k e ilne is we...

Page 138: ...t 1 I 1 4 i I J J a I ll I I I J 6 5 40 d J 1 tf I t 1 h I I I J 1 2 10 I I Il 1 1 I I...

Page 139: ...oll y s lng 1 nt0 th e rin J gr ov on the piston c ppl 1 a thln layer of br ke fll Jlq to t sEla IIng rlng aM plst 2 3 NofEft r1 l 11 Is asy to tll th brtlkeplst i InsJali wlth 4 f 3 ire at care I c l...

Page 140: ...nlng soew arid vashGlr 5 9 carefLiIlY takeoH thebrake pedal splra l spring and piv otbushing 7 8 9 InstqJlln the opposlte ofworK NotE When lnslalllng grease the piv otbushing wlth app 0 5 gof RETINAX...

Page 141: ...t plate Wlth a feeler g uge Turn the adjusllng scr w 3 onthe ma ilE lr cyllnder untll sllght reslstanc S feit lt the stop buHerwhen thebrakepedal ls Of era ted TI hten locknut 4 on the adjustlng sc ew...

Page 142: ...e excesslvely firm CI19Ckbrake pads Arebrake pGlds glazed over badly warn 0 Check brake jJlstons cylinders Are pistOns partl 91led stllf In cyllnders no Check brake system 1 feed from braka fluid rese...

Page 143: ...lBek brake Exoesslve lateral runout Cilock Wllool s Excesslve axial runout7 110 Brakes blndlntJ not fully relea sl d 1 I 0 1 hydraullc malfuncllonlng no Check brflk Plst s Are pistons stlcklT1g no Che...

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Summary of Contents for K100RS 16V

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BMW K100RS 16V, Repair Manual

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Summary of Contents for K100RS 16V

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