BMW R 1100 S EVO Maintenance Manual Download Page 93

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34.28

Removing and refitting front brake line

Summary of Contents for R 1100 S EVO

Page 1: ...BMW Motorrad After Sales R 1150 R Maintenance BMW Integral ABS...

Page 2: ...ter Sales UX VS 2 All rights reserved Not to be reprinted translated or duplicated either wholly or in part without prior written permission Errors and omissions excepted subject to technical amendmen...

Page 3: ...t Replace the Poly V belt every 60 000 km 36 000 miles do not adjust it 60 000 Check brake fluid level at front and rear Check operation of brake system and freedom from leaks repair replace items if...

Page 4: ...en cold and correct if necessary Check headlight setting and adjust if necessary Check tightness of rear wheel studs note correct tightening torque Check tyre pressures Fill up with fuel Integral ABS...

Page 5: ...0 rpm Throttle cable setting for cold start increased idle speed for throttle twistgrip cable for divider cable zero play approx 0 5 0 02 zero play mm in free travel Brakes Colour of identification ma...

Page 6: ...ol 5 16 Fuel tank and lines 5 18 Exhaust system 6 21 Clutch 6 23 Transmission 7 31 Front fork 7 32 Steering 8 33 Rear wheel drive 8 34 Brakes 9 36 Wheels and tyres 10 46 Frame 10 51 Equipment 11 61 Ge...

Page 7: ...00 2...

Page 8: ...en one nut 2 Tighten nut to initial torque Nm 20 3 Tighten nut to wrench angle 180 4 Slacken and retighten M 10 screw Nm 40 Timing gear carrier to cylinder head Nm 9 Bearing cap on rocker shaft Nm 18...

Page 9: ...to oil cooler Nm 25 Oil cooler to bracket Nm 8 Oil cooler return line to engine block Nm 35 Oil cooler connection to crankcase Nm 9 Cylinders Tightening sequence 1 M 8 screw Nm 20 2 M 6 screw Nm 9 3 C...

Page 10: ...21 Spacer to alternator Nm 21 Positive lead to alternator Nm 15 Belt pulley to alternator Nm 50 Belt pulley to crankshaft Nm 50 Poly V belt preload Nm 8 Spark plug NGK BKR 7 EKC Nm 25 Model R 1150 R...

Page 11: ...ilencer to rear frame at top Nm 35 Oxygen sensor to silencer Nm 45 apply Optimoly TA to thread End cap to rear silencer Nm 8 threads greased Bracket to rear silencer Nm 15 threads greased Model R 1150...

Page 12: ...plate Nm 42 clean thread Loctite 243 Model R 1150 R Connection 31 Front fork Quick release axle clamp screws Nm 22 Clamp fork fixed tube to fork bridge Nm 45 free from oil and grease Slider tube brid...

Page 13: ...Threaded ring Nm 160 clean thread Loctite 577 Hexagon nut input bevel gear Nm 200 clean thread Loctite 2701 Cover to rear wheel drive housing Nm 35 Fixed bearing stud bolt swinging arm to gearbox Nm...

Page 14: ...701 Brake disc to rear wheel drive Nm 21 clean thread Loctite 2701 Master cylinder to footrest assembly Nm 9 Footbrake lever to footrest assembly Nm 21 clean thread Loctite 2701 Footbrake lever stop N...

Page 15: ...42 clean thread Loctite 2701 to engine Nm 42 Carrier plate for main stand to engine right M 12 screw Nm 72 clean thread Loctite 2701 Pivot mount to engine left M 12 screw Nm 72 clean thread Loctite 2...

Page 16: ...ctite 243 Headlight bracket to fork bridge Nm 20 Model R 1150 R Connection 51 Equipment Mirrors Nm 15 Ignition steering lock to fork bridge Nm 20 micro encapsulated Model R 1150 R Connection 61 Genera...

Page 17: ...e sealant 81 22 9 407 301 50 ml tube Loctite 577 Thread locking compound 07 58 2 328 736 5 g tube Curil K 2 Heat conductive sealant 81 22 9 400 243 250 g can Adhesives and retaining agents Loctite 648...

Page 18: ...or damage 16 Checking that delivery is complete 16 Filling and charging the battery 17 Removing the fuel tank 17 Filling and charging the battery 17 Checking engine oil when engine is cold topping up...

Page 19: ...00 14...

Page 20: ...00 15 00 General view of crated motorcycle...

Page 21: ...cross struts out or the motorcycle may be damaged Remove the end walls Remove the side walls eImportant Remove any nails projecting from the base of the packing or lying on the base or on the floor L...

Page 22: ...flow pipe Disconnect the fuel line quick release coupling Disconnect the fuel pump plug connection L Note Place a cloth between the fork stabilizer and the fuel tank to prevent paintwork damage to the...

Page 23: ...erminals Connect the battery breather line Fit the fuel tank Connect the fuel pump connector and the fuel line quick release couplings Connect bleed line and overflow pipe Fit oil cooler with air duct...

Page 24: ...g for headlight beam angle adjuster 25 cm 9 8425 in at a distance of 10 m 32 8 ft Checking tightness of rear wheel studs X Tightening torque Securing screws for rear wheel 105 Nm Checking tyre pressur...

Page 25: ...pair work Performing BMW Integral ABS pull away test The ABS warning light must go out when a speed of 5 km h approx 3 mph is reached L Note The ABS warning light and the general warning light must bo...

Page 26: ...instruments and indicator lights optional equipment and accessories fitted features of BMW Integral ABS brake servo residual braking function pump noises self diagnosis with pull away test The user m...

Page 27: ...00 22...

Page 28: ...ilter 30 Inspection III In normal operating conditions every 40 000 km 24 000 miles if fuel quality is poor every 20 000 km 12 000 miles Checking battery fluid level and topping up if necessary cleani...

Page 29: ...tegral ABS Bleeding changing brake fluid in rear system 40 Integral ABS Changing bleeding brake fluid in wheel circuit 42 Change brake fluid in wheel circuit once a year Inspection IV Integral ABS Ble...

Page 30: ...lacing spark plugs 55 Inspection II check Inspection III replace Tightening cylinder heads 56 Inspection I Checking adjusting valve clearances 56 Inspections I II and III Checking throttle cable freed...

Page 31: ...00 26...

Page 32: ...ions I II III and IV Remove front rear seat Connect the BMW MoDiTeC to the diagnostic connector Read all fault code memories Perform all requisite repair work Integral ABS Performing bleed test with B...

Page 33: ...ealing ring on the new oil filter element with oil and install filter Refill with oil to correct level Insert and tighten the screw plug eImportant Never top up the engine oil level past the MAX mark...

Page 34: ...quarts Oil grade for transmission Brand name hypoid gear oil SAE 90 API class GL 5 00 11 229 Changing the oil in the rear wheel drive Inspections I III and IV Every 40 000 km 24 000 miles or at the l...

Page 35: ...able trim Remove oil cooler with air ducting and fold for wards eImportant Fuel is flammable and a hazard to health Observe relevant safety regulations Remove fuel tank retaining screw Remove bleed li...

Page 36: ...ps with pliers BMW No 13 1 500 eImportant Make sure that O ring 2 is in perfect condition Installation is the reverse of the removal proce dure X Tightening torque Fuel pump unit 5 Nm e Important Afte...

Page 37: ...dis tilled water Grease the battery terminals Acid proof battery terminal grease e g Bosch Ft 40 V1 13 72 000 Replacing intake air filter element Inspection III In very dirty and dusty operating cond...

Page 38: ...he poly V belt in position tension it and turn the engine over once then relieve belt ten sion Poly V belt tensioning procedure 1 Slightly tighten hex nut 1 on adjusting screw 2 by hand do not use too...

Page 39: ...fault Front brake Place the motorcycle on its centre stand Turn the handlebars to the right Required level with new brake pads MAX exactly between the centre point of the sight glass and the top edge...

Page 40: ...Required level not below MIN Brake fluid DOT 4 Checking brake system for correct operation and freedom from leaks repairing replacing if necessary Inspection III Check brake system for leaks Checking...

Page 41: ...minimum value Always replace the brake pads as a complete set Minimum pad thickness 1 0 mm 0 3937 in If the brake disc is visible through the bore in the wheel side brake pad the brake lining is worn...

Page 42: ...in accordance with the in structions for filling the reservoir Pistons with old brake pads should only be pressed back just far enough for the new brake pads to fit in Remove old brake pad and insert...

Page 43: ...capes proceed in accordance with the in structions for filling the reservoir Force back the pistons Check the springs for correct seating and instal lation position The engraved arrow indicates the di...

Page 44: ...luid and clean the reservoir Refit the reservoir cap with rubber diaphragm Remove the brake pads Use the reset device BMW No 34 1 531 and the positioning piece BMW No 34 1 532 to press back and positi...

Page 45: ...re of the sight glass Brake fluid DOT 4 X Tightening torque Front brake caliper bleed screw 9 Nm Handlebars tightening sequence 1 Front connection to system in direction of travel 21 Nm 2 Rear connect...

Page 46: ...of the vacuum extraction process it might not be possible to tell whether there is brake fluid in the hose of the brake bleeding device when it is free of bubbles In this case bleed the system manual...

Page 47: ...ke fluid to come into contact with painted motorcycle parts as brake fluid destroys paint Open front wheel circuit reservoir 1 Draw off the old brake fluid from the wheel circuit reservoir Remove the...

Page 48: ...aster the fluid is pumped through the system which means that the level in the wheel circuit reservoir drops all the more rapidly Pump off brake fluid until it emerges clear and free from air bubbles...

Page 49: ...eeze the handbrake lever until the front brake caliper pistons are butt against the reset device BMW No 34 1 531 Switch off the ignition Top up the fluid in the wheel circuit reservoir until one of th...

Page 50: ...e dWarning The brake fluid must not foam in the hose If this should happen follow the procedure for bleeding changing brake fluid in the front wheel cir cuit a 00 42 Pump brake fluid through the syste...

Page 51: ...f the external brake pad With the handle outwards use the reset device BMW No 34 1 531 on the rear brake caliper to press back the pistons completely and to position them Wrap a cloth around the brake...

Page 52: ...pres sure to begin with then vary the brake pressure L Note The higher the brake pressure the faster the fluid is pumped through the system which means that the level in the wheel circuit reservoir d...

Page 53: ...ignition Top up the fluid in the wheel circuit reservoir until one of the three protrusions in the filler neck just touches the surface of the fluid arrow Remove the reset device BMW No 34 1 531 with...

Page 54: ...4 2 541 Pump the brake fluid under virtually no pressure to begin with then vary the brake pressure d Warning The brake fluid must not foam in the hose If this should happen follow the procedure for b...

Page 55: ...all the way to the left Repeatedly and slowly pull the front brake lever lightly to expel air from brake master cylin der Place motorcycle on its centre stand Remove fuel tank Place the front wheel a...

Page 56: ...rake lever fully and close the bleed screw 4 Release the brake lever slowly 5 Repeat steps 1 to 4 until the brake fluid is clear and has no bubbles Fit the protective caps on the bleed screws Top up t...

Page 57: ...not allow the brake fluid level to drop below the MIN mark as other wise air will be drawn into the brake system Bleed the system again if this happens dWarning Avoid rapid and forceful pumping of the...

Page 58: ...id level Inspections II and III eImportant Keep the brake fluid in the clutch operating system away from painted motorcycle parts as brake fluid attacks paint Support the motorcycle on its side stand...

Page 59: ...ant While bleeding the system do not allow the brake fluid level to drop below the bottom edge of the ring mark as otherwise air will be drawn into the clutch system Bleed the system again if this hap...

Page 60: ...ell Retinax EP2 Checking function of side stand contact switch Inspections I II III and IV Place the motorcycle on its centre stand Retract the side stand if extended Disengage the clutch and select a...

Page 61: ...al torque 20 Nm 1 3 Angle tighten nut 180 2 Undo tighten M 10 bolt 40 Nm 11 34 004 Checking adjusting valve clearances Inspections I II and III Check valve clearance with feeler gauge and if necessary...

Page 62: ...le approx 2 mm 0 0787 in Connect the BMW Synchro hose to the vacuum adapter and connect the cables to BMW MoDiTeC Adjust idle speed by turning the air bypass screws while checking that the carburettor...

Page 63: ...from left to right and check the settings Make sure that engine speed does not vary when the handlebars are moved in this way Repeatedly open the throttle gradually and in crease engine speed from idl...

Page 64: ...correcting engine oil level Tyre pressures Solo front 2 2 bar 31 3 bar rear 2 5 bar 35 6 psi With pillion passenger front 2 5 bar 35 6 psi rear 2 7 bar 38 4 psi With pillion passenger and luggage fron...

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Page 66: ...Integral ABS Removing and refitting rear ABS sensor 10 Removing and refitting footbrake lever 11 Removing and refitting brake master cylinder 11 Checking and adjusting piston rod play 12 Removing and...

Page 67: ...filling instructions 22 Filling rear wheel circuit 23 Rear wheel circuit filling instructions 24 Integral ABS Reading fault code memory with BMW MoDiTeC 24 Integral ABS Performing a bleed test with BM...

Page 68: ...mum lining thickness front mm in 1 0 0 0393 Rear wheel Brake disc diameter mm in 276 10 8663 Brake disc thickness mm in 5 0 0 1969 Minimum thickness mm in 4 5 0 1772 Brake pad surface area cm2 sq in 3...

Page 69: ...s back against the brake disc arrow by pressing the brake caliper eImportant Do not damage brake pads Carefully remove the brake caliper Installation is the reverse of the removal proce dure eImportan...

Page 70: ...ng the compressed air gun on the brake line connection carefully force out the brake pistons 5 Remove the two sealing rings from the brake pis ton holes Inspect the brake caliper piston for hairline c...

Page 71: ...he brake pads pistons Remove the brake caliper Installation is the reverse of the removal proce dure Fill and bleed the brake system Integral ABS Bleed fill the rear wheel circuit a 34 23 To bleed und...

Page 72: ...cylinder Inspect the brake caliper piston for hairline cracks score marks and other damage X Tightening torque Bleed screw to brake caliper 7 Nm Assembling rear brake caliper Coat the new sealing ring...

Page 73: ...thrust washers between the right brake disc and the front wheel and to the ABS sensor ring between the left brake disc and the front wheel eImportant Note direction of installation for the brake disc...

Page 74: ...1 in sensor line Remove the left brake caliper Remove the sensor 2 Installation is the reverse of the removal proce dure eImportant Route the sensor cable correctly Check that the clips 3 are correct...

Page 75: ...nector 1 in sensor line Before removing refitting clean the sensor and bore Remove the sensor 2 Installation is the reverse of the removal proce dure Coat the O rings with oil before fitting them eImp...

Page 76: ...d Loctite 2701 21 Nm 34 31 Removing and refitting brake master cylinder eImportant Do not allow brake fluid to come into contact with painted motorcycle parts as brake fluid destroys paint Drain the b...

Page 77: ...ravel between the brake light switch lever and the stop on the footrest plate arrow Feeler gauge thickness 0 2 mm 0 0078 in Slacken locknut 1 Turn the piston rod 2 to the right in the direction of the...

Page 78: ...rocedures and processes should be strictly observed Use only new brake fluid from an unopened contain er Removing the ABS pressure modula tor eImportant Do not allow brake fluid to come into contact w...

Page 79: ...the plug connec tion is opened Ensure correct positioning Install new spring clips Fit the protective caps to the brake line Clip in the brake lines Check that the spring clips arrows are seated corre...

Page 80: ...d brake fluid from the wheel circuit reservoir Remove front brake pads eImportant Only use the piston reset device BMW No 34 1 531 if the wheel circuit res ervoir cover is open Use the reset device BM...

Page 81: ...ce BMW No 34 1 531 on the rear brake caliper to press back the pistons completely and to position them Wrap a cloth around the brake caliper Connect the brake bleeding device to the bleed screw but do...

Page 82: ...er with rubber diaphragm Draw off old brake fluid and clean the reservoir Draw off the brake fluid in accordance with the sequence using the ring spanner BMW No 34 2 532 Front dosing cylinder 1 front...

Page 83: ...MAX mark arrow eImportant During the filling and bleeding procedure make sure that the fluid replenishing hole is always below the level of the brake fluid otherwise air will be drawn into the brake...

Page 84: ...close the bleed screw 4 Release the brake lever slowly 5 Repeat steps 1 to 4 until the brake fluid is clear and has no bubbles Fit the protective caps on the bleed screws Top up the brake fluid level...

Page 85: ...therefore necessary to bleed the hose by hand in the predefined sequence and in accordance with the rules for bleeding Switch off the bleed device In sequence bleed the rear dosing cylinder 1 rear int...

Page 86: ...the ignition is switched on Do not operate the brake lever until self diagnosis is complete eImportant The piston in the base of the wheel circuit reservoir must always be covered by the fluid as othe...

Page 87: ...elf diagnosis is complete Squeeze the handbrake lever until the front brake caliper pistons are butt against the reset device BMW No 34 1 531 Switch off the ignition Top up the fluid in the wheel circ...

Page 88: ...mplete its self diagnosis Do not operate the brake lever until self diagnosis has completed eImportant The piston in the base of the wheel circuit reservoir must always be covered by the fluid as othe...

Page 89: ...rake calipers are being fitted If necessary carefully press back the pistons un til the brake disc just fits between the brake pads Fit the brake pads and brake caliper at the rear Hand tighten the re...

Page 90: ...cuit reservoir bleed lines Remove the cover of the wheel circuit reservoir with bleed lines Install in reverse order ensuring that the bleed lines are not kinked bleed lines which have been shortened...

Page 91: ...rts as brake fluid destroys paint Drain the brake system Remove brake lines Installation is the reverse of the removal proce dure eImportant Remove sealing rings for brake line Secure the brake line t...

Page 92: ...dle bars are turned L Note When replacing the brake lines always replace the seals Quad rings between the brake lines and the pressure modulator Carefully remove the quad rings 3 using the dis mantlin...

Page 93: ...34 28 Removing and refitting front brake line...

Page 94: ...34 29 Removing and refitting rear brake line...

Page 95: ...34 30...

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