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This manual is based on the org BMW Repair manual

This file is an almost global cooperation to assure that all information for our
old bikes will be available after the org book is sold out.

Involved:
Australia, UK ,Ireland , Canada, Germany

Printing:
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 take the K1100 file

I´ve only added infos in chapter 31 for K75 Showa frontfork from 8.1991 up

Thx and regards to all who made it possible

6.12.2011

by

a kind

approval

of

the

BMW

AG

for

www.

flyingbrick

. de

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Содержание K100 LT

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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