Change oil when engine at regular operating temperature, renew oil filter element 1)

Inspect crates on receipt for signs of damage

Motorcycle:

???unpack

???check scope of delivery

???install front wheel

???complete

???clean

Battery:

???remove

???add battery acid

???charge

???grease the terminal posts

???re-install (mark date)

Check complete specification delivery:

???tools

???handbooks and documents

???keys

???optional extras

Check front and rear wheel brake fluid levels (only disc brake)

Check switch function of electrically-operated side stand (angle)

Check torque setting of the rear wheel retaining studs

Check tyre pressure

Fuel the motorcycle

Safety/operating check as final inspection:

???idle speed

???clutch, gear shifting

???steering

???front and rear brakes, ABS

???telltale and warning lights, instruments, lighting and signalling equipment

???adjust the headlight

???test ride, if necessary

BMW

Pre-delivery check

Key to maintenance intervals

???Inspection at 1000 km (600 miles)I

???BMW Service at 10,000 km (6000 miles))II

???BMW Inspection at 20,000 km (12,000 miles)III

Changing engine oil

Inspections I, II, III, IV

LT000010

??? [RS] Remove lower section of fairing.

2

LT000020

???Change oil at operating temperature.

???Oil drain plug (1).

???Remove oil filter cover retainer (2).

???Unscrew oil filter with special wrench

BMW No. 11 4 650.

L Note:

Coat sealing ring on new oil filter element with oil. Screw in oil filter handtight, take note of hint at filter.

Changing oil in transmission (gearbox)

Inspections I, III, IV

2

1

LT000030

???Drain off oil with engine at operating tempera- ture.

???Oil drain plug (1)

???Oil filler plug (2)

L Note:

Renew sealing rings.

X Tightening torques:

Changing oil in rear wheel drive

Inspections I, III, IV

2

1

LT000040

???Drain off oil with drive at operating temperature.

???Oil drain plug (1)

???Oil filler plug (2)

L Note:

Fill oil only up to the bottom-most thread turn of the filler hole.

Changing oil in telescopic fork

Inspection I, III, IV

???Support motorcycle on stand.

???Unscrew oil filler plugs.

1

LT000050

??? Release left and right oil drain plug (1).

???Pump out oil by compressing forks several times.

???Screw in oil filler plugs.

???Lift vehicle with lifting gear, BMW No. 00 1 510, until the front wheel can move freely.

L Note:

The load on the front wheel must be relieved to en- sure as much air as possible flows in before the fixed tubes are closed off with the filler plugs so as to provide additional damping.

???Fill with specified quantity of oil.

???Close off fixed tubes.

Renewing intake air cleaner

Inspection III

???Detach battery panel on right.

???Remove right knee pad.

???Detach right side section of fairing.

???[LT] Take off intake air pipe.

1

LT000060

???Release clips (1) at front and rear.

???Slightly raise casing cover, lift out air cleaner.

???Install in the reverse order of removal.

L Note:

Note installation position of air cleaner. Lettering at rear, arrow marking ???TOP-OBEN???.

Renewing fuel filter

Inspection III

???If necessary, reduce fuel level with pump until fil- ter is clear.

???Loosen hose clip (1) and shift towards filter.

???Detach line and remove filter together with line from the fuel tank.

???Change fuel filter.

L Note:

Note direction of fuel flow on filter.

???Reconnect line to pump.

???Install in the reverse order of removal.

L Note:

Gasket (2) must not close off the overflow hole. En- sure recesses (arrows) in gasket are fitted in correct position.

Cleaning inductive pulse generator at rear wheel drive

Inspections I, III, IV

1

LT000080

???Release securing screw (1).

???If necessary lever out inductive pulse generator and clean with rag.

Checking brake pads, brake discs for wear and renewing if necessary

Inspection II, III

Front wheel brake

1

LT000090

???Remove rear section of mudguard.

???Remove brake caliper.

L Note:

It is not necessary to release the brake line at the brake caliper if only the brake pads are to be changed.

???Drive out retaining pin (1).

???Remove brake pads by pulling in downward direction.

e Caution:

The brake pad thickness (arrows) must not drop be- low the minimum specified value.

Change pads only as complete sets.

Min. pad thickness on carrier plate....1.5 mm (0.06 in)

??? Install in the reverse order of removal.

34 1 500

LT000100

L Note:

Before installing the brake caliper, completely press back pistons with resetting tool (1),

BMW No. 34 1 500.

LT000110

???Measure thickness of brake disc with a microm- eter.

Rear wheel brake

1

LT000120

???Lever off cap from brake caliper.

???Remove brake caliper.

???Drive out retaining pins (1) from wheel side.

???Remove brake pads by pulling upward.

???Install in the reverse order of removal.

Checking brake fluid level and cor- recting if necessary

Inspections I, II, III

Checking brake fluid level

Checking ABS sensor spacing and adjusting if necessary

Inspections I, II, III

Front sensor

Max.Max.

Min.

Min.

LT000310

L Note:

When checking front brake fluid level, the cover of the brake fluid reservoir must always be horizontal (see SI 00 027 95 (716)).

Adding brake fluid

???Take off the reservoir cover together with the diaphragm

L Note:

When adding brake fluid, note the remaining brake pad thickness. If the brake pads are new, add fluid up to the MAX mark.

???Add brake fluid.

???Replace the diaphragm and reservoir cover in position.

???Tighten the retaining screws without using undue force.

Brake fluid grade:

Use only brake fluid in quality category DOT 4 (e.g.

ATE ???SL??? brake fluid).

Checking brake system

Inspection III

???Check all brake lines for damage and ensure they are fitted in the correct position.

???Wipe clean all screw connections of the brake lines.

???Operate brake with force and hold for a short space of time at this point. Then inspect brake lines for any leakage points.

???To adjust, release sensor (1) and set spacing with spacer plates (shims) (2).

Rear sensor

???To adjust, release sensor (1) and set spacing with spacer plates (shims) (2).

Renewing brake fluid

Renewing front brake fluid

??? Remove the break pads

e Caution:

Do not tilt the brake caliper when removing or install- ing, or the brake pads could be damaged.

???Take off the brake fluid reservoir cover complete with the diaphragme.

???Add brake fluid.

e Caution:

While renewing the brake fluid, its level must not drop below the MIN mark, or else air will be drawn into the brake circuit.

If this happens, the brake system will have to be bled.

???Connect a suitable vessel to the bled screws on the brake caliper to trap the escaping brake fluid, and open the bleed screw by half a turn.

34 1 500

LT000100

???Using piston resetting tool, BMW No. 34 1 500, press the pistons fully back into the brake cali- pers.

???Take out the piston resetting tool and insert spacer, BMW No. 34 1 520.

???Press the pistons back in the second brake cali- per, but do not remove the piston resetting tool.

???Close the bleed screw.

???Apply the hadbrake lever several times until braking pressure is felt to build up.

???Hold the handbrake lever in to maintain the braking pressure and open the bleed screw, at the same time pulling the hanbrake lever up firmly.

eCaution:

Do not release the handbrake lever until the bleed screw has been closed.

???Close the bleed screw, then release the hand- brake lever.

???Allow brake fluid to escape from both brake cal- ipers in succession until it is clear and free from air bubbles.

???Close the bleed screw.

???Install the brake pads/brake calipers.

L Note:

When adding brake fluid, note the thickness of the brake pads. If the pads are new, add fluid up to the MAX mark.

???Brake fluid level = Max mark.

???Place the diaphragm and reservoir cover back in position.

???Tighten the retaining screws without using undue force.

???Make a functional check on the brakes and bleed the brake system if necessary.

Renewing rear brake fluid

???The rear brake caliper does not have to be re- mov-ed, nor its pistons forced back.

???Continue the procedure as described for front brake fluid renewal.

eCaution:

Do not release the brake pedal until the bleed screws have been closed.

Checking function of electric switch on side stand and adjusting if nec- essary

Inspections I, II, III

???Place motorcycle on centre stand on even sur- face or lifting platform.

???Spray switching kinematics of the side stand with quick-action cleaner and fold in and out several times.

???Completely fold out side stand and mark position on ground surface.

???Make a second marking at distance ???a??? and a third marking at distance ???b???.

???Fold in side stand and start engine.

???Slowly fold out side stand, the engine must stall in the area of dimension ???b???.

???If the engine does not stall, the switch must be checked and replaced if necessary.

e Caution:

Bending the contact spring can result in malfunc- tioning of the switch.

Therefore:

Never bend the contact spring!

???Operate starter while slowly folding in the side stand; the engine must start up in area ???b???.

???If the engine does not start up or if the side stand is difficult to move, check the switch or disas- semble the side stand.

Checking clutch clearance and adjusting if necessary

Inspections I, III

B

1

2

LT000160

???Detach clutch cable at clutch release lever (1).

???Slightly push back rubber sleeve (2).

???With the aid of setting gauge,

BMW No. 21 3 500,set dimension ???b??? with ad- justing screw at clutch hand lever.

Dimension ??? B ??? ..... 75 ?? 1 mm (2.952 ?? 0.03937 in)

??? Reattach clutch cable at clutch release lever.

6

7

LT000170

???Using box spanner, BMW No. 21 3 610,release locknut (6) of adjusting screw (7) at clutch re- lease lever.

???Unscrew adjusting screw by one to two turns, then screw in until pressure can be felt.

???Lock adjusting screw with locknut.

3

A 5

4

LT000180

???Set dimension ???A??? with adjusting screw at clutch hand lever.

???Lock adjusting screw (5) with knurled nut (3).

eCaution:

Adjust to take up wear only at the adjusting screw on the clutch release lever.

Reading out Motronic defect code memory

Inspections II, III

???Carry out this job only on motorcycles with cata- lytic converter.

L Note:

To read out Motronic defect code memory, see the booklet entitled:

???BMW Diagnosis, Motronic 2.1 with oxygen-sensor control??? (order No. 01 70 9 798 970).

Checking valve clearance and adjusting if necessary

Inspections I, III

e Caution:

Never unscrew the spark plugs before measuring the valve clearance. Carbon particles may settle be- hind an exhaust valve head and falsify the measured result.

???[RS] Remove bottom section of fairing .

???Remove left side section of fairing.

???Remove cylinder head cover.

???Remove cover for Hall generator.

???Only crank engine at the crankshaft (counter- clockwise!).

???Measure valve clearance with feeler gauge.

???Max. engine temperature 35 ??C.

???Determine the replacement tappet by way of nominal/actual value comparison.

Valve clearance:

Adjusting valve clearance

???The camshafts must be removed in order to change the bucket tappets.

???Set cylinder No. 1 (timing end) to ignition TDC.

11 3 700

LT000190

???The setting device for the camshafts,

BMW No. 11 3 700, must fit in the slots at the ends of the shafts.

???Unscrew screw plug in chain case cover.

1

11 2 640

2 3

LT000200

???Lock chain tensioner and timing chain in position with eccentric tensioner, BMW No. 11 2 640.

???Pull back clamping pin (1), screw in eccentric pin

(2) by 3-4 turns.

???Push in clamping pin above the timing chain.

???Fix timing chain and chain tensioner in position by slightly turning eccentric pin in clockwise di- rection.

???Secure eccentric pin with locknut (3).

Removing sprockets

1

LT000210

???Release retaining bolts of sprockets and remove sprockets.

Removing camshafts

???Remove chain guide from stud bolt.

???First remove thrust bearing of camshafts to avoid misalignment.

???Remove remaining camshaft bearings and lift out camshaft.

???Remove bucket tappets to be changed with relay pliers BMW No. 61 1 250, or a magnet.

L Note:

Only the bucket tappets replaced during the 1000 km (600 miles) inspection can be re-used.

Installing camshafts

???The camshafts are marked to ensure they cannot be confused.

eCaution:

Camshaft identification.

Inlet: Groove after the thrust bearing

Exhaust: No groove

???The camshaft bearing caps are also identified. Inlet side: Odd numbers

Exhaust side: Even numbers

???The order is ascending from the front (timing end) to the rear.

???Install camshafts with the bearing points slightly oiled.

???Evenly tighten bearing cap working from the in- side towards the outside.

???Install thrust bearing (timing end) last.

X Tightening torque:

Bearing cap................................................... 9 Nm

11 3 700

LT000190

???Turn camshafts so that the grooves at the rear ends are positioned vertically with respect to the cylinder head.

???The grooves at the front end must face the inside towards the crankshaft.

???Fit setting device, BMW No. 11 3 700, and se- cure to the bearings of the camshaft.

Installing sprockets

3

2

1

LT000210

???Install lower sprocket (1) together with chain and chain guide (2); the pin on the sprocket must en- gage in the groove on the camshaft.

???When installed, the marking (triangle) on the sprocket must face upward.

???Then install the upper sprocket (3) with chain.

???Initially, only tighten sprocket retaining bolts hand-tight.

e Caution:

Remove setting device before finally tightening the sprockets, otherwise the camshafts will be dam- aged.

???Remove eccentric tensioner.

???Firmly tighten sprockets while holding at the hex- agon on the camshaft.

??? Check valve clearance once again.

Installing cylinder head cover

11 1990

11 1 980

LT000230

???Screw fitted bolt, BMW No. 11 1 980, (arrow) into inner hole at the front.

???Press centring pin, BMW No. 11 1 990, with gripper, BMW No. 00 5 500, into locating hole under the third camshaft bearing.

LT000240

??? Insert gasket into cylinder head cover.

L Note:

Begin installation at the crescents (1).

???The marks (arrows) on the cover and gasket must agree at the front and rear.

???First press in the crescent at the rear (transmis- sion end).

???Lightly coat the gasket groove and the crescent areas in the cover with oil to facilitate installation.

???Apply a little 3-bond 1209 in the joint area at the top and bottom chain case cover - cylinder head (surfaces free of grease).

???Fit cylinder head cover with gasket over the cen- tring tools onto the cylinder head.

???Screw in all retaining bolts such that they are still not under preload.

???Firmly tighten retaining bolts crosswise working from the inside towards the outside.

???Remove fitted bolt and centring pin, screw in last retaining bolt and firmly tighten.

X Tightening torque:

Cylinder head cover to cylinder head ............ 9 Nm

Checking steering bearing play and adjusting if necessary

Inspection III

1 2

LT320120

???Place a piece of adhesive tape (arrow) on the fork bridge above the setting ring (1).

???Mark current position of setting ring (1) on the adhesive tape and on the setting ring (2).

???Slide thrust ring (3), BMW No. 31 4 890, over the locking tube (4).

???Lock thrust ring with hexagon nut (5) while hold- ing the locking tube.

???Using the hexagon nut, turn back the setting ring a little then firmly tighten to the specified setting torque.

???Mark new position of setting ring on adhesive tape.

???Loosen hexagon nut and remove thrust ring.

???Firmly tighten locking tube, firmly tighten hexa- gon nut.

L Note:

The position of the setting ring must no longer change!

???The position of the setting ring must no longer change!

???Firmly tighten clamping screws.

X Tightening torque:

Checking idle speed, synchronising and CO value and adjusting if nec- essary

Inspections I, II, III, IV

L Note:

The basic settings (ignition, valve clearance) must be correct.

Adjusting idle speed

???Remove knee pad.

???Remove left side section of fairing.

e Caution:

The throttle butterfly adjusting screws (2) are sealed with lacquer and must not be turned.

???Adjust synchronisation at idle speed by turning the air control screws (3) until the bars/curves are at the same height, then adjust idle speed.

LT000290

L Note:

Engine must be at operating temperature (85 ??C). The basic settings (ignition, valve clearance) must be correct.

???Insert test probe (arrow) approx. 30 cm into the silencer.

e Caution:

Do not take this measurement in an enclosed space; risk of asphyxiation.

L Note:

If unsuitable air extraction equipment is used, it may falsify the reading.

??? Run the engine at idle speed.

1

2 3

LT000300

e Caution:

Adjusting screw (2) has no limit stop in both direc- tions.

??? Turn adjusting screw (2) to vary the CO value.

Turn in direction (1) for a richer mixture; the CO value will rise towards its maximum value. Turning further in direction (1) will not vary the CO value any further. Turn in direction (3) for a leaner mixture; the CO val- ue will drop to a minimum. Turning further in direc- tion (3) causes the engine???s emergency-run programme to operate and has no influence on the CO value.

eCaution:

If the engine???s emergency-run programme comes into operation, fault 1111 will be memorised by the engine control unit.

???If necessary, perform fault diagnosis, rectify the fault and cancel the memory entry.

???Using the BMW synchrotester, adjust idle speed at the recirculating-air screws.

Removing engine

???Remove fuel tank.

???Remove knee pads.

???Remove fuel tank.

???Remove lower section of fairing at left and right.

???Remove radiator surround.

???Drain coolant.

???Remove radiator.

???Detach the engine wiring harness.

???Separate the plug connections for the speed and ABS signals.

???Detach the throttle cable.

???Detach the choke cable.

???Disconnect clutch cable.

???Remove the exhaust system.

???Remove suspension strut.

???Detach engine mounting at frame.

???Secure front wheel to hoist.

???Attach hoist, BMW No. 00 1 510, to oil sump.

???Remove rear shield plate with coolant level equalising tank.

???Remove Motronic control unit.

eCaution:

Detach negative battery terminal first, then positive terminal. Connect the positive battery terminal first, then the negative terminal.

??? Remove the battery.

eCaution:

Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid destroys paint.

??? Drain the brake fluid.

eCaution:

Avoid damage to the brake lines.

???(ABS I) Detach both pressure modulators and secure them to the frame.

???(ABS II) Remove the ABS unit.

???Detachcarrier. the brake hose fastening at the battery

???Remove the left footrest plate.

???Remove the right footrest plate together with the brake line and master brake cylinder.

???Raise the frame with telescopic fork and frame support, BMW No. 46 5 620, over the engine block, and set it down.

???Remove the battery holder.

???Remove the starter motor.

???Remove the coils.

???Remove the main (centre) stand.

???Take out the two lower gearbox bolts.

???Screw the main (centre) stand on hand-tight.

???Remove the alternator cover.

1

2

LT110840

???Screw guide pins (1) und (2), BMW No. 23 1 820, into the holes with the reamed sleeve; the longer pin (2) must be at the right.

???Pull the gearbox off slowly.

Removing clutch housing

11 2 800

LT110100

???Install the retaining device (arrow),

BMW No. 11 2 800, in the position illustrated.

???Unscrew hex nut (1) and take off thrust ring (2).

???Push O-ring (3) forwards with the clutch housing and remove with a hook.

???Pull out clutch housing (4), noting the presence of thrust washer (5).

33 1 830

LT110110

???If necessary, pull the clutch housing off with a three-arm puller, BMW No. 33 1 830.

???Remove the intermediate flange.

00 8 570

00 8 574

LT110170

Dismantling and assembling freewheel

Stripping down freewheel

???Pull freewheel gear (1) off layshaft (5).

???Clamp the layshaft into a vice with soft jaws (smooth side down).

???Remove cover plate (2).

???Pull off freewheel cage (3).

???Take out cup spring (4).

???Pull needle roller bearing (6) out of the freewheel gear with counter-holder, BMW No. 00 8 570, and internal puller 21/3, BMW No. 00 8 574.

Assembling freewheel

LT110180

???Press the needle roller bearing into the freewheel gear so that distance (x) is the same at both sides.

LT110190

???Place the cup spring in position.

???Insert the freewheel (oiled with engine oil) into the outer race.

???Install the outer race (with clamp block facing cover plate); the cup spring must snap into the outer race.

???Place the cover plate in position.

???Push the freewheel gear on to the layshaft while turning it clockwise.

???Pushshaft.the thrust washer and O-ring on to the lay-

Removing and installing layshaft nee- dle roller bearing

Removing bearing

???Heat the bearing seat to 100 ??C.

???Pull out the bearing with counter-support, BMW No. 00 8 570, and internal puller 21/3,

BMW No. 00 8 574.

???If the bearing is defective and cannot be pulled out, carefully cut through the needle roller sleeve with a grinder.

Installing bearing

???Heat the bearing seat to 120 ??C.

???Centre the bearing and drive it in with a 21 mm (0.82 in) drift with a pin of smaller diameter (15.95 mm/0.628 in).

4

3

2

1

5

LT110200

Removing timing chain cover

Removing the Hall-effect signal transmitter

???Remove cover (1).

???Take off gasket (2).

???Remove Hall-effect signal transmitter (3), noting the semi-circular shim washers.

L Note:

Mark the correct installed position of the adjusting washer on the engine block, or remove it in the TDC position.

???Remove gate rotor (4) and take off adjusting washer (5).

Remove the crankshaft cover

LT110210

???Detach the coolant hose at the water pump and radiator.

???Remove the cover.

Removing cylinder head cover

???Remove the ignition leads.

???Remove the cylinder head cover.

Removing and installing sealing ring in timing case cover

???Drive the sealing ring out with a suitable drift.

???Drive the sealing ring in from the inside using handle, BMW No. 00 0 500, and drift,

BMW No. 11 1 610.

Removing the timing chain

1

LT110240

???Set cylinder 1 (timing end) to TDC, noting direc- tion of rotation (arrow). Pin (1) on the crankshaft must be aligned with the marking on the housing.

Removing chain tensioner

???Secure chain tensioner (1) with clamp, BMW No. 11 5 500, (arrow) and remove it.

Removing chain tensioner rail

???Remove clip (2) and washer (3).

???Pull out tensioner rail (4).

Renewing chain tensioner rail facing

LT110790

Removing camshaft chain sprockets

???When taking out the retaining screws, hold the hexagon on the camshaft to prevent it from turn- ing.

1

Removing chain guide

???Removepins. keepers (2) and washers (3) at the pivot

???Raise chain guide (4) slightly at the cylinder head and press it down again.

???The toothed washer with eccentric (arrow) must project slightly.

???Pull out the toothed washer.

???Take off the chain guide with the timing chain.

Removing valves

11 1 749

LT110280

???Screw support plate, BMW No. 11 1 749, for the valve spring clamping tool on to the rear of the cylinder head.

11 1 740

1

LT110290

???Attach valve spring clamping tool,

BMW No. 11 1 740.

???Use pressure cage (1), BMW No. 11 1 748.

???Place the cylinder head flat on a wooden board and clamp the valve spring.

1

2

3

4

LT110300

???Pull valve collets (1) out with a magnetic screw- driver.

???Release valve spring (3) and remove the various components.

???Upper spring plate (2), lower spring plate (4).

???Pull out the valve stem seal with pliers,

BMW No. 11 1 250.

Remachining valve seat

LT110310

D = valve diameter

B = valve seat width

???When remachining, the correct width of the valve seat must always be maintained.

L Note:

Machine the valve seat with turning tool,

BMW No. 11 0 500.

???If the valve seat has been remachined, a new valve must be installed.

Removing crankshaft

Removing big end bearings

???Move the piston in cylinders 1 and 4 to the bot- tom dead centre (BDC) position.

1

LT110340

??? Remove the big end bearing caps.

L Note:

Push protective tube (1) (app. 50 mm (2 in) long) on to big end bolts.

??? Repeat the work sequence at cylinders 2 and 3.

Removing main bearings

???Take out all main bearing bolts except one (ar- row).

???Take off the bearing caps.

???Take out the last bolt.

???Take off the bearing cap, pressing the crankshaft in towards the housing while doing so.

L Note:

Bearing caps 1-3 are marked for identification. Bearing 4 (thrust bearing) and bearing 5 are not marked. Cylinder 1 = timing end of engine.

Removing pistons with conrods, strip- ping down and re-assembling

Removing piston with conrod

???Press the piston with conrod out from the crank- shaft side.

Dismantling piston

???Remove the circlip (1) at one side.

???Press out piston pin (2) with drift,

BMW No. 11 2 930.

???Carefully remove piston rings (3).

???Clean the piston.

Checking piston dimensions

A

Assembling pistons

1

2

3

Removing and installing small-end bushing

30??

???Install piston rings, using piston-ring pliers. 1st groove: rectangular-section ring

2nd groove: micro-chamfer ring (note pin for ring gap and TOP marking).

3rd groove: equal-chamfer ring with tubular spring, (note TOP marking).

L Note:

The tubular spring gap must be offset by 180?? from the equal-chamfer ring gap.

Checking cylinder dimensions

LT110380

???Set the internal micrometer to the nominal cylin- der bore diameter.

???Press out the small-end bushing.

???The gap in the new bushing, when pressed in, must be at an angle of 60?? either to the left or the right of the centre axis.

???Ream out the small-end bushing.

???Drill the oil hole and deburr it.

e Caution:

It should be possible to push the piston pin through the small-end bushing with only light pressure.

LT110400

???Check that conrod bores are parallel.

???The difference over the measured length ???P??? must not exceed 0.06 mm (0.0024 in).

Removing slipring seal and shaft sealing ring

???Press out slipring seal (6) with a drift.

???Using a 5 mm (0.2 in) wide screwdriver, carefully press out sealing ring (5).

Removing pressure relief valve

???Loosen threaded union (12) and pull out spring (13).

???Pull valve piston (14) out with a magnet and ex- amine it for damage.

Installing pressure relief valve

???Oil valve piston (14) lightly before installing.

???Insert spring (13) and insert and tighten the screw plug with a new seal.

Install the shaft sealing ring and slipring seal

???Drive in sealing ring (5) from the water side with the open side downwards, using drift,

BMW No. 11 1 640, and handle, BMW No. 00 5 500.

???Press in slipring seal (6) with drift,

BMW No. 23 1 780, and handle, BMW No. 00 5 500.

Installing pump shaft and impeller

???Oil pump shaft (7) lightly and push it into the housing from the oil side.

???Place impeller (9) with spacing bushing (10) in position. When tightening, hold the pump shaft to prevent it from turning.

1

2

3

LT110440

Removing output shaft

Removing oil sump

???After removing the screws, loosen the seal with light blows of a plastic-faced hammer.

Removing oil filter

???Unscrew oil filter (1) with the oil filter wrench,

BMW No. 11 4 650.

Removing lower section of crankcase

???Take out retaining screws and screws (3) holding the output shaft.

???With light blows of a plastic-faced hammer, loos- en the gasket and take off the lower section of the housing. Note presence of O-rings.

???Carefully lift out the output shaft; the needle roller bearing and circlip are loose on the shaft.

Removing and installing oil level sight glass

???Pierce the plastic disc with a large screwdriver and lever out the oil level sight glass.

???Oil the sealing face of the oil level sight glass lightly and drive it in with a drift,

BMW No. 00 5 550.

1

3

2

7

8

9

10

4 11

6

5

LT110450

Stripping and assembling output shaft

Stripping down output shaft

???Take off needle roller race (1) and circlip (2).

???Pull output shaft (3) out of damper housing (4).

???Drive the output shaft out of the inner section of the damper (5) with a plastic-faced hammer.

Stripping down tensioning gear

???Remove circlip (7) with Seeger circlip pliers.

???Using two-arm puller, BMW No. 00 8 400, and thrust block, BMW No. 33 1 307, pull off ball bearing (8).

???Take off spacing ring (9).

???Remove tensioning gear (10) with counter-hold- er, BMW No. 12 4 600.

???Remove tensioning spring (11).

L Note:

Inspect all parts for damage or wear.

Assembling tensioning gear

???Insert the tensioning spring.

???Install tensioning gear with counter-holder,

BMW No. 12 4 600.

???Clamp the tensioning gear with damper housing together into a vice with soft jaws.

a

LT110470

???Measure distance ???a??? from ball bearing seat to tensioning gear.

LT110480

???Place a suitable spacing washer (arrow) on the tensioning gear.

L Note:

The thickness of the spacing washer must never ex- ceed this measurement.

???Heat the ball bearing to 80 ??C and install it (with shoulder upwards).

LT110490

???Clamp the damper housing and the ball bearing together in the vice (with soft jaws).

???Place the circlip (arrow) in the groove in front of the bearing, using Seeger circlip pliers.

???The circlip must snap completely into the groove.

Installing damper

4

3

2

???Insert damper rubbers (1) into damper housing (2).

???Push retaining plate (3) on to output shaft; heat the inner section of damper (4) slightly and press it on.

???Push the damper housing on to the output shaft.

Assembling the crankcase

Installing oil mesh strainer

??? Note presence of O-ring (2).

Installing oil filter

???Coat the oil filter sealing ring with oil.

???Do not tighten the oil filter more than half a turn beyond the point where it makes contact.

Installing oil sump

???Coat the sealing faces (which must be free from oil and grease) with 3-Bond 1209.

Measuring crankshaft bearing play

Measuring radial play

???Crankshaft bearing points must be clean and lightly oiled.

???Place the crankshaft in the crankcase and install the bearing caps so that the joint lines are aligned.

L Note:

Bearing caps 1???3 are marked; bearings 4 (thrust bearing) and 5 are not marked.

LT110540

???Tighten the bearings in the order shown, starting from the centre and working outwards.

???Turn the crankshaft to top dead centre at the bearing to be measured.

???Take off the bearing cap.

???Turn the crankshaft further by approximately an- other 30??.

???Wipeshell. off oil at the bearing journal and bearing

LT110550

???Measure bearing play with Plastigage Type Pg-1,

BMW No. 00 2 590.

???Place the Plastigage strip (arrow) over the entire width of the bearing, 6???8 mm (0.24???0.32 in) from the centre.

L Note:

Do not turn the crankshaft any more.

LT110560

???Remove bearing cap.

???Determine the width of the strip and thus the bearing play with the comparison scale (arrow).

Installing piston with conrod

???Turn the corresponding crankpin to bottom dead centre.

???The piston ring gaps must be offset by app. 120?? in each case.

L Note:

The gap of the micro-chamfer ring in groove 2 is de- termined by the pin.

???Oil the piston rings, piston skirt and cylinder wall thoroughly.

11 2 925

LT110600

???Using tensioning strap, BMW No. 11 2 925, com- press the piston rings.

???Insert the piston with conrod into the cylinder.

???Drive the piston carefully into the cylinder with a hammer handle.

???The arrow on the piston crown must point to- wards the timing end of the engine (cyl. 1).

???Make sure that the pistons are in the same weight category.

Measuring big end bearing play

???Turn the crankpin 30?? away from bottom dead centre.

???Wipe oil off crankpin and bearing cap.

LT110610

???Place Plastigage strip (arrow), Type PG-1, BMW No. 00 2 590, over the entire width of the bearing, 6???8 mm (0.24???0.32 in) away from the centre of the crankpin.

???Attach the bearing caps with the joint lines aligned, and tighten them.

L Note:

The crankshaft must not be turned any more at this stage.

LT110630

???Unscrew and remove the bearing cap.

???Determine bearing play against comparison scale (arrow).

???If bearing shells are renewed, note paint marks on crankpin and on big end bearing.

???Regrinding stages ???0??? and ???1??? are available; the crankpins are marked with a corresponding number of paint spots.

???If there are no paint spots, this indicates regrind- ing stage ???0???.

L Note:

The crankshaft can only be reground in stage ???0???, and must be hardened and finished afterwards.

11 2 210

1

LT110620

???Tighten the big end bearings with wrench angle indicator (1), BMW No. 11 2 210.

Installing big end bearing

???Move the crankpin of the cylinder concerned to bottom dead centre.

???Oil the crankpin and attach the conrod.

???Pull the protective tubes off the bolts.

???Attach the bearing caps with the joint lines aligned, and tighten them.

???Using wrench angle indicator,

BMW No. 11 2 500, tighten the big end bearing.

Installing cylinder head

???Move the piston in cylinder 1 to top dead centre (cylinder 1 = timing end).

???Place the cylinder head gasket in position; no holes or passages must be obstructed.

L Note:

Use only cylinder head bolts with long thread

[from 12/94].

???Place the cylinder head in position and insert bolts (1) with washers (2) as far as possible.

???Attach tighten angle measuring device,

BMW No. 11 2 500, using two T 50 Torx inserts,

BMW No. 00 2 630.

???Tighten the cylinder head bolts, to the specified torque and angle, as specified.

Installing timing chain

???Turn the camshaft so that the grooves on the ends are vertical in relation to the cylinder head at the rear.

???The grooves at the front end must point towards the crankshaft.

11 3 700

???Place the timing chain round the crankshaft chain sprocket and press the guide rail on to the pivot pin.

???Secure the guide rail at the lower pivot pin (2) with the washer and clip.

???Install chain sprocket (3) for the inlet camshaft so that the timing chain is pulled taut towards the guide rail.

???Insert the retaining screw as far as possible.

???Press tensioning rail (4) on to the pivot pin and secure with the large washer and clip (5).

???Install chain sprocket (6) for the exhaust cam- shaft so that the timing chain is as taut as possi- ble between the chain sprockets.

???Insert the retaining screw as far as possible.

???Using tensioning tool, BMW No. 11 5 500, install chain tensioner (7) and secure.

Installing freewheel

???Insert the freewheel into the crankcase with the helical-cut gearwheel leading.

???Oil the needle roller bearing well.

Installing countershaft

???Clean tapped hole and screw (must be free from grease).

???Push driver on to layshaft.

???Secure retaining screw with Loctite 273 FL.

Installing alternator

??? Install the alternator with the damping rubber.

2

1

???Apply a thin coat of 3-Bond 1209 to the sealing faces, which must be free from oil and grease.

???Pass the wires for the telltale lights (oil pressure, coolant temperature) through the cable duct (ar- row).

???Place the timing case cover in position and tight- en it.

???Screw adjusting disc (1) and gate rotor (2) to the crankshaft.

???Insert baseplate (3) for Hall-effect transmitter.

???The cutouts in the baseplate and timing case cover should coincide.

???Insert the retaining screws with shim washer and semi-circular washer (4).

Installing cylinder head cover

11 1 990

LT110720

???Insert reamed bolt (arrow), BMW No. 11 1 980, into inner front hole.

???Press centering pin, BMW No. 00 5 500, into mount under the third camshaft bearing.

LT110730

???Install the cylinder head cover gasket with the half-moon cutouts first. The marks at the front and rear of the gasket and the cylinder head cov- er must coincide.

???Oil the gasket and half-moons lightly.

???Press in the half-moon on the gearbox side first.

???Apply a small amount of 3-Bond 1209 to the joint area of the cylinder head and timing case cover.

???Attach the cylinder head cover with gasket.

???Insert all retaining screws as far as possible.

???Tighten the retaining screws in a crosswise pat- tern, working from the inside outwards.

???Take out the reamed and centering screw and in- sert the remaining retaining screws.

Installing engine

???Attach hoist, BMW No. 00 1 510, to the oil sump.

???Set the engine down on the hoist platform.

???Releaseblock. the engine mounting at the engine

???Install the throttle rail.

???Install the inner bulkhead at the cylinder (3).

???Installing. the lower section of the air cleaner hous-

???Install the fuel return line with pressure regulator.

???Connect the crankcase breather.

???Position the frame with telescopic fork and frame support over the engine.

???Bolt the engine and driveline together.

???Bolt the engine and frame together in the order stated here:

1.Insert all 5 bolts loosely but do not screw them fully in. Insert a 1 mm thick spacing washer at the front right, between the cylinder head and frame strut, and a support washer on the inside.

2.Tighten bolts 1, 4 and 3.

3.Shim to the correct thickness at the front left and install the support washer on the outside, then tighten the bolt.

4.Shim the attachment point at the intermediate flange and tighten the bolt.

Checking/adjusting valve clear- ances

e Caution:

Never unscrew the spark plugs before measuring valve clearances. Particles of oily soot could be- come lodged behind an exhaust valve head and fal- sify the measurement.

???Remove left side section of fairing.

???Remove the cylinder head cover.

???Remove cover for Hall-effect transmitter.

???Turn the engine only at the crankshaft (direction of rotation: anti-clockwise).

???Measure valve clearance with feeler gauge.

???Max. engine temperature 35 ??C.

???Determine size of replacement tappets by com- paring desired and actual measurements.

Valve clearances:

Adjusting valve clearances

???The camshaft must be removed before the buck- et tappets can be renewed.

???Set cylinder 1 (timing end) to top dead centre on the ignition stroke.

1

2

3

LT110800

???Hold the chain tensioner and timing chain with eccentric tensioner, BMW No. 11 2 640.

???Pull back tensioning pin (1) and screw in eccen- tric (2) by 3???4 turns.

???Push the tensioning pin forward above the timing chain.

???Turn the eccentric slightly to the right to locate the timing chain and chain tensioner.

???Secure the eccentric with locknut (3).

???Remove the chain sprockets.

???Remove the camshafts.

???Renew the bucket tappets as necessary.

???Assemble in the reverse order of work.

Adjusting ignition timing

???Remove radiator cowling.

???Remove bottom left fairing.

???Remove fuel tank.

???Disconnect plug connection on Hall generator lead under the fuel tank.

???Connect adapter lead (2), BMW No. 12 3 651, to Hall generator lead.

???Connect ignition setting device (3), BMW No. 12 3 650,to adapter line.

???Disconnect spark plug connector with flat-nose pliers.

???Unscrew spark plugs with spark plug box span- ner, BMW No. 12 3 500.

00 2 580

LT120030

???Screw dial gauge with extension (1), BMW No. 00 2 580, into cylinder No. 1.

???Set piston to TDC.

???Set scale ring of dial gauge to 0.

???Turn engine back in clockwise direction until pis- ton setting ignition point is reached.

Ignition point:

6 ?? before TDC = 0.24 mm (0.00945 in) before TDC

Disassembling and assembling alternator

Alternator

[only LT up to 1992 model year]

??? Remove damper elements (1)

3

???Remove coupling housing (2) with holding tool (3), BMW No. 12 4 600.

???Pull off fan wheel (4).

???Remove key (5).

???Release retaining screw (6) for bearing end plate.

???Clamp alternator in vice with jaw guards.

???Remove bearing end plate (7) with three-point puller, BMW No. 33 1 830.

???Remove regulator (8) with carbon brushes.

???Carefully lift out armature (9) together with bear- ing (10).

???Remove bearing (10) from armature shaft.

???Unsolder stator (11) on diode plate (12); mark the wires.

???Remove diode plate.

???Remove O-ring (14).

???Install in the reverse order of removal.

L Note:

During assembly, insulate the solder points on the diode plate with silicone. Coat bearing seat in hous- ing with Molykote paste.

Checking exciter winding

61 1 510

???Measure resistance between slip rings and ar- mature.

L Note:

The resistance must be infinitely large.

Checking resistance between phase outputs

???Check winding outputs individually with respect to earth.

L Note:

The resistance must be infinitely large. Measurement result: OL = open line.

3

1

LT120130

Check contacts of cable connections. Do cable connections have poor contact.

no

Check regulator.

Is regulator defective?

no

Check carbon brushes.

Are carbon brushes defective?

no

Check rectifier.

Is rectifier diode defective/does rectifier diode have short to earth (ground)?

no

yes

yes

yes

yes

Repair cable connections/plug contacts.

Renew regulator.

Renew carbon brushes.

Renew diode carrier.

Check alternator.

Does stator have short to earth (ground)?

no

Check rotor.

Does rotor partly have short to earth (ground)?

yes

Renew stator.

yes

Renew rotor.

Check regulator.

Is regulator defective?

no

Check supply line.

Does supply line have break/short circuit?

no

yes

Renew regulator.

yes Repair break;

renew cable/connection elements.

Check carbon brushes.

Are carbon brushes defective?

no

Check rotor winding.

Is rotor winding defective?

no

yes

yes

Renew carbon brushes.

Replace rotor.

Check exiter current circuit.

Is exiter current circuit broken?

no

Check diode/diode carrier.

Is diode/diode carrier defective?

no

Check cable D +/61.

Has cable short to ground?

yes Repair break;

renew cable/connection elements.

yes

Replace diode/diode carrier.

yes Repair short-circuit; if necessary renew cable.

Check indicator lamp.

Is lamp defective?

no

Check battery.

Is battery discharged/defective?

no

yes

yes

Replace indicator lamp.

Charge/renew battery.

Check alternator.

Has generator short at positive diode?

no

Check cable.

Is cable loose/damaged?

no

Check regulator.

Is regulator defective?

no

Check carbon brushes. Are carbon brushes worn?

no

Check rotor winding.

Do slip rings have oxidation layer?

no

Check rotor winding.

Is rotor winding broken?

yes

yes

yes

yes

yes

Secure connections/renew cable.

Renew regulator.

Renew carbon brushes.

Repair alternator.

Renew rotor.

Troubleshooting on starter

Starter does not turn when start switch is operated.

Switch on light. Does light operate?

no

Check battery.

Is battery discharged, defective?

no

Check power circuit.

Does power circuit have a break?

yes

yes

Charge or renew battery.

Repair break.

Switch on light. Does light operate?

yes

yes Connect jumper at connection between termi- nal 50 and 30. Does starter turn?

yes

Check ignition switch and supply line.

Is ignition switch defective?

yes

Is there a break in supply line?

yes

Repair break.

Check carbon brushes.

Are carbon brushes too short?

no

Are carbon brushes jammed?

no

yes

yes

Replace carbon brushes.

Release carbon brushes.

Is spring pressure acting on carbon brushes too low?

yes

Replace compression spring.

Check battery voltage.

Is battery voltage too low?

no

Check battery terminals.

Are terminals loose or oxidised?

no

Check connections.

Are connections loose?

no

Check collector.

Is collector dirty?

no

Check armature winding.

Is armature winding defective?

yes

yes

yes

yes

yes

Charge battery, replace if necessary.

Clean poles and terminals, firmly tighten.

Secure connections.

Clean collector.

Repair starter.

Drive pinion does not engage. Starter turns idle at high speed.

Check drive pinion.

Is drive pinion excessively dirty?

yes

Repair starter.

Acid level too low.

Check level.

Is level below set level?

no

Check charge status. Is battery overcharged?

yes

yes

Top up with distilled water.

Top up with distilled water.

Check charge status of battery.

Is battery discharged?

no

Check acid concentration.

Is acid concentration too low?

no

Check line network. Is there short-circuit in line network?

no

yes

yes

yes

Charge battery.

Adjust acid concentration.

Check electrical system.

Check alternator. Alternator does not charge correctly?

yes Check generator/regulator; replace if neces- sary.

Check acid level.

Is acid level too high?

no

Check charging voltage.

Is charging voltage too high?

Excessive drop in terminal voltage under load.

yes

yes

Adjust acid level.

Check regulator; replace if necessary.

Check voltage at battery. Is battery discharged?

no

Check charging voltage.

Is charging voltage too low?

yes

Charge battery.

yes

Check regulator; replace if necessary.

Insufficient power output

Check connection terminals. Are terminals loose/oxidated?

no

Check acid level.

Is level below top edge of plates?

no

Check charge status.

Is charge too low?

Battery constantly overcharged.

Check charging system.

Is there a defect in charging system?

no

Check cell for short-circuit. Does a cell have a short-circuit?

yes

Clean/tighten terminals.

yes

Top up with distilled water.

yes

Charge battery/replace defective battery.

yes

Replace battery.

Adjusting CO value

LT000290

L Note:

Engine must be at operating temperature (85 ??C). Basic settings (ignition timing, valve clearances) must be correct.

???Insert the measuring probe (arrow) app. 30 cm (12 in) into the silencer (muffler).

eCaution:

Do not perform this measuring work in an enclosed space: risk of asphyxiation.

L Note:

If the air extraction equipment is unsuitable, it may falsify the measurement.

??? Run the engine at idle speed.

1

2

3

LT000300

e Caution:

Adjusting screw (2) has no limit stop in both direc- tions.

??? Turn adjusting screw (2) to obtain correct CO.

L Note:

Turn in direction (1) for a richer mixture; the CO value will rise to a maximum. Turning further in direction (1) has no effect on the CO value.

Turn in direction (3) for a leaner mixture; the CO val- ue will drop to a minimum. Turning further in direc- tion (3) will cause the engine???s emergency-run programme to operate, but has no influence on the CO value.

e Caution:

If the engine???s emergency-run programme operates, fault 1111 will be memorised in the engine control unit.

???If necessary, carry out fault diagnosis, rectify the fault and cancel the memory entry.

???Using the BMW Synchrotester, adust idle speed at the recirculating-air screws.

Removing/installing and checking/ adjusting throttle position sensor

Removing and installing throttle posi- tion sensor

???Unscrew the throttle position sensor and pull it off the throttle shaft.

???Loosen wire keeper (1) and pull off multi-pin plug

(2).

???Install in the reverse order of work.

e Caution:

If the throttle position sensor has been removed, the basic settings must be checked and corrected if necessary after installing it again.

L Note:

See the booklet ???BMW Diagnosis, Motronic MA 2.1 with oxygen sensing??? or ???without oxygen sensing???, or the booklet ???BMW Diagnosis MA 2.2???.

Checking trottle position sensor

???Connect the diagnostic cable.

???Press the left switch on the switch cabinet up to the detent position.

???Switch on the ignition.

???[MA 2.1] If the temperature warning light comes on, the throttle position sensor is correctly adjust- ed.

???[MA 2.1] If the temperature warning light does not come on, re-adjustment is needed.

???[MA 2.2] If small zeroes are visible on the tester display, the throttle position sensor is correctly adjusted.

???[MA 2.2] If no zeroes are visible, check the throt- tle end stops and re-adjust.

Adjusting throttle position sensor

L Note:

Only adjust if the throttle position sensor was re- moved or renewed.

???Loosen the fastening for the sensor at the throttle rail.

Removing and installing throttle rail

???Remove fuel tank.

???Remove left fairing side section.

???Remove left-hand heat-insulating bulkhead.

???Release fuel hose (1) at injection rail.

???Release injection rail (2) at cylinder head and pull out together with injectors.

???Disconnect multiplug at throttle sensor.

L Note:

Only remove throttle sensor if it is to be replaced (basic setting necessary).

???Detach throttle cable (3).

???Detach operating cable (4) for start speed in- crease.

5

LT130110

???Release hose clips at the air intake lines, loosen at the throttle coupling.

???Remove throttle rail from stub pipe.

???Pull air return pipe (5) off throttle rail.

???Disconnect indicator lamp plug connection for start speed increase.

???Install in the reverse order of removal.

L Note:

Do not change the location of the hose clips on the throttle coupling unions.

Firmly tighten hose clips at the air intake lines with special tool, BMW No. 31 1 500.

Removing and installing injectors

???Release wire retainer (1) and detach plug (2).

???Release clip (3) at the injector and pull it out.

???Install in the reverse order of removal.

L Note:

Ensure that the O-ring on the injector is in good con- dition!

Removing and installing intake stub pipe

???

???

Connect test pressure gauge,

BMW No. 16 1 500, on the delivery side. Run engine at idle speed.

???

???

Crank engine with starter while kneading hose between water pump and filler neck Assemble motorcycle.

Removing and installing radiator

???Remove fuel tank.

???[RS] Remove bottom section of fairing

???Remove left/right side fairing.

???Remove radiator cowling.

1

LT170050

??? Remove air line (1).

???Release connections (2,3,4) of the coolant hos- es.

???Disconnect plug connection (5) for fan motor.

LT170060

???Release hose connection (6) and mounting (7) for radiator.

???Install in the reverse order of removal.

Troubleshooting

Coolant temperature warning lamp lights up.

Check coolant in expansion tank. Is coolant level too low?

no

Check thermostat.

Is thermostat defective?

no

Check water pump.

Is water pump defective?

yes

yes

yes

Top up coolant.

Replace thermostat.

Repair/renew water pump.

Fan motor does not switch on.

Check fuse F7.

Is fuse defective?

no

Check fan relay.

Is fan relay defective?

no

Check power circuit.

Does circuit have poor contact/break?

no

Check fan motor.

Is fan motor defective?

no

yes

yes

yes

yes

Renew fuse.

Replace fan relay.

Make contact/repair break.

Repair/renew fan motor.

Check thermostat. Thermostat does not open?

yes

Replace thermostat.

18

Removing and installing exhaust system

???Release mounting (1) on cylinder head.

???Release mounting (2) on transmission.

???Release mounting (3) on footrest plate.

???[CAT] - Detach plug connection for oxygen sensor.

L Note:

Use new sealing rings (4) during installation.

3

2

LT180010

Removing clutch

???Secure lifting gear, BMW No. 00 1 510, to the oil sump.

???Remove main stand.

???Remove rear mudguard.

???Remove right-hand footrest plate.

???Remove Motronic control unit.

???Remove battery.

???[ABS I] Remove ABS control unit.

???[ABS I] Secure pressure modulators to rear section of frame.

???[ABS II] Remove ABS unit.

???[ABS I] Remove holder for demodulators.

???Release bottom retaining bolts (1) holding trans- mission.

???Re-install main stand without switch for electric side support.

???Remove transmission together with the com- plete rear wheel drive and rear wheel.

L Note:

Keep transmission at installation height until the clutch control rod can be seen completely, since it can be easily bent.

L Note:

To remove the ABS unit, see also Group 34, ???Re- moving ABS unit???.

???Secure retaining fixture?(1), BMW No. 11 2 800, as shown.

???Release hexagon nut (2).

???Remove thrust ring (3) with pliers.

???Move clutch housing to and fro until O-ring (4) is visible.

???Cut through O-ring.

If clutch housing is difficult to move, use three-point puller, BMW No. 33 1 830, and pressure tool.

Do not damage bushing for thrust bearing!

2

1

LT210070

???Detach clutch cable at the clutch release lever (1).

???Slightly pull back rubber gaiter (2).

???With the aid of setting gauge,

BMW No. 21 3 500, set dimension ???B??? with ad- justing screw at clutch hand lever.

Dimension ???B??? ... 75 ?? 1 mm (2.95275 ?? 0.03937 in)

??? Re-attach clutch cable at clutch release lever.

7 6

LT210090

???With the aid of box wrench, BMW No. 21 3 610, release locknut (6) of adjusting screw (7) on clutch release lever.

???Unscrew adjusting screw by one to two turns, then screw in until pressure point can be felt.

???Lock adjusting screw with locknut.

???Set dimension ???A??? with adjusting screw at clutch hand lever.

???Lock adjusting screw (5) with knurled nut (3).

Dimension ???A??? .... 4 ?? 0,5 mm (1.5748 ?? 0.19685 in)

e Caution:

Take up subsequent wear only at the adjusting screw on the clutch release lever.

Troubleshooting

Clutch slips.

Check clutch clearance.

Is clutch clearance incorrect?

no

Check clutch lining.

Is clutch lining oiled?

no

yes

Replace thrust ring on transmission input shaft.

Renew clutch disc.

Is clutch lining worn?

Clutch slips.

Check clutch adjustment.

Is clutch adjustment incorrect?

no

Check clutch disc.

Is clutch disc damaged/worn?

Clutch does not release.

Check clutch cable.

Is clutch cable broken?

no

yes

yes

yes

yes

Renew clutch disc.

Perform basic setting.

Renew clutch disc.

Renew clutch cable.

Check clutch control rod.

Is clutch control rod blocked?

yes Clutch thrust bearing damaged. Renew clutch thrust bearing.

Removing transmission (gearbox)

Preparatory work

???[RS] Remove left fairing side section .

???Remove exhaust system.

???Disconnect CAT plug connection for oxygen sensor.

???Remove left and right footrest plate.

???Remove rear mudguard.

???Remove rear brake caliper.

???Remove rear wheel.

???Remove suspension strut.

???Remove rear wheel drive.

???Remove swinging arm.

???Remove rear cover panel with coolant level equalising tank.

???Remove Motronic control unit.

???Remove battery.

???[ABS I] Remove control unit.

???[ABS I] Detach pressure modulators from holder and secure to rear section of frame.

???[ABS I] Remove holder for pressure modulators.

???[ABS II] Remove ABS unit.

???Remove battery carrier.

???Remove starter motor.

L Note:

Secure brake caliper, pressure modulators, reser- voir and, footrest plate with adhesive tape to frame.

L Note:

For removal of ABS unit see Group 34, ???Removing ABS unit???.

???

???

Secure lifting gear, BMW No. 00 1 510, to the oil sump and slightly raise engine.

Release mounting for main stand.

Disassembling/assembling transmis- sion cover

Removing and installing bearing shell

00 8 560

100??C

00 8 563

LT230020

???Heat bearing cover to 100 ??C.

???Remove bearing shell with Kukko support, BMW No. 00 8 560, and internal extractor 21/5,

BMW No. 00 8 563.

00 5 500

23 1 770

LT230030

???Fit bearing shell in transmission cover while still hot.

???Drive bearing shell onto the bottom of its seat with drift, BMW No. 23 1 700, and handle

BMW No. 00 5 500.

Removing and installing shaft sealing ring on input shaft

00 5 500

23 1 770

LT230040

???Drive out shaft sealing ring with drift from the in- side.

???Fit new sealing ring with drift, BMW No. 23 1 770 and handle, BMW No. 00 5 500.

L Note:

If the coefficient of friction of the input shaft is to be checked, do not fit sealing ring until measurement has been completed.

Removing and installing locking lever

1

LT230050

???Release retaining ring (1)

???Lift short arm of spring over contact surface (ar- row).

???Remove lever and spring.

???Install in the reverse order of removal.

Removing gear selector drum

???Remove shafts (1) of gearshift forks.

???Press pawl (2) towards the outside and secure with clamping fixture (arrow),

BMW No. 11 5 500.

???Tilt back input shaft by approx. 45??

???Turn gearshift forks towards the outside until guide pins are free.

???Remove gear selector drum?(3).

L Note:

Note sleeves on guide pins.

Removing gearshift forks

1

3

11 5 500

2

LT230070

1.Gearshift fork, 1st and 2nd gear

2.Gearshift fork, 5th gear

3.Gearshift fork, 3rd and 4th gear

Removing selector shaft

LT230110

???Release setscrew (arrow) (secured with Loctite).

???Pull out selector shaft together with gearshift le- ver.

Removing segment

1

3

2

LT230120

???Remove retaining ring (arrow).

???Remove segment (1) together with coil spring (2) and limit stop (3).

???Install in the reverse order of removal.

eCaution:

Secure setscrew with Loctite 242; screw and hole must be clean and free of grease.

Removing and installing shaft sealing ring on input shaft

??? Drive out shaft sealing ring from inside.

00 5 500

23 1 760

LT230130

???Fit shaft sealing ring using drift,

BMW No. 23 1 760 and handle, BMW No. 00 5 500.

Removing and installing shaft sealing ring for gear selector drum

???Switch for gear indicator removed.

???Gear selector drum removed.

Removing and installing ball bearing on intermediate shaft

???The intermediate shaft can only be replaced as a complete unit.

Disassembling and assembling input shaft

Disassembling input shaft

00 7 500

LT230180

???Clamp spline end of input shaft in vice with jaw guard.

???Remove retaining ring (1).

???Using universal puller, BMW No. 00 7 500, and pressure tool (arrow), remove spur gear (3) to- gether with taper roller bearing (2).

???Also remove second taper roller bearing.

Assembling input shaft

00 7 500

LT230190

???Fit washer (6), coil spring (5), thrust piece (4) and spur gear (3) on input shaft.

???Using universal puller, tension spur gear against coil spring until the 2nd groove (arrow) can be seen ahead of the spur gear.

???Heat taper roller bearing to 100 ??C and fit in po- sition.

???Fit retaining ring (1) in front of the taper roller bearing.

???Remove spur gear for 1st (1) and 5th gear (2) with spacer shim rings.

???Heat bearing bush (4) to 80 ??C.

4

3

5

230240

???Carefully remove spur gear for 3rd gear (5) to- gether with spacer shim ring (3) and bearing bush (4).

???Heat bearing bush (6) to 80 ??C.

???Carefully remove spur gear for 4th gear (8), spacer shim ring (7) and bearing bush (6).

???Remove retaining ring (9).

???Remove serrated washer (10).

???Remove spur gear for 2nd gear (11).

???Remove split needle cage (12).

???Remove serrated washer (13) and retaining ring (14).

Installing spur gears

???Slide serrated washer (10) over smooth end (ar- row) onto output shaft up to the bearing seat.

???Slide on retaining ring (11) and fit in groove ahead of serrated washer.

???Fit split needle cage (9) well oiled.

???Slide spur gear for 2nd gear (8) from the spline side over the needle cage with the window side first.

???Fit serrated washer (7) followed by retaining ring (6).

5

4

LT230270

???Clamp output shaft in vice with jaw guards, spline facing upward.

???Fit spur gear for 3rd gear (4) with windows facing upwards.

???Fit spacer shim ring.

???Heat wide bushing to 80 ??C and slide on up to the spacer shim ring.

???Fit spur gear for 5th gear (5) with claws facing downward.

???Fit spacer shim ring.

???Heat ball bearing up to 80 ??C and slide on up to the spacer shim ring.

???Turn output shaft in vice, splines facing down- ward.

???Fit spur gear for 4th gear (1), claws facing down- ward.

???Fit spacer shim ring.

4.3.

125.8-0.1

LT230280

???Check dimension 125.8 mm (4.9528 in), include spacer shim ring between spur gears for 1st and 4th gear.

???Heat narrow bushing to 80 ??C and slide on up to the spacer shim ring.

L Note:

Wide bushes are fitted on the spline side.

???Fit spur gear for 1st gear with smooth side facing upward.

???Fit spacer shim ring.

???Heat ball bearing to 80 ??C and fit.

???As a check measure the axial clearance of the spur gears.

Installing transmission shafts

???Heat bearing points for intermediate shaft and output shaft in the housing to 80??C.

???Fit input shaft.

???Install intermediate shaft and output shaft to- gether.

???With the aid of light blows (plastic-headed ham- mer), check that bearing is fitted in the base of the seat.

???Fit gearshift forks for 1st and 2nd gear (2) with short guide end facing downward in the upper section of the output shaft.

???Fit gearshift fork for 3rd and 4th gear (3) with short guide end facing downward in the interme- diate shaft.

L Note:

Lightly coat sleeves of guide pins with grease when fitting.

Measuring distances between trans- mission shafts

Measuring bearing distance of shafts

???Place transmission measuring plate,

BMW No. 23 3 660 (arrow), on the transmission housing.

???Measuring procedure for intermediate shaft and output shaft:

Using depth gauge, BMW No. 00 2 550, meas- ure distance between ball bearing outer race and measuring plate. Before measuring, knock the corresponding shaft to the base of its seat.

???For the input shaft, measure through the window in the measuring plate the distance from the bearing collar to the measuring plate.

???Enter all measurements in a table, see example.

L Note:

The dimension for the input shaft must be entered with a negative sign in the table!

LT230320

Mab = Dimension output shaft to measuring plate Mzw = Dimension intermediate shaft to measuring

plate

Man = Dimension measuring plate to collar on input shaft

H = Height of measuring plate

Total measurement:

Gab = Mab + H

Gzw = Mzw + H

Gan = H ??? Man

???Measure from the parting surface of the trans- mission cover to the base of the bearing seat.

???Only applies to intermediate shaft and output shaft

00 2 550

LT230340

???The dimension for the input shaft is measured with the taper roller bearing installed.

???Measure from bearing inner face to parting sur- face of transmission cover.

???Enter all measurements in a table, see example.

DabDzw

Dan

LT230350

Dab = Cover dimension output shaft

Dzw = Cover dimension intermediate shaft Dan = Cover dimension input shaft

Permissible axial clearance:

Intermediate shaft and

output shaft ... 0.05...0.15 mm (0.00197...0.0059 in)

Permissible preload:

Input shaft ... 0.03...0.08 mm (0.00118...0.00315 in)

Installing transmission cover

LT230420

???Knock out cap (arrow) from the inside using a drift.

???Heat up transmission cover to 100??C.

???Parting surface at housing and cover must be clean and free of grease.

???Thinly coat one of the two parting surfaces with

Loctite 574 or with Three-Bond 1209.

LT230370

???With the aid of a drift or screwdriver, press back locking lever in direction shown by arrow.

???Carefully fit cover on the housing.

???Screw in screws holding transmission cover and firmly tighten.

LT230380

???Thinly coat end cap (arrow) with Three-Bond 1209 and knock in with drift by 8 mm (0.31496 in).

???Fit idle lock (ball and spring) in idle position.

???Screw in screw for idle lock coated with

Loctite 243.

LT230490

L Note:

??? Note line arrangement for electrical side stand.

Installing starter

??? Connect positive and negative leads.

LT230510

???[ABS I] Install support bracket for pressure mod- ulators.

L Note:

Note arrangement of wiring loom.

Removing telescopic fork

???Secure lifting gear, BMW No. 00 1 510, to oil sump.

???Remove fuel tank.

???Remove front mudguard.

???Remove brake caliper.

Removing fork stabilisor

Removing telescopic fork without fork bridge

???Release clamping screws (1,2), pull down telescopic fork and remove.

Removing telescopic fork with fork bridge

Removing upper fork bridge

???Release hexagon nut (4).

???Release locking tube (5).

???Disconnect plug connection for ignition lock (3).

???Loosen clamping screws (1).

???Remove fork bridge.

???Remove setting ring (6).

???Remove fork by pulling from below together with light hammer blows (plastic-headed hammer) on the steering tube.

Removing and installing lower taper roller bearing

Removing and installing upper taper roller bearing

Removing taper roller bearing

1

3 2

Removing taper roller bearing

3

1

LT310030

???Press down steering tube (1) by approx. 5 mm and press back again.

???Press off taper roller bearing (2) and dust ring (3) using two large screwdrivers.

Installing taper roller bearing

???Heat taper roller bearing to 80 ?? C and slide onto the steering tube together with the dust ring as far as it will go.

L Note:

Dust ring must have no clearance!

???Grease bearing with, for example,

Shell ???Retinax A???.

LT310040

???Using a drift, knock out taper roller bearing to- gether with dust ring (2,3) out of setting ring (1).

Installing taper roller bearing

???Heat taper roller bearing to 80 ?? C and press to- gether with dust ring into setting ring.

L Note:

Dust ring must have no clearance!

???Grease bearing with, for example,

Shell ???Retinax A???.

Measuring telescopic fork

L Note:

After a collision, the telescopic fork must be exam- ined for cracks and damage.

Checking lower fork bridge

???Place two test straight edges,

BMW No. 31 4 620, over the upper and lower ends of the fixed tubes.

???Determine any distortion by visual alignment (ar- rows).

eCaution:

Replace distorted fork bridges.

???

???

Clamp fork bridge at steering tube in vice with jaw guards.

Install upper fork bridge.

Removing fixed tube

???Loosen clamping screws at lower fork bridge.

???Remove fixed tube with slider tube from fork bridge.

???Drain oil.

???Clamp slider tube at mounting for brake caliper in vice with jaw guards.

Disassembling slider tube

???Clamp slider tube at mounting for brake caliper vertically in vice with jaw guards.

???Using a blunt knife, lever out dust sleeve (1) from the outside.

???Using a small screwdriver, lever out retaining ring

(2) for sealing ring.

???Fit support ring (3), BMW No. 31 3 610, on slider tube.

???Lever out shaft sealing ring (4) using a slightly rounded off screwdriver.

???Remove steel ring (5).

???Using both index fingers, remove plain bush (6) from slider tube.

???Check plain bush for damage/wear; replace if necessary.

Disassembling fixed tube

??? Loosen screw plug (1) in fixed tube.

31 5 550

LT310140

???Screw base screw fitting (arrow) loosely into damper cartridge.

???Lightly press damper cartridge into fixed tube using clamping fixture, BMW No. 31 5 550, and clamping insert, BMW No. 31 5 553.

4 3

2

LT310150

???With the aid of a screwdriver, push apart retain- ers (2) on the piston rod.

???Remove perforated disc (3) and spacer (4).

???Remove damper cartridge (5) with support spring

(6) and guide sleeve (7).

Assembling slider tube

???Install damper cartridge with hole pattern ???Z??? (tension stage) in the right-hand slider tube.

???Install plain bush (1) lubricated with fork oil.

???Slide fixed tube into slider tube.

???Screw together fixed tube and slider tube, if nec- essary use new sealing ring.

???Fit steel ring (2) in slider tube.

???Lightly oil radial sealing ring (3) with fork oil and slide from above over the fixed tube.

31 3 620

L Note:

Prior to assembly, lightly coat radial sealing ring with tyre fitting paste.

Installation location: Large groove at bottom, label- ling facing up.

???Fit retaining ring (4) in groove above the sealing ring.

???Fit dust gaiter (5) also with drift,

BMW No. 31 3 650, dished side.

L Note:

Pack grease pocket in the dust gaiter with, for ex- ample, SHELL Retinax A or Gleitmo 805.

Adjusting steering bearing play

1 2

LT320120

???Fit a piece of adhesive tape (arrow) on the fork bridge above the setting ring.

???Mark current position of the setting ring (1) on the adhesive tape and on the setting ring (2).

???Fit thrust ring (3), BMW No. 31 4 890, over the locking tube (4).

???Lock thrust ring with hexagon nut (5) while hold- ing the locking tube.

???With the aid of the hexagon nut, turn back the adjusting ring a little then tighten to the specified setting torque.

???Mark new position of setting ring on adhesive tape.

???Release hexagon nut and remove thrust ring.

???Firmly tighten locking tube, tighten hexagon nut.

L Note:

The position of the setting ring must no longer change!

???Firmly tighten clamping screws.

???Install handlebar.