Page 1
Repair Manual
F 650 GS/GS Dakar
BMW Motorrad
After Sales
Page 2
Introduction
This Repair Manual will help you to perform all the main maintenance and repair work correctly and efficiently. If it is consulted regularly by workshop personnel it will form a useful addition to the theoretical and
practical knowledge acquired at the BMW Training Centre. It is a contribution towards achieving even higher Service quality.
A new issue of this Repair manual will be published if amendments or additions (supplements) are needed.
All information in both text and illustrations refers to motorcycles in standard condition or with genuine
BMW accessories installed, and not to motorcycles which have been modified in any way to depart from
the manufacturer’s specification.
The Repair Manual is structured in the logical sequence of the work to be performed: Removal, Disas-
•
sembling, Repair, Assembly, Installation.
The entire contents are divided into individual chapters, corresponding to the Construction Groups.
•
11 . 10
Chap. Page number within chapter
If a reference is needed to a different page or chapter, an arrow symbol is shown followed by the chapter
and page numbers, e.g. (
a 12.5)
Work to be performed during an Inspection is described in Group “00”. The various inspection routines
•
are numbered I, II, III and IV. This numbering is repeated in the work descriptions which follow, so that
work can take place without interruption.
Use of the BMW special tools needed for certain tasks is described in the work instructions.
•
If the need arises, repair instructions are also issued in the form of Service Information. This information is
of course incorporated into the next issue of the Repair Manual. We also recommend, as an additional
source of information, the Electronic Parts Catalogue (ETK), which contains clear and easy-to-follow
illustrations.
If the work described here is restricted to a particular equipment specification, for instance if a specific optional extra (OE) is fitted, this is stated in square brackets at the start of the item concerned, e.g. [Dakar].
Please refer to the following pages as well for a description of other symbols used and how to work with them.
BMW Motorrad
After Sales
Published by BMW Motorrad
After Sales
UX-VS-2
D-80788 München
All rights reserved. Not to be reprinted, translated or duplicated either wholly or in part without prior written
permission.
Errors and omissions excepted; subject to technical amendment.
Produced in Germany
Page 3
Structure
Each chapter starts with the list of contents.
The list of contents is followed by the technical data table.
Chapter 00 “Maintenance and general instructions” lists all tightening torques and the operating fluids.
Key to symbols
In this Repair Manual for the F 650 GS/GS Dakar, the following symbols are used; their meanings are explained in the tables.
Special instructions aimed at improving the work procedures
L Note:
Special information on operating and inspecting the motorcycle as well as maintenance and adjustment
procedures.
e Important:
Instructions and precautions specifically intended to prevent damage to the motorcycle. Disregarding them
may render the warranty invalid.
d Warning:
This symbol stands for precautions and measures which are essential in order to protect the rider or other
persons from possibly severe or fatal injury.
Contents
Headlines for the work described in the chapter............. with the relevant page number
Activities
Activities
•
The bullet symbol indicates work steps that are described in greater detail under another headline
•
– Preceding activities
– A line indicates work steps that are described in greater detail under another headline or in another
chapter
The term “remove” means that:
the fastener (e.g. screw) must be slackened off and taken out
or
a component (e.g. injection rail) has to be removed to the extent that components behind it (e.g. throttle
valve) are rendered accessible
The term “loosen” means that:
the fastener (e.g. screw) must be backed off, but not removed
X Tightening torques:
Values are stated if they differ from the DIN EN 24 014 or DIN 912 ISO industrial standards.
Page 4
BMW Motorcycle
Maintenance schedule
F 650 GS/F 650 GS Dakar
Customer Licence plate no.
Order No. Mechanic’s signature
Read the fault code memory with the BMW MoDiTeC
Change the engine oil while at regular operating temperature; replace the oil filter
element
if motorcycle is used only for short journeys or at outside temperatures below 0°C (32°F): every
3 months or at the latest after 3,000 km (1,800 miles)
Renew oil in telescopic forks [Dakar version only]
Check the coolant and restore to correct level if necessary *
)
Replace the coolant
(every 2 years)
Check valve clearances, adjust if necessary
Replace the spark plug
Drain the outlet hose from the air filter box
Replace intake air filter
If motorcycle is operated in very dirty or dusty conditions, clean or replace the intake air filter every
10,000 km (6,000 miles); check every 3,000 km (1,800 miles)
Replace fuel filter (every 20,000 km/12,000 miles)
Check clutch play, adjust if necessary
Check wheel spoke tension and tighten if necessary
more frequently if motorcycle is ridden in severe off-road conditions
Examine brake pads and discs for wear, replace if necessary *
more frequently if motorcycle is ridden in severe off-road conditions
)
Check brake fluid level at front and rear and top up if necessary *)
Check for operation of brake system and freedom from leaks; repair/replace if necessary *
Replace the brake fluid at least once a year
BMW Inspection at
1,000 km (600 miles)
BMW Service
10,000 km
(6,000 miles)
BMW Inspection every
20,000 km
(12,000 miles)
BMW Annual Service
every
2years
20,000
km
)
Replace the primary front/rear brake master cylinder cup
(every 40,000 km/24,000 miles on a motorcycle with ABS)
Check or, if necessary, replace chain, sprocket, chain guide rollers and pinion *
more frequently if motorcycle is ridden in severe off-road conditions
Check chain tension and adjust if necessary *
)
)
40,000
km
Check battery acid level, add distilled water if necessary
more frequently if motorcycle is ridden in severe off-road conditions
Clean and grease the battery terminals, if necessary
Check steering head bearings and adjust *) or replace if necessary *
)
Grease the side and main stands
Grease the brake pedal
Check bolts and nuts on engine mountings, frame connections, exhaust system
mountings, pivot lever [Dakar version only], main and side stands for tightness
Final inspection with road safety and functional check:
– (Clutch, gearshift)
– Steering
– Front and rear brakes
Side stand contact switch
– Condition of tyres and wheels, tyre pressures
– Lights and signalling equipment, indicator and warning lights, instruments
– Test ride, if necessary
)
*
Associated work invoiced separately, see Flat rates brochure, Motorcycle 2000
Order No. 01 71 0 021 836 UX-VS-2, 02/00 Printed in Germany
Page 5
BMW Motorcycle
Pre-delivery Check
F 650 GS/F 650 GS Dakar
Customer Licence plate no.
Order No. Mechanic’s signature
Check the shipping crate for damage
Motorcycle:
– unpack
– inspect for damage
– install remaining items
– clean
Battery:
– remove
– add acid
– charge
– grease terminal posts
– fit (mark with fitting date)
BMW
Pre-delivery check
Check that the delivery is complete:
– Toolkit
– Documentation
– Motorcycle keys
– Optional extras
Read the fault code memory with the BMW MoDiTeC
Check tyre pressures
Fill fuel tank
Final inspection as functional check:
– Oil inspection
– Clutch, gearshift
– Steering
– Hand brakes and foot brakes
– Check lights and signalling equipment, warning and indicator lights,
instruments, ABS
– Test ride, if necessary
Order No. 01 71 0 021 836 UX-VS-2, 02/00 Printed in Germany
Page 6
BMW Motorcycle
Service data
F 650 GS/F 650 GS Dakar
Item Rated value Unit of
Oil capacities
Engine (with filter)
2.3 (4.05/2.43)
measurement/
specification
Litres (Imp. pints/US quarts)
Specification: see current
Service Information
Telescopic fork – for each post [Dakar version only]
Coolant
Cooling system (entire)
Expansion tank
Brake fluid DOT 4
Valve clearances
Measured cold (max. 35 °C/95 °F)
Spark plugs
Electrode gap
Idle speed 1350 +100 rpm
0.55 (0.97/0.58)
1.3 (2.29/1.37)
0.1 (0.18/0.11)
Inlet: 0.10-0.15
(0.004-0.006)
Exhaust: 0.25-0.30
(0.010-0.012)
0.6...0.7 (0.02...0.03)
Litres (Imp. pints/US quarts)
BMW telescopic fork oil
Litres (Imp. pints/US quarts)
Litres (Imp. pints/US quarts)
Composition:
Water: 50%
Antifreeze: 50%
Antifreeze protection
to –25 °C ( –13 °F)
mm (in)
mm (in)
NGK D8 EA
mm (in)
Clutch cable play
Hand lever cable
Tyre pressure (on cold tyres)
solo
when fully loaded
Tightening torques:
Engine oil drain plug
Engine water drain plug
Oil tank drain plug
Oil filter cap
Valve cap
Camshaft bracket
Spark plug
Telescopic fork oil drain plug
Round nut, steering bearing
Steering bearing locking tube
Flanged nut on locking tube
Fork stabilizer clamping screws
Brake caliper at fork slider tube
Deflection lever/frame
Deflection lever/spring strut
Deflection lever/tension strut
1.0 - 2.0
(0.004 - 0.008)
front/rear
1.9/2.1 (27/30)
2.1/2.3 (30/33)
40
10
21
10
10
10
20
6
25
65
65
21
41
50
47
71
mm (in)
bar (psi)
bar (psi)
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Order No. 01 71 0 021 845 UX-VS-2, 02/00 Printed in Germany
Page 7
Contents
<< Back
Group / Chapter
00 Tightening torques Operating fluids
00 Pre-delivery check
00 Maintenance
11 Motor
12 Engine electrics
13 Fuel preparation and control
16 Fuel tank and lines
17 Radiator
18 Exhaust system
21 Clutch
23 Gearbox
27 Drive chain
W
M
B
31 Front forks
>> Continuation
Page 8
Group / Chapter
32 Steering
33 Rear wheel drive
34 Brakes
36 Wheels and tyres
46 Frame
>> Continuation
51 Equipment
61 General electrical equipment
62 Instruments
63 Lights
<< Back
Page 9
00
00 Tightening torques
Operating fluids
Contents Page
Tightening torques .......................................................................................................................3
11 Engine ...........................................................................................................................................3
12 Engine electrics ........................................................................................................................4
13 Fuel preparation and control ...............................................................................................4
16 Fuel tank and lines ...................................................................................................................5
17 Radiator ........................................................................................................................................5
18 Exhaust system .........................................................................................................................5
21 Clutch ............................................................................................................................................6
23 Transmission ..............................................................................................................................6
27 Drive chain ..................................................................................................................................6
31 Front forks ...................................................................................................................................6
32 Steering ........................................................................................................................................7
33 Rear wheel drive .......................................................................................................................7
34 Brakes ...........................................................................................................................................7
46 Frame ............................................................................................................................................8
51 Equipment .................................................................................................................................10
61 General electrical equipment ............................................................................................10
62 Instruments ...............................................................................................................................10
63 Lights ...........................................................................................................................................10
Table of operating fluids .........................................................................................................11
00.1
Page 10
Contents Page
00.2
Page 11
00
Tightening torques
Model F 650 GS / GS Dakar
Connection
11 Engine
Freewheel housing and freewheel Nm 35
(clean thread + Loctite 648)
Engine block Nm 10
Double drive gear on crankshaft Nm 180
(clean thread + Loctite 243)
Driver Nm 140
(clean thread + Loctite 243)
Pressure plate Nm 10
Magnet hub Nm 180
(clean thread + Loctite 243)
Signal transmitter Nm 8
Ignition cover Nm 10
Cylinder base Nm 10
Spark plug Nm 20
Fastener for chain tensioner Nm 40
Oil circuit
Oil tank to intake air silencer Nm 9
Oil filter cover Nm 10
Oil pressure switch Nm 12
(clean thread + Loctite 243)
Oil tank drain plug Nm 21
Engine oil drain plug Nm 40
Oil supply/oil return lines to engine Nm 42
(with copper seals)
Oil pump cover Nm 6
(clean thread + Loctite 243)
Oil pressure valve Nm 24
Oil check valve Nm 24
Cylinder head
Collar nuts for cylinder head Nm 60
Collar screws for cylinder head Nm 33
Machine screws (chaincase) Nm 10
Camshaft mount Nm 10
Chain sprockets to camshafts Nm 60
threads oiled
Chain guide to camshaft mount Nm 10
(clean thread + Loctite 243)
00.3
Page 12
Model F 650 GS / GS Dakar
Connection
11 Engine
Cylinder head cover Nm 10
Machine screw (hole for locating pin) Nm 25
Cylinder head to frame Nm 41
Cylinder head to frame, adjusting sleeve Nm zero play, max. 5
Cylinder head to frame, locknut Nm 100
Model F 650 GS / GS Dakar
Connection
12 Engine electrics
Magnet hub Nm 180
(clean thread + Loctite 243)
Signal transmitter Nm 8
Engine block cover, left/right Nm 10
Starter to clutch cover Nm 10
Necked-down bolts, starter housing Nm 6
Cable cover to engine block Nm 4
Ignition coil and holder Nm 9
Model F 650 GS / GS Dakar
Connection
13 Fuel preparation and control
Air intake pipe to cylinder head Nm 25
Fuel filter to frame Nm 9
Injector holder to throttle valve Nm 5
Connecting flange, air filter box to battery
carrier
Intake air silencer to retainer Nm 9
Oil tank to intake air silencer Nm 9
Throttle-valve potentiometer to
throttle valve stub
Nm 5
Nm 3
Throttle lifter to throttle valve stub Nm 5
00.4
(clean thread + Loctite 243)
Page 13
Model F 650 GS / GS Dakar
Connection
16 Fuel tank and lines
Fuel tank to rear frame (M 8 stud) Nm 21
Fuel filler cap to fuel tank Nm 3
Roll-over valve to fuel tank Nm 2
Bracket, activated charcoal filter to fuel tank Nm 3
Fuel pump to fuel tank Nm 36
Model F 650 GS / GS Dakar
Connection
17 Radiator
Air duct to frame trussing Nm 3
Expansion tank to radiator Nm 9
Radiator to main frame Nm 9
Water pump drain screw Nm 10
Left engine block cover to engine block Nm 10
Water pump cover Nm 10
Temperature sensor in cylinder head Nm 15
Bleed screw Nm 12
Model F 650 GS / GS Dakar
Connection
18 Exhaust system
Oxygen sensor to exhaust Nm 45
Exhaust manifold to cylinder head Nm 20
Silencer to exhaust manifold
(Torca clamp)
Silencer to rear frame Nm 9
Heat shield to silencer Nm 9
Nm 55
00.5
Page 14
Model F 650 GS / GS Dakar
Connection
21 Clutch
Driver Nm 140
(clean thread + Loctite 243)
Pressure plate Nm 10
Engine block cover, left Nm 10
Model F 650 GS / GS Dakar
Connection
23 Transmission
Selector lever to selector shaft Nm 15
Model F 650 GS / GS Dakar
Connection
27 Drive chain
Drive pinion cover to engine Nm 2
Chain takeup roller to frame Nm 21
Chain sprocket to chain sprocket mount Nm 21
Quick-release shaft nut Nm 100
Drive chain tensioning screws Nm 10
Central nut to main shaft Nm 140
(clean thread + Loctite 243)
Model F 650 GS F 650 GS Dakar
Connection
31 Front forks
Fork stabiliser to fork leg Nm 21
Clamp screws for fork bridges, top/bottom Nm 21
Plate for bottom fork bridge to fork bridge Nm 9
Oil drain plug Nm 6
Damper retaining screw Nm 20
Round nut
Preload Nm 25
Back off through angle of rotation ° 60
Counter-tube to steering head bearing Nm 65
Hexagon nut to counter-tube Nm 65
Screw plug in fork Nm – 25
00.6
Page 15
Model F 650 GS / GS Dakar
Connection
32 Steering
Handlebars to fork bridge Nm 21
(apply Optimoly TA to thread)
Handlebar weight to handlebars Nm 9
Clutch fitting to handlebars, M 6 Nm 9
Clutch switch to handlebar fitting Nm 5
Pivot pin for brake lever Nm 6
Locknut for pivot pin, clutch lever Nm 8
Model F 650 GS / GS Dakar
Connection
33 Rear wheel drive
Suspension strut to frame Nm 58
Wrench angle ° 45
Suspension strut to angled lever Nm 47
Knob for adjusting suspension-strut
damping to holder
Holder, suspension-strut damping to
frame
Swinging-fork pivot shaft Nm 100
Reaction link to swinging fork Nm 41
Reaction link to angled lever Nm 71
Angled lever to frame Nm 58
Wrench angle ° 45
Model F 650 GS / GS Dakar
Connection
34 Brakes
Bleed screw in front/rear brake caliper Nm 7
Brake caliper to fork slider tube Nm 41
Brake disc and sensor ring to front wheel Nm 9
Nm 21
Nm 9
(clean thread + Loctite 243)
Brake disc to rear wheel Nm 9
(clean thread + Loctite 243)
Brake fluid reservoir for rear brake to rear
frame
Brake pedal to frame Nm 21
Nm 1.5
00.7
Page 16
Model F 650 GS / GS Dakar
Connection
34 Brakes
Brake lines/hoses
Brake hose to brake caliper Nm 18
Brake hose to brake lever fitting Nm 18
Brake hose/brake line interfaces Nm 18
Brake line to master brake cylinder, rear
wheel
ABS
ABS sensor front/rear Nm 9
ABS pressure modulator to holder Nm 21
Holder for ABS pressure modulator to
frame transverse tube
Brake line to ABS pressure modulator Nm 18
Sensor ring to rear wheel Nm 5
Brake disc and sensor ring to front wheel Nm 9
Model F 650 GS / GS Dakar
Connection
36 Wheels and tyres
Clamp nut, front quick-release axle Nm 21
Front quick-release axle to fork leg Nm 45
Nm 18
Nm 9
(clean thread + Loctite 243)
(clean thread + Loctite 243)
Rear quick-release axle to swinging fork Nm 100
Chain sprocket to chain sprocket mount Nm 21
Model F 650 GS / GS Dakar
Connection
46 Frame
Body
Fairing sections/covers Nm 3
Fairing support bracket to frame Nm 21
Grip to rear frame Nm 9
End trimmer to rear frame Nm 9
Tail to rear frame Nm 4
Tail section (mounting for case holder) to
rear frame
Nm 4
(clean thread + Loctite 243)
00.8
Page 17
Model F 650 GS / GS Dakar
Connection
46 Frame
Seat lock to rear frame Nm 9
Number-plate carrier to rear section of rear
mudguard
Mudguards/wheel guards
Front mudguard, rear section to front section Nm 3
Front mudguard to fork bridge Nm 3
Rear mudguard, front and rear sections to
rear frame
Rear mudguard, front section to bracket
for case carrier
Wheel cover, bottom, to bracket Nm 3
Wheel cover bracket to swinging fork Nm 9
Frame
Footrest plate to main frame Nm 21
Footrest rubber to rear footrest Nm 5
Retaining bracket for intake air silencer to
main frame
Nm 3
(clean thread + Loctite 243)
(clean thread + Loctite 243)
Nm 9
Nm 21
(clean thread + Loctite 243)
Nm 9
Engine guard to frame truss Nm 9
Rear frame to main frame, top Nm 21
Rear frame to main frame, bottom Nm 21
(clean thread + Loctite 2701)
Centre stand to main frame Nm 41
Side stand to bottom truss Nm 40
Side stand bottom truss to main frame Nm 21
Engine mounts
Engine/crankcase to main frame at rear Nm 41
Cylinder head to frame Nm 41
Cylinder head to frame, adjusting sleeve Nm zero play, max. 5
Cylinder head to frame, locknut Nm 100
Engine/cylinder head to main frame at top Nm 41
Engine shell to engine Nm 41
Engine shell to bracing tube Nm 21
00.9
Page 18
Model F 650 GS / GS Dakar
Connection
51 Equipment
Ignition/steering lock to fork bridge Nm 21
Model F 650 GS / GS Dakar
Connection
61 General electrical equipment
ABS sensor cable to sliding tube Nm 9
ABS sensor to brake caliper mount, rear Nm 9
Clutch switch to clutch handlebar fitting Nm 5
Brake light switch to handlebar fitting Nm 3
Brake light switch, footbrake, to frame Nm 5
Wiring harness with electronic equipment
box to frame
Lid of electronic equipment box to frame Nm 4
Positive/ground leads, battery Nm 7
Battery holder to battery tray Nm 9
Voltage regulator to bracket Nm 7
Horn to fork bridge Nm 18
Ground terminal, wiring harness to engine
block, right
Model F 650 GS / GS Dakar
Connection
62 Instruments
Instrument cover to instrument cluster Nm 2
Model F 650 GS / GS Dakar
Connection
Nm 7
Nm 8
63 Lights
Front turn indicator with cover to cockpit
fairing
Rear light cluster to number-plate carrier Nm 4
00.10
Nm 3
Page 19
Table of operating fluids
Item Use Order number Quantity
Lubricant
Staburags NBU 30 PTM High-performance lubricating paste 07 55 9 056 992 75 g tube
Optimoly MP 3 High-performance lubricating paste 07 55 9 062 476 100 g tube
Optimoly TA High-temperature assembly paste 18 21 9 062 599 100 g tube
Silicone grease 300, heavy Damping grease 07 58 9 058 193 10 g tube
Retinax EP2
Contact spray Contact spray 81 22 9 400 208 300 ml spray
Chain spray Drive chain
Sealants
3-Bond 1110 B Surface sealant 07 58 9 056 998 5 g tube
3-Bond 1209 Surface sealant 07 58 9 062 376 30 g tube
omni VISC 1002 Surface sealant (max. 200 °C/392 °F) 07 58 1 465 170 90 g tube
Loctite 574 Surface sealant 81 22 9 407 301 50 ml tube
Wheel, steering head and taper roller
bearing grease
83 22 9 407 845 100 g tube
72 60 2 316 676
72 60 2 316 667
50 ml spray
300 ml spray
Curil K 2 Heat-conductive sealant 81 22 9 400 243 250 g can
Hylomar SQ 32 M Permanently elastic sealant 81 22 9 400 339 100 g tube
Adhesives and retainers
Loctite 648 Joint adhesive (narrow gap) 07 58 9 067 732 5 g bottle
Loctite 638 Joint adhesive (wide gap) 07 58 9 056 030 10 ml bottle
Loctite 243 Thread retainer, medium-strength 07 58 9 056 031 10 ml bottle
Loctite 270 Thread retainer, strong 81 22 9 400 086 10 ml bottle
Loctite 2701 Thread retainer, strong 33 17 2 331 095 10 ml bottle
Loctite 454 Cyanacrylate adhesive (gel) 07 58 9 062 157 20 g tube
Cleaners
Brake cleaner Brake cleaner 83 11 9 407 848 600 ml spray
Metal Polish Polish for chrome-plated parts 82 14 9 400 890 100 g tube
Testing agents
Penetrant MR 68
Crack testing agent for aluminium
housings
83 19 9 407 855 500 ml spray
Developer MR 70
Installation aid
BMW chilling spray Chilling components before assembly 83 19 9 407 762 300 ml spray
Crack testing agent for aluminium
housings
81 22 9 407 495 500 ml spray
00.11
Page 20
00.12
Page 21
00
00 Pre-delivery check
Contents Page
General view of crated motorcycle ...................................................................................15
Checking the shipping crate for damage ...........................................................................15
In case of damage in Germany ...............................................................................................15
In case of damage in importer markets ..............................................................................15
Unpacking the motorcycle ....................................................................................................15
Inspecting motorcycle for damage ...................................................................................16
Installing remaining items on motorcycle .....................................................................16
Installing the front wheel ............................................................................................................16
Installing windscreen ...................................................................................................................17
Installing front mudguard, mirrors
and handlebar weights ...............................................................................................................18
Filling and charging the battery .........................................................................................19
Removing right and centre covers .........................................................................................19
Filling and charging the battery ...............................................................................................20
Checking that delivery is complete ..................................................................................21
Reading the fault code memory with the BMW MoDiTeC ....................................21
Checking tyre pressures ........................................................................................................21
Adding fuel to tank ....................................................................................................................21
Final inspection and function check ................................................................................21
Final cleaning ...............................................................................................................................22
Handing over the motorcycle ..............................................................................................22
00.13
Page 22
Contents Page
00.14
Page 23
00
General view of crated motorcycle
Checking the shipping crate for damage
When the motorcycle arrives, check the crate im-
•
mediately for damage and if necessary examine
the contents for consequential damage.
In case of damage in Germany
Note the damage on the delivery slip.
•
Read the information sheet on damage in transit.
•
Notify the supplier without delay
•
(e.g. freight company or DB) and also
Bavaria Wirtschaftsagentur GmbH
Abteilung ZW - 12
D-80788 München
Tel. 089/14327-632
Fax. 089/14327-639
In case of damage in importer markets
E000251
Notify the supplier (e.g. freight company) without
•
delay.
Unpacking the motorcycle
Lever off the cover.
•
Take out the separate pack of items.
•
Force off cross-struts with a suitable lever.
•
e Caution:
Do not hammer out the cross-strut panels or the
motorcycle may be damaged.
Remove the end panels.
•
Remove the side panels.
•
e Caution:
Make sure that the motorcycle cannot topple.
Remove the straps at front and rear.
•
Note the damage on the delivery slip.
•
Comply with specific national market procedu-
•
res.
In case of doubt, please submit enquiries to:
Bavaria Wirtschaftsagentur GmbH
Abteilung ZW - 12
D-80788 München
Tel. +49 (0)89 14327 632
Fax. (+) 89/14327-639
e Caution:
Remove nails projecting from the base of the crate
or lying on the base or on the floor.
00.15
Page 24
Dispose of the packing materials in an environ-
•
mentally responsible manner as described in
Circular 23/91 - Sales.
Check the contents of the enclosed package:
•
– Front mudguard with fasteners and washers
– Windshield
– Mirrors with clamping screws and nuts
– Handlebar weights with screws
– Spacer sleeve, spacer
– four washers for front mudguard
– Rider's Manual
– Service and Technical booklet
– Booklet listing service centres in Europe
– BMW emergency service sticker
– Handling instructions for batteries
Inspecting motorcycle for damage
Check for defects.
•
Use the “express handling service” to notify
•
BMW AG Sparte Motorrad, UX-VS-1
Fax: 00 49 89 382-33220
Rectify the fault.
•
If parts are needed, order them by using the
•
electronic parts list.
Costs are to be processed by the warranty claim
•
system (stage 4).
Defect codes:
– Parts missing 10 01 00 00 00
– Parts damaged 10 02 00 00 00
– Incorrect parts delivered 10 03 00 00 00
If the parts that are needed do not appear in the
•
electronic parts list (e.g. parts for official-user
motorcycles),
send an order form to:
Fax number 030-3396-2262
2
1
Install spacer sleeve (1).
•
Insert the front wheel between the telescopic
•
fork legs.
Install quick-release axle (2) with spacer (3).
•
4
3
E000390
E000400
Installing remaining items on
motorcycle
Installing the front wheel
e Caution:
Take care not to damage the ABS sensor, sensor
ring, brake disc and brake pads when installing.
Raise front of motorcycle (e.g. with crane).
•
Clean the quick-release axle and the contact
•
face of the shaft sealing ring and grease them
with Optimoly TA.
Tighten the quick-release axle (arrow).
•
Lower the front wheel to the ground, compress
•
the front suspension firmly several times.
Tighten clamping screw (4) securing the quick-
•
release axle.
X Tightening torques:
Quick-release axle ....................................... 45 Nm
Clamping screw ........................................... 21 Nm
00.16
Page 25
Installing windscreen
Wheel the motorcycle clear of the wooden pallet.
•
E000260
[GS] Tighten the windscreen securing screws.
•
1
2
3
4
5
5
E000311
[Dakar] After turning the handlebars to full left/
•
right lock, align the hand protectors (4) with the
windscreen and the handlebar fittings.
[Dakar] Tighten fasteners (5).
•
X Tightening torques:
Windscreen to cockpit fairing......................... 2 Nm
Hand protector to handlebars ........................ 9 Nm
1
E000410
[Dakar] Align retainer (3) in bottom fairing panel.
•
[Dakar] Place windscreen (1) in position with
•
spacer (2).
[Dakar] Tighten fasteners of windscreen (1).
•
e Important:
[Dakar] Make sure that hand protectors do not contact windscreen or handlebar fittings when handlebars are turned to full lock.
L Note:
If necessary, the handlebars can be turned slightly
(max. 1.5°) toward the rider.
00.17
Page 26
Installing front mudguard, mirrors and handlebar weights
E000271
Install front mudguard.
•
e Caution:
Insert four washers (arrow) between front mudguard
and lower fork bridge.
3
2
1
E000310
Install handlebar weights (1).
•
Tighten clamp screw (2) on handlebar fitting.
•
Install each mirror and secure by tightening
•
nut (3).
X Tightening torques:
Front mudguard to fork bridge........................ 3 Nm
Clamp screw to handlebar fitting.................. 21 Nm
Union nut of mirror .......................................18 Nm
Handlebar weight to handlebar....................... 9 Nm
00.18
Page 27
5
6
4
1
3
Filling and charging the battery
Removing right and centre covers
L Note:
Do not remove the windscreen after the side panels
have been removed, as otherwise the headlight
beam setting will have to be checked.
2
E000280
Remove the lid of the stowage compartment.
•
Remove the seat.
•
Remove the fasteners securing turn indicator (1).
•
Slacken front securing screw (2).
•
Remove securing screws (5) from side cover.
•
Pull side cover (4) out of the anchorage (arrow) at
•
the bottom and lift it clear of the centre panel at
the top.
Remove securing screws (6) from centre cover.
•
Remove centre cover (3).
•
00.19
Page 28
Filling and charging the battery
d Warning:
Battery acid is highly caustic.
Protect your eyes, face, hands, clothing and the
paintwork.
Disengage the rubber strap holding the battery.
•
Disconnect the battery breather hose.
•
Remove the battery.
•
Top up the battery acid to the upper level mark.
•
Allow the battery to stand for at least an hour.
•
Shake the battery slightly to allow the remaining
•
air bubbles to escape.
If necessary, top up again to the upper level mark
•
with battery acid.
Recharge the battery and allow to stand for
•
24 hours.
Charge current (amps)
.........................10 % of rated battery capacity (Ah)
Check the acid level and, if necessary, top up
•
with distilled water to the upper level mark.
Make a note of the charging date on the battery.
•
E000290
e Caution:
Connect the positive battery terminal first, then the
negative terminal.
Apply acid-proof grease to the battery terminal
•
posts.
Install the battery.
•
Install right and centre covers.
•
Install seat.
•
X Tightening torques:
Right/left covers with centre cover
to mounting frame.......................................... 2 Nm
Right/left covers to centre cover .................... 2 Nm
Centre cover to main frame at front................ 2 Nm
00.20
Page 29
Checking that delivery is complete
Adding fuel to tank
All optional extras
•
Toolkit:
•
– Reversible screwdriver
– Small star screwdriver
– 3 open-ended wrenches
a/f 8×10, 14×19, 24
– Extension for open-ended wrenches
– Spark plug wrench
– Wrench for socket-head screws, a/f 8
– 3 Torx wrenches
Torx T25, T30, T40, T45
– 3 fuses
7.5A, 15A, 20A
Documentation
•
Motorcycle keys, 3
•
Reading the fault code memory with the BMW MoDiTeC
Fill up with fuel.
•
Final inspection and function check
L Note:
When the motorcycle arrives, the oil level in the tank
might be below the sight glass.
2
E000300
1
E000340
Unclip diagnosis plug (1) behind cover on right.
•
Connect the diagnosis unit to the diagnosis plug.
•
Read out the fault memory.
•
Perform all requisite repair work.
•
Clip diagnosis plug into position behind cover on
•
right.
Checking tyre pressures
Check/correct tyre pressures.
•
Tyre pressures:
Solo .....................................front 1.9 bar (27.0 psi)
............................................. rear 2.1 bar (29.9 psi)
Oil check: if oil is not visible in the sight glass,
•
check whether the oil tank (2) contains oil.
Clutch
•
Check gear shift action.
•
Steering
•
Front and rear brakes
•
Check lights and signalling equipment:
•
Front and rear parking lights
•
Instrument lighting
•
Low and high headlight beams, headlight flasher
•
Brake light (operate brake at front and rear)
•
Turn signals left/right
•
Horn
•
Telltale and warning lights
•
Instruments
•
As applicable, check function of optional extras:
•
ABS: perform starting test. In the event of a fault
•
in the system, the ABS warning light comes on
as soon as the motorcycle is ridden for at least
10 seconds at a speed of 30 km/h
(approx. 20 mph) or more.
If necessary, take the motorcycle for a test ride.
•
Confirm pre-delivery check in Service and Tech-
•
nical Booklet.
See “Inspecting motorcycle for damage” if de-
•
fects are detected.
With full load......................... front 2.1 bar (29.9 psi)
............................................. rear 2.3 bar (32.7 psi)
00.21
Page 30
Final cleaning
Handing over the motorcycle
Clean the motorcycle.
•
L Note:
Do not use a steam or high-pressure water jet. The
high steam or water pressure could damage seals,
the hydraulic system or electrical components.
L Note:
The number-plate carrier is not pre-drilled so that
number plates of any shape can be set to the best
possible position.
This is the ideal opportunity to familiarise the customer with the motorcycle in order to ensure the customer’s satisfaction and safety.
The following points must be demonstrated and
•
explained to the customer:
– documentation and stowage space
– toolkit and stowage space
– suspension preload adjustment to suit total
weight
– checking brake fluid
– how to adjust the mirrors
– controls
– instruments and telltale lights
– optional equipment and accessories fitted
The user must be given the following information:
•
– running-in recommendations and inspection in-
tervals
– safety check
00.22
Page 31
00
00 Maintenance
Contents Page
Key to maintenance intervals ..............................................................................................27
Reading the fault code memory with the MoDiTeC .................................................28
(Inspections I, II, III and IV) .................................................................................................................28
Changing the engine oil and oil filter element ...........................................................28
(Inspections I, II, III and IV) .................................................................................................................28
Preparatory work ...........................................................................................................................28
Draining engine oil ........................................................................................................................28
Replacing oil filter element ........................................................................................................29
Filling with engine oil ....................................................................................................................29
Checking coolant, topping up if necessary .................................................................30
(Inspections I, II and III) ......................................................................................................................30
Checking coolant ..........................................................................................................................30
Adding coolant ...............................................................................................................................30
Changing coolant .......................................................................................................................30
(Inspection IV, every 2 years) ..............................................................................................................30
[Dakar] Changing oil in telescopic forks .......................................................................32
(Inspection III) ....................................................................................................................................32
Checking and adjusting valve clearances ....................................................................33
(Inspections I, II and III) ......................................................................................................................33
Checking valve clearances .......................................................................................................33
Preparatory work ...............................................................................................................................33
Removing the intake air silencer together with the intake air pipe. .....................................................33
Exposing the radiator ........................................................................................................................33
Exposing cylinder head .....................................................................................................................33
Turning crankshaft to TDC position ....................................................................................................34
Checking valve clearance ..................................................................................................................34
Adjusting valve clearances ........................................................................................................34
Installing cylinder head cover ............................................................................................................35
00.23
Page 32
Contents Page
Replacing spark plugs .............................................................................................................36
(Inspection III) ....................................................................................................................................36
Emptying drain hose from intake air silencer .............................................................36
(Inspections II and III) .........................................................................................................................36
Replacing air cleaner element ............................................................................................36
(Inspection III) ....................................................................................................................................36
Replacing fuel filter ...................................................................................................................37
(Inspection III, every 20,000 km/12,000 miles) ...................................................................................37
Checking clutch play, adjusting if necessary ..............................................................38
(Inspections I, II and III) ......................................................................................................................38
Checking wheel spoke tension, adjusting if necessary ........................................38
(Inspections II and III) .........................................................................................................................38
Checking brake pads and discs for wear, replacing if necessary ...................39
(Inspections II and III) .........................................................................................................................39
Checking brake pads for wear ................................................................................................39
Brake pads, front brake .....................................................................................................................39
Brake pads, rear brake ......................................................................................................................39
Replacing brake pads .................................................................................................................39
Brake pads, front brake .....................................................................................................................39
Brake pads, rear brake ......................................................................................................................40
Checking the brake discs ..........................................................................................................40
Checking the brake fluid level and topping up if necessary ..............................41
(Inspections II and III) .........................................................................................................................41
Brake fluid level (front brake) ....................................................................................................41
Checking brake fluid level (front brake) ..............................................................................................41
Topping up brake fluid level (front brake) ............................................................................................41
Brake fluid level (rear brake) .....................................................................................................41
Checking brake fluid level (rear brake) ...............................................................................................41
Topping up brake fluid level (rear brake) .............................................................................................41
Checking operation of brake system and checking for leaks;
repairing/replacing as necessary ......................................................................................41
(Inspection III) ....................................................................................................................................41
Changing brake fluid and bleeding brake system ....................................................42
(Inspection IV) ....................................................................................................................................42
Changing brake fluid (front brake) ..........................................................................................42
00.24
Page 33
Contents Page
Changing brake fluid (rear brake) ...........................................................................................43
Replacing primary sealing boot front brake master cylinder ............................44
(Inspection III, every 40,000 km/24,000 miles for motorcycles with ABS) ...........................................44
Replacing primary sealing boot, rear brake master cylinder .............................45
(Inspection III, every 40,000 km/24,000 miles for motorcycles with ABS) ...........................................45
Checking chain, chainwheel and chain sprocket, replacing if necessary ..46
(Inspections II and III) .........................................................................................................................46
Checking chain tension, adjusting if necessary ........................................................46
(Inspections I, II, III and IV) .................................................................................................................46
Checking chain tension ..............................................................................................................46
Adjusting chain tension ..............................................................................................................47
Checking battery acid level, adding distilled water if necessary .....................47
(Inspections II, III and IV) ....................................................................................................................47
Checking battery acid level ......................................................................................................47
Adding distilled water ..................................................................................................................47
Cleaning and greasing the battery terminals, if necessary ................................48
(Inspection IV) ....................................................................................................................................48
Checking and adjusting steering head bearing play,
renewing if necessary ..............................................................................................................48
(Inspections II and III) .........................................................................................................................48
Checking steering head bearing play ..................................................................................48
Adjusting steering head bearing play ...................................................................................49
Greasing the side and main stands and the brake pedal lever .........................50
(Inspections II and III) .........................................................................................................................50
Side stand ........................................................................................................................................50
Main (centre) stand .......................................................................................................................50
Brake pedal ......................................................................................................................................51
Checking security of threaded fasteners ......................................................................51
(Inspections I, II, III and IV) .................................................................................................................51
Final inspection with road safety and functional check .......................................52
(Inspections I, II, III and IV) .................................................................................................................52
Road safety check .............................................................................................................................52
Tyre tread depth (recommended minimum value) ...............................................................................52
Tyre pressures (tyres cold) .................................................................................................................52
Roadworthiness check ......................................................................................................................52
00.25
Page 34
Contents Page
00.26
Page 35
00
Key to maintenance intervals
Maintenance intervals consist of the first Inspection
(after the first 1,000 km/600 miles), the BMW Service, BMW Inspection and BMW Annual Service.
Inspection 1,000 km (600 miles)
BMW Running-in Check after the first 1,000 km
(600 miles).
BMW Service
After the first 10,000 km (6,000 miles) and each additional 20,000 km (12,000 miles) (at 40,000 km ...
60,000 km ... 80,000 km) (at 18,000 miles ... 30,000
miles ... 42,000 miles).
BMW Inspection
After the first 20,000 km (12,000 miles) and each
additional 20,000 km (12,000 miles) (at 40,000 km
... 60,000 km ... 80,000 km) (at 24,000 miles ...
36,000 miles ... 48,000 miles).
BMW Annual Service
Certain tasks maintenance depend on elapsed time
as well as the distance the motorcycle has covered.
They should therefore be carried out at least once a
year (e.g. changing brake fluid).
If these tasks cannot be carried out during a Service
or an Inspection, a BMW Annual Service must be
performed.
In this Repair Manual, the individual maintenance intervals are shown by the following codes:
— Inspection at 1,000 km (600 miles)......................I
— BMW Service at 10,000 km (6,000 miles)...........II
— BMW Inspection at 20,000 km (12,000 miles) .. III
— BMW Annual Service........................................ IV
00.27
Page 36
00 13 624 Reading the fault code
memory with the MoDiTeC
00 11 215
Changing the engine oil and
oil filter element
(Inspections I, II, III and IV)
E000050
Unclip diagnosis plug (arrow) behind cover on
•
right.
Connect the diagnosis unit to the diagnosis plug.
•
Read out the fault memory.
•
Carry out repairs as specified.
•
(Inspections I, II, III and IV)
L Note:
If an engine failure occurs, the oil tank and feed line
must be cleaned with the material used for this purpose in the workshop, and then blown through with
compressed air.
00 11 215
– Remove left cover (a 46.5).
– Remove engine guard (
– Remove cover for chain sprocket from engine.
00 11 215
Preparatory work
a 46.8).
Draining engine oil
d Warning:
Observe the hazard avoidance instructions for running internal combustion engines in enclosed
spaces.
Warm up the engine to operating temperature.
•
Place a suitable container in position to catch
•
the oil.
3
212
E000110
Slacken drain plug (2) in oil tank.
•
Remove retaining screw (1).
•
Remove clamps (3).
•
Pull out the oil tank, tilt it to the left and remove
•
drain plug (2).
Use the spark-plug wrench (toolkit) to remove
•
the filler cap from the oil tank.
Fully drain the tank.
•
Remove the oil drain plug from the engine and
•
fully drain the oil from the engine.
00.28
Page 37
00 11 215 Replacing oil filter element
1
3
11 7 511
E000190
Remove the left-hand screw (3) securing the oil-
•
filter cover (1).
Remove the cable for the neutral-indicator
•
switch from its guide.
Engage the oil drain guide, BMWNo.117511,
•
on the pins (arrows) on the engine block.
Position a drip tray beneath the engine.
•
Remove the screws (2) and remove the oil-filter
•
cover.
Remove the filter element.
•
Fully drain the oil and clean the oil-filter housing.
•
00 11 215
Install the oil drain plug in the oil tank with a new
•
sealing ring and tighten.
Install the oil drain plug in the engine with a new
•
sealing ring and tighten.
Fill the oil tank with 2 l (3.52 Imp. pints/
•
2
2.11 US quarts) of engine oil and install the filler
cap.
Filling with engine oil
d Warning:
Observe the hazard avoidance instructions for running internal combustion engines in enclosed
spaces.
Run the engine for thirty seconds.
•
Add another 0.3 l (0.53 Imp. pints/
•
0.32 US quarts) of engine oil to the oil tank.
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
e Important:
Dispose of the used oil and oil filter in an environmentally compatible manner.
Fit a new filter element onto the oil-filter cover.
•
Coat the O-ring of the filter element lightly with
•
oil.
Check the O-ring of the oil-filter cover for dam-
•
age and replace if necessary.
Install the oil-filter cover complete with filter ele-
•
ment.
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
L Note:
Do not reinstall the engine guard, cover and chain
sprocket cover at this stage, if other maintenance
work has to be performed on assemblies normally
concealed by these components.
X Tightening torque:
Oil filter cover............................................... 10 Nm
Cover for chain sprocket................................ 2 Nm
E000010
e Important:
Make sure that when the engine is at operating temperature, the oil level is not above the specified
level (arrow).
Check the oil level with the engine at operating
•
temperature and top up if necessary.
Operating fluids:
Brand-name HD oil, API classification SF, SG or SH;
suffix letters CD or CE are permitted; alternatively,
brand-name HD oil of CCMC classification G4 or
G5; suffix PD2 is permitted.
Engine oil capacity:
For filter change
.....................2.3 l (4.05 Imp. pints/2.43 US quarts)
X Tightening torques:
Oil tank drain plug........................................ 21 Nm
Engine oil drain plug..................................... 40 Nm
Engine guard to frame.................................... 9 Nm
BMW recommends Castrol
00.29
Page 38
Checking coolant, topping up if necessary
(Inspections I, II and III)
L Note:
Check coolant level only when the engine is cold.
Do not refill the coolant expansion tank if valve clearance still has to be checked/adjusted.
Checking coolant
Check coolant level through the sight glass in the
•
left cover.
Top up the coolant if the level is below the
•
MIN mark.
Adding coolant
– Remove left cover (a 46.5).
L Note:
Mix the coolant to a ratio of 50 % antifreeze,
50 % water.
Check coolant level in the expansion tank, top up
•
coolant if necessary.
Maximum level........................................................A
Minimum level.........................................................B
Installation is the reverse of the removal
•
procedure.
17 00 035 Changing coolant
(Inspection IV, every 2 years)
– Remove left cover (
– Place motorcycle on side stand.
– Position a drip tray beneath the engine.
a 46.5).
A
B
E000020
e Important:
Anti-freeze protection must be guaranteed to at
least -30 °C (-22 °F). Use only nitrite-free long-term
antifreeze and corrosion inhibitor.
Do not top up expansion tank past the
MAX mark (A).
Check antifreeze concentration in the expansion
•
tank, top up antifreeze if necessary.
1
E000210
Remove drain plug (1) from water pump.
•
Hold a funnel below the drain and open the radi-
•
ator cap.
Drain off all the coolant.
•
00.30
Page 39
2
E170030
Disconnect the coolant hose (arrow) at the frame
•
on the left and drain the radiator.
1
E000020
Remove fastener (1), lift out the expansion tank
•
and drain off all coolant.
e Important:
Dispose of old coolant in an environmentally compatible manner.
E170090
Slacken bleed screw (2) in cylinder head.
•
Connect a hose to the bleed screw.
•
Fill the radiator until coolant escapes at the bleed
•
screw; repeatedly squeeze the coolant hoses to
expel the air.
Tighten bleed screw (2).
•
Top up coolant until the level reaches the top of
•
the filler neck (arrow).
Top up expansion tank to the MAX mark.
•
Filling capacity
Cooling system
.....................1.2 l (2.11 Imp. pints/1.27 US quarts)
In expansion tank
................... + 0.l l (0.18 Imp. pints/0.11 US quarts)
Antifreeze
Use only nitrite-free long-term antifreeze and corrosion inhibitor.
Concentration
Antifreeze.........................................................50%
Water ...............................................................50%
Run the engine for a short time, then switch it off.
•
Check coolant level and top up if necessary.
•
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
L Note:
Do not install and refill the coolant expansion tank if
valve clearance still has to be checked.
Install the expansion tank.
•
Install the drain plug with a new sealing ring and
•
tighten.
Place motorcycle on its centre stand.
•
L Note:
Do not reinstall the cover at this stage, if other maintenance work has to be performed.
X Tightening torques:
Drain plug .................................................... 10 Nm
Expansion tank to radiator ............................. 9 Nm
Bleed screw................................................. 12 Nm
00.31
Page 40
00 11 279 [Dakar] Changing oil in tele-
scopic forks
(Inspection III)
– Install stand, BMW No. 00 1 610, and place the
motorcycle on the stand.
– Relieve load on front wheel.
1
E310150
d Warning:
Note that screw plugs (1) at left and right are springloaded.
2
E310160
Position a drip tray beneath the telescopic forks.
•
Slacken oil drain plugs (2) on left and right.
•
Allow all the oil to drain off.
•
e Important:
Dispose of used oil in an environmentally compatible manner.
Install the oil drain plugs (5) with new sealing
•
rings and tighten.
Fill with specified quantity of oil.
•
Lightly oil thread of screw plug.
•
Release screw plugs (1).
•
L Note:
Check O-ring of screw plug for damage and renew
if necessary.
d Warning:
Note that screw plugs (1) at left and right are springloaded.
Install and tighten screw plugs on left and right.
•
Capacity per fork leg
...................0.55 l (0.97 Imp. pints/0.58 US quarts)
Operating fluids:
Telescopic fork...................BMW telescopic-fork oil
X Tightening torque:
Oil drain plug.................................................. 6 Nm
Screw plug in fork ........................................ 25 Nm
00.32
Page 41
00 11 602 Checking and adjusting
valve clearances
(Inspections I, II and III)
Exposing cylinder head
0011601
Preparatory work
– Remove left, right and centre covers (
– Remove battery (
Removing the intake air silencer together with the intake air pipe.
•
•
•
•
•
•
•
•
•
Exposing the radiator
Checking valve clearances
a 46.5).
a 61.10).
Remove the fastener for the intake air silencer
from the oil tank.
Remove the fasteners for the intake air silencer
from the retainer.
Remove the starter relay from the holder.
Slacken the fasteners for the lid of the electronic
equipment box.
Remove the fasteners for the battery tray.
Disengage the clamp securing the breather hose
and disconnect the hose from the intake air si-
lencer.
Press the oil tank slightly to the left and carefully
disconnect the intake air silencer from the throt-
tle valve stub.
Pull the intake air silencer with intake air pipe and
battery carrier to the rear to remove.
Cover/seal the throttle valve stub.
1
2
3
4
5
7
Disconnect starter coil (2) at plug.
•
Pull spark plug connector off spark plug.
•
Remove screws securing ignition coil (1) to cylin-
•
der head cover.
Disengage throttle cable from adapter (arrow).
•
Remove circlip (6) from throttle-cable holder and
•
disengage throttle cable.
Disengage cover (4) from the anchorages on
•
main frame on each side and remove.
Remove spark plug.
•
Use pliers, BMWNo.175500, to release hose
•
clip (5) and disconnect cylinder-head breather
hose (7).
Open the clips securing the oil tank.
•
Remove the oil tank and tilt it to the right.
•
6
E000030
E000150
L Note:
When temporarily securing the expansion tank, make
sure that the cap is above the level of the coolant.
Disconnect the expansion tank from the radiator
•
and pull it to one side. Use cable ties to secure it
to the handlebars.
Unclip the MoDiTeC plug from its holder.
•
Disconnect plug for fan.
•
Disengage the clips at top and bottom and re-
•
move the fan.
Protect the interior of the radiator with cardboard
•
or similar.
L Note:
Note the position of the two anchorages for ignition
coil (1) on the cylinder-head cover.
Remove 8 fasteners (3) and remove the cylinder-
•
head cover with gasket.
00.33
Page 42
Turning crankshaft to TDC position
Remove the central threaded plug in the
•
magnetic housing.
E110140
L Note:
TDC position: marks on the timing-chain sprockets
are parallel with the cylinder head, the bores in the
timing-chain sprockets are at the top.
Use an Allen key to turn the crankshaft clockwise
•
to the TDC position.
00 11 602
Adjusting valve clearances
11 6 570
E000350
L Note:
Watch out for escaping oil and catch it in a suitable
container.
Remove the screw at the oil feed stub pipe and
•
insert locating screw, BMW No. 11 6 570, to
lock the crankshaft at TDC.
Checking valve clearance
E000160
Use a feeler gauge (arrow) to determine valve
•
clearance.
Make a note of the valve clearances, or adjust
•
them if necessary.
Valve clearances:
Inlet valve............ 0.10...0.15 mm (0.004...0.006 in)
Exhaust valve ........ 0.25...0.30 mm (0.01...0.012 in)
1
Remove the fasteners securing the chain
•
guide (arrows) and remove chain guide (1).
E000360
00.34
Page 43
E000370
Use cable ties (arrow) to secure the timing chain
•
to both sprockets.
Remove the upper section of the camshaft carrier.
•
e Important:
Oil the camshaft bearings to facilitate removal and
installation of the camshafts.
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
When installing the inlet camshaft, press the
•
chain rail back against the chain tensioner
if necessary.
L Note:
TDC position: marks on the timing-chain sprockets
are parallel with the cylinder head, the bores in the
timing-chain sprockets are at the top.
Before installing the chain guide, remove the lo-
•
cating screw and install the screw plug, fitted
with a new sealing ring.
Turn the engine over once and bring it to TDC.
•
Check the TDC positions of the camshaft
•
sprockets.
Check valve clearances.
•
Clean the threads of the securing screws for the
•
chain guide, coat threads with Loctite 243 and
install the screws.
Installing cylinder head cover
Carefully remove the inlet camshaft and lay it
•
aside.
Carefully remove the exhaust camshaft and lay it
•
aside.
E000380
Turn the bucket tappet until the shim (arrow) can
•
be levered out at the groove in the bucket tappet.
Before installing new shims, check thickness
•
with a micrometer.
Position the shim in the bucket tappet.
•
e Important:
Check that the shim is correctly seated in the bucket
tappet.
Before installing the cylinder head cover, remove
•
all traces of the gasket and clean the sealing face
with degreasing agent. Also clean the groove
and the seating faces for the gasket.
L Note:
Do not reinstall the unit consisting of intake air silencer, intake duct and battery carrier at this stage,
if the fuel filter has to be removed.
Make sure that the intake pipe is correctly seated on
the throttle valve stub.
If necessary, top up the coolant in the expansion
•
tank.
Valve clearances:
Inlet valve............ 0.10...0.15 mm (0.004...0.006 in)
Exhaust valve........ 0.25...0.30 mm (0.01...0.012 in)
X Tightening torques:
Cylinder head cover to cylinder head ........... 10 Nm
Ignition coil to cylinder head........................... 9 Nm
Lid of electronic equipment box ..................... 4 Nm
Spark plug in cylinder head.......................... 20 Nm
Oil tank to intake air silencer .......................... 9 Nm
Intake air silencer to frame............................. 9 Nm
Expansion tank to radiator ............................. 9 Nm
Trim panel/cover ............................................ 3 Nm
Camshaft bearing cap to cylinder head ........ 10 Nm
Chain guide to bearing cap
(clean threads + Loctite 243)........................ 10 Nm
Threaded plug in left side of engine block .... 25 Nm
00.35
Page 44
00 12 620 Replacing spark plugs
(Inspection III)
Pull spark plug connector off spark plug.
•
Remove the spark plug with the a/f 18 socket
•
wrench.
Installation is the reverse of the removal proce-
•
dure.
X Tightening torque:
Spark plug....................................................20 Nm
Emptying drain hose from intake air silencer
00 13 630
Replacing air cleaner ele-
ment
(Inspection III)
– Remove right cover (
Remove connecting flange from air filter box.
•
a 46.5).
1
(Inspections II and III)
Have a funnel and drip tray ready.
•
E000130
Remove the plug (arrow) and drain off all the oil.
•
e Important:
Dispose of used oil in an environmentally compatible manner.
2
E000140
Pull intake air duct (1) out of the holder.
•
Remove air filter element (2).
•
Clean the intake air silencer.
•
Assembly is the reverse of the disassembly pro-
•
cedure.
X Tightening torque:
Connecting flange.......................................... 5 Nm
00.36
Page 45
0016617 Replacing fuel filter
(Inspection III, every 20,000 km/12,000 miles)
d Warning:
Comply with safety precautions when handling or
working with fuel; note that the fuel lines are pressurised.
– Remove left cover (a 46.5).
Slacken the hose clamps.
•
d Warning:
Fuel escapes from the filter when the lines are disconnected.
Disconnect fuel lines (3, 5, 7) from the filter.
•
Remove clamp (4) from the fuel filter.
•
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
2
E000110
Remove clips (2) and fastener (1) and pull the oil
•
tank out of the holder.
Remove the BMS control unit from the holder.
•
5
3
4
6
1
e Important:
Note the installed positions of fuel feed line (7) and
fuel return line (3).
Close hose clamps with pliers,
•
BMW No. 13 1 500.
X Tightening torques:
Fuel filter to frame .......................................... 9 Nm
Oil tank to intake air silencer .......................... 9 Nm
Air filter box to frame...................................... 9 Nm
Connecting flange, air filter box
to battery tray................................................. 5 Nm
13 3 010
7
Remove the fastener securing the fuel filter to
•
frame (6).
Close off fuel supply line (7) and the line to the
•
fuel injector (5) with hose clips,
BMWNo.133010.
E130100
00.37
Page 46
21 00 004 Checking clutch play,
adjusting if necessary
Checking wheel spoke tension, adjusting if necessary
(Inspections I, II and III)
A
1
E000240
Release lever (1) on the gearbox must be located
•
on the splines such that when it is pressed forward as far as the release point, distance “A” is
as specified.
Distance “A” ............... 47...52 mm (1.85...2.047 in)
2
3
B
(Inspections II and III)
Tap the spokes and listen for differences in the
•
pitch of the sound.
If spokes are loose, tighten them with spoke nip-
•
ple wrench, BMW No. 36 3 800.
Vertical runout..........................max. 2 mm (0.08 in)
Lateral runout...........................max. 2 mm (0.08 in)
E000200
Adjust distance “B” by turning adjusting
•
screw (2) on the clutch handlebar lever.
Lock adjusting screw (2) with knurled nut (3).
•
Distance “B”............ 1.0...2.0 mm (0.039...0.078 in)
00.38
Page 47
Checking brake pads and discs for wear, replacing if necessary
Replacing brake pads
(Inspections II and III)
Checking brake pads for wear
Brake pads, front brake
E000060
Visually inspect the brake pads.
•
– The brake pad wear marks (arrows) must be
clearly visible.
e Important:
Do not operate the brake when dismantled.
Do not permit the brake pads to wear past the specified minimum thickness.
Always replace the brake pads as a complete set.
00 34 630 Brake pads, front brake
Press the brake caliper against the brake disc in
•
order to force the piston back.
1
32
E340030
Brake pads, rear brake
E000070
Measure brake pad thickness (arrows)
•
Minimum pad thickness ............... 1 mm (0.039 in)
Remove keeper (3).
•
Drive out retaining pin (2).
•
Remove the brake pads.
•
Remove fasteners (1) and remove brake caliper.
•
4
E340010
Make sure that spring (4) is correctly seated and
•
installed right way round: engraved arrow must
point in forward direction of travel.
Install the brake pads.
•
Install the keeper and the retaining pin.
•
Install brake caliper.
•
Operate brake several times until brake pads are
•
bedded.
X Tightening torque:
Brake caliper to fork slider tube.................... 41 Nm
00.39
Page 48
00 34 633 Brake pads, rear brake
Press the brake caliper against the brake disc in
•
order to force the piston back.
1
2
3
E340021
Remove keeper (1).
•
Drive out retaining pin (2).
•
Remove brake pads.
•
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
L Note:
When replacing brake pads, remove separator (3)
from the original brake pad and clip it to the new
brake pad on the piston side.
Checking the brake discs
Carefully check the brake discs for cracks, dam-
•
age, deformation and scoring.
E000080
Measure the thickness of the brake discs at sev-
•
eral points with a caliper gauge.
Brake disc wear limits
Front brake disc ........................... 4.5 mm (0.18 in)
Rear brake disc............................ 4.5 mm (0.18 in)
Operate brake several times until brake pads are
•
bedded.
00.40
Page 49
Checking the brake fluid level and topping up if necessary
Brake fluid level (rear brake)
(Inspections II and III)
L Note:
The volume of the brake fluid (MIN/MAX) is sufficient
for brake-pad thicknesses from new to the wear limit. It is not normally necessary to top up the fluid to
accommodate brake-pad wear.
A level below MIN indicates the possibility of other
faults.
Brake fluid level (front brake)
Checking brake fluid level (front brake)
3
Checking brake fluid level (rear brake)
1
E0000090
Maximum level ............................................ “MAX”
Minimum level.............................................. “MIN”
Topping up brake fluid level (rear brake)
Take off cover (1) with rubber gaiter.
•
Top up the brake fluid level to the
•
“MAX” mark (arrow).
Wipe the rim of the reservoir, the rubber gaiter
•
and the cover to remove brake fluid.
E000120
Turn the handlebars so that the cover of the res-
•
ervoir is horizontal.
– The brake fluid must be between the top of the
sight glass and the centre of the sight
glass (arrow).
Topping up brake fluid level (front brake)
Release fasteners (3).
•
Remove cover complete with rubber gaiter.
•
Add brake fluid up to the top of the sight glass.
•
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
Wipe the rim of the reservoir, the rubber gaiter
•
and the cover to remove brake fluid.
Brake fluid grade .........................................DOT 4
Brake fluid grade .........................................DOT 4
Checking operation of brake system and checking for leaks; repairing/replacing as necessary
(Inspection III)
Check all brake lines for damage and correct
•
routing.
Wipe down all threaded unions on the brake lines
•
and check them.
Apply firm pressure to the brake lever and brake
•
pedal and keep this pressure applied for a few
moments.
Release the brakes and check the brake lines for
•
leaks.
d Warning:
Defective lines and threaded unions in the brake
system must always be replaced without delay.
00.41
Page 50
00 34 606 Changing brake fluid and
bleeding brake system
(Inspection IV)
e Important:
Refer to notes on the hazards involved in handling
brake fluid.
Do not allow brake fluid to come into contact with
painted parts of the motorcycle, because brake fluid
destroys paint.
Changing brake fluid (front brake)
– Remove brake pads (a 00.39).
Connect the brake bleeding device to the bleed
•
screw on the brake caliper.
Open the bleed screw by half a turn.
•
e Important:
While bleeding the system, do not allow the brake
fluid level to drop below the centre of the sight glass
(arrow), as otherwise air will be drawn into the brake
system. Bleed the system again if this happens.
Draw off brake fluid until it emerges clear and
•
free from air bubbles.
Tighten the bleed screw.
•
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
Before reassembling, carefully wipe the rim of
•
the reservoir, the rubber gaiter and the cover to
remove all traces of brake fluid.
1
34 1 500
Using resetting tool, BMW No. 34 1 500, and
•
strips of metal sheet (1) (approx. 9 mm/0.35 in
thick), force back the brake pads.
2
E000420
L Note:
[ABS] Place rubber diaphragm and reservoir cap in
position.
Carefully tighten the securing screws.
e Important:
If the vehicle is equipped with ABS, the brake system has to be bled using the BMWMoDiTeC, and
the Control Units, Toolbox ABS, routine; this procedure is supplementary to that described in the Repair Manual.
If the BMWMoDiTeC is not used there is a danger of
residual air remaining in the control circuits of the
ABS system.
[ABS] Bleed the brakes using the BMWMoDiTeC.
•
Brake fluid grade .........................................DOT 4
X Tightening torques:
Bleed screw................................................... 7 Nm
E000120
Turn the handlebars so that the cover of the
•
reservoir is horizontal.
Remove cover (2) complete with rubber gaiter
•
and top up the level of brake fluid in the reservoir.
00.42
Page 51
Changing brake fluid (rear brake)
Press the brake caliper against the brake disc in
•
order to force the piston back.
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
Before reassembling, carefully wipe the rim of
•
the reservoir, the rubber gaiter and the cover to
remove all traces of brake fluid.
2
E0000090
Remove cover (2) complete with rubber gaiter
•
and top up the level of brake fluid in the reservoir.
Connect the brake bleeding device to the bleed
•
screw on the brake caliper.
Open the bleed screw by half a turn.
•
e Important:
Brake fluid level must not drop below the MIN mark
during the bleeding process, otherwise air will be
drawn into the brake system. Bleed the system
again if this happens.
L Note:
[ABS] Place rubber diaphragm and reservoir cap in
position.
Carefully tighten the securing screws.
e Important:
If the vehicle is equipped with ABS, the brake system has to be bled using the BMWMoDiTeC, and
the Control Units, Toolbox ABS, routine; this procedure is supplementary to that described in the Repair Manual.
If the BMWMoDiTeC is not used there is a danger of
residual air remaining in the control circuits of the
ABS system.
[ABS] Bleed the brakes using the BMWMoDiTeC.
•
Brake fluid grade .........................................DOT 4
X Tightening torques:
Bleed screw................................................... 7 Nm
Draw off brake fluid until it emerges clear and
•
free from air bubbles.
Tighten the bleed screw.
•
00.43
Page 52
Replacing primary sealing boot front brake master cylinder
(Inspection III, every 40,000 km/24,000 miles for motorcycles with ABS)
– Place the motorcycle on its main (centre) stand.
e Important:
Do not allow brake fluid to come into contact with
painted parts of the motorcycle, because brake fluid
destroys paint.
5
6
7
Drain the front brake system.
•
Remove the hand-brake lever.
•
1
2
Remove thrust pin (2) with boot (1) and spring.
•
Carefully force back the brake piston.
•
4
E340120
E340140
Remove spring (6) with insert (5).
•
e Important:
Note the washer between the brake piston and the
boot.
Remove front boot (7).
•
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
e Important:
Sealing lips of the boots toward the pressure chamber.
Install new front boot.
•
Prior to installation, coat the brake piston and the
•
boots with the assembly fluid supplied.
Lightly grease the thrust pin with Shell Retinax A.
•
e Important:
If the vehicle is equipped with ABS, the brake system has to be bled using the BMWMoDiTeC, and
the Control Units, Toolbox ABS, routine; this procedure is supplementary to that described in the Repair Manual.
If the BMWMoDiTeC is not used there is a danger of
residual air remaining in the control circuits of the
ABS system.
3
Remove retaining ring (3).
•
Use pliers to remove brake piston (4).
•
00.44
E340130
Fill and bleed the brake system.
•
X Tightening torques:
Pivot pin of handbrake lever........................... 7 Nm
Locknut of handbrake lever............................ 7 Nm
Page 53
Replacing primary sealing boot, rear brake master cylinder
(Inspection III, every 40,000 km/24,000 miles for motorcycles with ABS)
– Place the motorcycle on its main (centre) stand.
e Important:
Do not allow brake fluid to come into contact with
painted parts of the motorcycle, because brake fluid
destroys paint.
Drain the rear brake system.
•
1
3
4
5
6
E340290
Remove spring (4) with insert (3).
•
e Important:
Note the washer between the brake piston and the
boot.
Remove front boot (5).
•
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
2
Disengage piston thrust rod (1).
•
Remove the piston thrust rod complete with
•
sealing boot (2).
Carefully force back the brake piston.
•
Remove the circlip.
•
Use pliers to remove the brake piston.
•
E340250
e Important:
Sealing lip of the boot toward the pressure chamber.
L Note:
Replace O-ring (6) prior to installation.
Install new front boot.
•
Prior to installation, coat the brake piston and the
•
boots with the assembly fluid supplied.
Lightly grease the thrust rod with Shell Retinax A.
•
e Important:
If the vehicle is equipped with ABS, the brake system has to be bled using the BMWMoDiTeC, and
the Control Units, Toolbox ABS, routine; this procedure is supplementary to that described in the Repair Manual.
If the BMWMoDiTeC is not used there is a danger of
residual air remaining in the control circuits of the
ABS system.
Fill and bleed the brake system.
•
00.45
Page 54
Checking chain, chainwheel and
chain sprocket, replacing if necessary
27 71 005
Checking chain tension,
adjusting if necessary
(Inspections I, II, III and IV)
(Inspections II and III)
– Remove the sprocket cover.
Check chainwheel and chain sprocket for
•
distortion.
1
2
3
F000230
– good (1)
– replace (2)
– replace (3)
e Important:
Always replace the chain, chainwheel and sprocket
as a set.
27 71 005
– Place the unloaded motorcycle on its main
(centre) stand.
Checking chain tension
e Important:
Check and adjust the chain tension only when the
motorcycle is unloaded.
E000100
Chains stretch unevenly, so turn the rear wheel
•
to find the point at which chain deflection midway
along the run between chainwheel and rear
sprocket is least.
At this point, push the chain up as far at it will go
•
and measure chain deflection.
Chain deflection ........ 35...45 mm (1.378...1.771 in)
00.46
Page 55
27 71 005 Adjusting chain tension
61 20 029
Checking battery acid level,
adding distilled water if necessary
(Inspections II, III and IV)
d Warning:
Battery acid is highly caustic!
3
Protect your eyes, face, hands, clothing and the
paintwork!
2
1
E270010
Loosen quick-release axle nut (2).
•
e Important:
When tensioning the chain, make sure that wheel
alignment is correct: check that the same number of
notch marks are visible in window (3) on each side
of the swinging fork.
Adjust chain slack with chain tensioning
•
screws (1).
Firmly tighten quick-release axle nut (2).
•
Check chain tension.
•
Tighten chain tensioning screws (1).
•
Chain deflection ........ 35...45 mm (1.378...1.771 in)
L Note:
Allow time for chain spray penetrate after spraying
on. This keeps grease off rider’s clothing.
61 20 029
– Remove left, right and centre covers (a 46.5).
Check the battery fluid level.
•
– The acid level must be between
the “UPPER LEVEL” and
the “LOWER LEVEL” marks.
61 20 029
Open the battery caps.
•
Checking battery acid level
Adding distilled water
e Important:
Use only distilled water to top up the acid level in the
battery. Never top up with diluted sulphuric acid.
Top up with distilled water until the fluid level
•
reaches the “UPPER LEVEL” mark.
Replace the battery caps securely.
•
Installation is the reverse of the removal
•
procedure.
X Tightening torques:
Quick-release shaft nut .............................. 100 Nm
Chain tensioning screws .............................. 10 Nm
00.47
Page 56
61 21 520 Cleaning and greasing the
battery terminals, if necessary
(Inspection IV)
32 00 454
Checking and adjusting steering head bearing play, renewing if necessary
– Remove left, right and centre covers (
a 46.5).
e Important:
Disconnect the battery only with the ignition
switched off.
Disconnect the negative battery terminal first, then
the positive terminal.
1
2
E610020
Disconnect ground cable (2) from the battery.
•
Disconnect positive lead (1) from battery.
•
Clean the battery terminals and grease them with
•
acid-proof battery grease.
(Inspections II and III)
Checking steering head bearing play
Relieve load on front wheel.
•
E360010
Move fixed fork tubes forward (arrows).
•
Adjust the steering head bearing if play is per-
•
ceptible.
Swing the fork legs all the way through their full
•
range of travel and check for catches.
– Replace the steering head bearings if there are in
the movement (
a 31.18).
Acid-proof battery terminal grease
...............................................e. g. Bosch Ft 40 V1
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
e Important:
Connect the positive battery terminal first, then the
negative terminal.
00.48
Page 57
32 00 454 Adjusting steering head bear-
ing play
e Important:
Cover or mask off the instrument cluster and trim to
prevent scratches.
1 2
E320010
Remove impact pad (2).
•
Remove clamp blocks (1).
•
Remove the handlebars and place them in front
•
of the instrument cluster.
3
6
31 6 521
E000220
Slacken round nut (6) with pin-wrench adapter,
•
BMW No. 31 6 521, then tighten to 25 Nm.
Turn forks back and forth twice from lock to lock,
•
and leave the forks at the full left lock position.
Mark a 40 mm (1.575 in) arc around the circum-
•
ference of the locking plate at the steering head,
with adhesive tape or similar (arrow).
Align the mark on pin-wrench adapter,
•
BMW No. 31 6 521, with the right-hand end of
the marked arc.
L Note:
40 mm (1.575 in) around the circumference of the
locking plate corresponds to an angle of rotation
of 60 °.
Turn the round nut clockwise until the pointer on
•
pin-wrench adapter, BMW No. 31 6 521, reaches the left-hand end of the marked arc.
Remove the mark/adhesive tape from the locking
•
plate.
4
E320020
Unscrew hex nut (5).
•
Release clamping screws (3) at upper fork
•
bridge.
Remove the upper fork bridge complete with the
•
ignition lock.
Remove counter-tube (4).
•
e Important:
5
Check the mating faces of the fork bridge and
knurled nut, rub down with an oilstone if necessary
and clean.
Tighten counter-tube (4).
•
Install fork bridge.
•
Tighten locknut (5).
•
Tighten the clamping screws at fork bridge (3).
•
Check play and freedom of movement.
•
00.49
Page 58
E000230
L Note:
Use the punch marks (arrow) to align the handlebars
as shown.
Greasing the side and main stands and the brake pedal lever
(Inspections II and III)
Side stand
d Warning:
Begin by tightening the front securing screws (as
viewed in the forward direction of travel) of the clamp
blocks, then tighten the rear securing screws.
Install handlebars and impact pad.
•
Take the load off the front wheel and perform fi-
•
nal check.
– With the front wheel off the ground, the weight of
the forks must be enough to turn the steering all
the way to the left and right full lock positions as
soon as the steering is moved away from the
straight-ahead position.
– If catches are perceptible in the movement of the
handlebars, replace the steering head bearings.
X Tightening torques:
Initial torque, round nut ................................25 Nm
Back off through angle of rotation .................... 60 °
Counter-tube to steering head bearing......... 65 Nm
Hexagon nut to counter-tube .......................65 Nm
Clamp screws at fork bridge.........................23 Nm
Handlebars to fork bridge............................. 23 Nm
E460010
Grease bearing bush (arrow) with a grease gun
•
until fresh grease emerges at the lubricated faces.
If very dirty and stiff to move, remove the side
•
stand and grease its pivots.
Main (centre) stand
E460020
00.50
Grease bearing bushes (arrows) with a grease
•
gun until fresh grease emerges at the lubricated
faces.
Lubricant:
for pivot bushing............... Staburags NBU 30 PTM
If very dirty and stiff to move, remove the main
•
stand and grease its pivots.
Page 59
Brake pedal
Checking security of threaded
fasteners
3
2
1
Remove hexagon fit bolt (2).
•
Remove bushing (1).
•
Grease the bushing and the fit bolt.
•
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
e Important:
Check operation of brake-light switch (3).
E340040
(Inspections I, II, III and IV)
Check the security of the following threaded fas-
•
teners:
– Engine mounting bolts and nuts
– Threaded fasteners of frame
– Main and side stands
– Exhaust mountings
– [Dakar] Angled lever
X Tightening torques:
Engine/crankcase
to main frame at rear.................................... 41 Nm
Engine/cylinder head to main frame at top ... 41 Nm
Engine/crankcase to engine mounting
at front ......................................................... 41 Nm
Engine mounting to main frame.................... 21 Nm
Footrest plate to main frame......................... 21 Nm
Engine guard to frame.................................... 9 Nm
Rear frame to main frame............................. 21 Nm
Centre stand to main frame.......................... 41 Nm
Side stand bottom truss to main frame ........ 21 Nm
Exhaust manifold to cylinder head................ 20 Nm
Silencer to exhaust manifold
(Torca clamp) ............................................... 55 Nm
Spring strut to angled lever .......................... 47 Nm
Angled lever to frame..........................58 Nm + 45°
Strut to angled lever..................................... 71 Nm
X Tightening torque:
Brake pedal to frame.................................... 21 Nm
Lubricant:
for pivot bushing............... Staburags NBU 30 PTM
00.51
Page 60
Final inspection with road safety and functional check
(Inspections I, II, III and IV)
Road safety check
Check wheels and tyres.
•
Check tyre pressures and correct if necessary.
•
Tyre tread depth (recommended minimum value)
d Warning:
Thread depth must comply with legal regulations
concerning minimum tyre tread depth.
Front wheel ...................................... 2 mm (0.08 in)
Rear wheel....................................... 3 mm (0.12 in)
Tyre pressures (tyres cold)
One-up
Front wheel ............................... 1.9 bar (27.56 psi)
Rear wheel ............................... 2.1 bar (30.46 psi)
With full load
Front wheel ............................... 2.1 bar (30.46 psi)
Rear wheel ................................2.3 bar (33.36 psi)
Roadworthiness check
– Clutch, gear shift
– Steering
– Handbrake and footbrake
– Lights and signalling equipment, telltale and
warning lights, instruments
– Side-stand switch
– If necessary, test ride
00.52
Page 61
11
11 Motor
Contents Page
Technical Data ................................................................................................................................ 5
Cutaway view of engine ..........................................................................................................11
Engine oil circuit .........................................................................................................................12
Valve gear .......................................................................................................................................13
Valves, components ..................................................................................................................14
Oil pumps, components ..........................................................................................................15
Removing and installing cylinder head, engine installed .....................................16
Preparatory work ...........................................................................................................................16
Removing camshafts ...................................................................................................................18
Removing cylinder head .............................................................................................................18
Removing cylinder, engine installed ................................................................................20
Removing engine ........................................................................................................................21
Preparatory work ...........................................................................................................................21
Removing engine ...........................................................................................................................22
Transferring engine to assembly frame ...............................................................................22
Disassembling engine ..............................................................................................................24
Removing cylinder head .............................................................................................................24
Removing camshafts .........................................................................................................................24
Checking camshaft for wear ..............................................................................................................25
Removing and installing timing-chain sprockets ................................................................................25
Checking centrifugal decompressor lever ..........................................................................................25
Disassembling and assembling the centrifugal decompressor ..........................................................25
Removing cylinder head ....................................................................................................................26
Checking timing chain for wear .........................................................................................................26
11.1
Page 62
Contents Page
Disassembling and assembling cylinder head .................................................................27
Removing valves ...............................................................................................................................27
Bore for bucket tappet ......................................................................................................................27
Checking valve guide for wear ...........................................................................................................28
Removing valve guide ........................................................................................................................28
Installing valve guide .........................................................................................................................29
Checking valve seat for wear .............................................................................................................29
Installing valve stem seal ...................................................................................................................30
Checking valve for wear ....................................................................................................................30
Installing valves .................................................................................................................................31
Removing cylinder ........................................................................................................................31
Checking cylinder .........................................................................................................................31
Removing piston ............................................................................................................................32
Disassembling piston ..................................................................................................................32
Determining clearance of piston in cylinder ......................................................................32
Determining piston ring gaps ..................................................................................................33
Determining piston pin clearance ..........................................................................................33
Assembling pistons ......................................................................................................................33
Removing ignition magnet .........................................................................................................33
Removing countershaft for starter .........................................................................................34
Disassembling and assembling freewheel .........................................................................35
Disassembling freewheel ...................................................................................................................35
Assembling freewheel .......................................................................................................................35
Removing clutch ............................................................................................................................36
Removing pressure plate ...................................................................................................................36
Removing clutch plates .....................................................................................................................36
Removing and installing oil pump ..........................................................................................37
Removing oil pump ............................................................................................................................37
Inspecting oil pump ...........................................................................................................................37
Installing oil pump .............................................................................................................................37
Removing double drive gear ....................................................................................................38
Removing crankshaft and balancing shaft .........................................................................38
Checking crankshaft for wear ............................................................................................................39
Removing compensating gear ................................................................................................39
Removing and installing crankshaft gear ............................................................................39
Removing and installing gearbox mainshaft bearings ..................................................40
Removing and installing gearbox countershaft bearings ............................................40
11.2
Page 63
Contents Page
Removing and installing grooved ball bearings of balancing shaft .........................41
Removing and installing main bearings ...............................................................................41
Removal ............................................................................................................................................41
Installation .........................................................................................................................................42
Assembling engine ....................................................................................................................43
Installing crankshaft and balancing shaft ...........................................................................43
Shimming crankshaft .........................................................................................................................43
Installing double drive gear .......................................................................................................44
Installing oil pump gears ............................................................................................................45
Installing clutch ..............................................................................................................................46
Installing clutch cage .........................................................................................................................46
Installing driver ..................................................................................................................................46
Installing pressure plate .....................................................................................................................47
Installing countershaft for starter motor ..............................................................................47
Installing magnetic ignition trigger .........................................................................................48
Installing piston ..............................................................................................................................49
Installing cylinder ...........................................................................................................................50
Installing cylinder head ...............................................................................................................50
Installing camshaft and adjusting valves ............................................................................52
Installing engine ..........................................................................................................................54
Bleeding engine oil circuit .................................................................................................................55
11.3
Page 64
11.4
Page 65
11
Technical Data F 650 GS / GS Dakar
Engine, general
Type Single-cylinder four-stroke, double overhead
camshafts driven by roller chain, 4 valves operated by bucket tappets, balancing shaft, liquidcooled cylinder and cylinder head, integral water
pump, 5-speed gearbox and dry sump lubrica-
tion.
Cylinder bore mm (in) 100 (3.94)
Stroke mm (in) 83.0 (3.27)
Displacement cc 652
Compression ratio 11.5 : 1
Power output kW (hp) 37 (50)
at 6,500 rpm
Max. torque Nm 60
at 5,000 rpm
Neutral speed rpm 1,400
Max. continuous engine speed rpm 7,000
Max. engine speed rpm 7,500
Crankshaft (main) bearings Plain bearing
Engine lubrication Dry sump, with oil pump
Cylinder Light alloy, “Nikasil” coated
Piston Cast aluminium with 3 rings
Oil filter Full-flow type
Oil pump 2 trochoid pumps, driven by primary drive
Oil capacity l (Imp.
2.3 (4.05/2.43)
pints/US
quarts)
Oil pressure (neutral speed) bar (psi) ≥ 0.5 (7.11)
(oil temperature 80 °C/176 °F)
Permissible oil consumption l/
1 (350 miles per Imp. pint/590 miles per US quart)
1,000 km
Crank gear
Main bearing play
Installed dimension mm (in) 0.030...0.070 (0.0012...0.0028)
Wear limit mm (in) 0.10 (0.004)
Wear limit, main bearing bore diameter mm (in) 46.08 (1.814)
Wear limit
Main bearing diameter mm (in) 47.97 (1.888)
Bearing play mm (in) 0.10 (0.004)
Runout at crankpin
Clutch side mm (in) 0.03 (0.001)
Magneto side mm (in) 0.05 (0.002)
BMW recommends Castrol
11.5
Page 66
Technical Data F 650 GS / GS Dakar
Connecting rod
Wear limit, connecting rod
Radial clearance
Big-end bore mm (in) 0.08 (0.003)
Small-end bore mm (in) 0.05 (0.002)
Big end bearing endplay
Installed dimension mm (in) 0.30...0.65 (0.012...0.026)
Wear limit mm (in) 0.80 (0.031)
Small-end bore
Installed dimension mm (in) 22.015...22.025 (0.8668...0.8671)
Wear limit mm (in) 22.04 (0.868)
Balancing shaft
Bearing journals
Wear limit mm (in) 19.96 (0.786)
Cylinder head
Camshaft journals, inlet/exhaust mm (in) 21.967...21.980 (0.8649...0.8654)
Wear limit mm (in) 21.950 (0.8642)
Camshaft bearing play, inlet/exhaust mm (in) 0.020...0.060 (0.0008...0.0023)
Wear limit mm (in) 0.090 (0.0035)
Valves
Valve clearances with engine cold
(max. 35 °C/95 °F)
Inlet valve mm (in) 0.10...0.15 (0.004...0.0059)
Exhaust valve mm (in) 0.25...0.30 (0.010...0.012)
Valve timing (at 3 mm (0.12 in) valve clearance)
Inlet opens 13° after TDC
Inlet closes 25° after BDC
Exhaust opens 25° before BDC
Exhaust closes 13° before TDC
Valve head dia.
Inlet mm (in) 36 (1.41)
Exhaust mm (in) 31 (1.22)
Stem dia.
Inlet mm (in) 4.90...4.94 (0.193...0.194)
Wear limit mm (in) 4.89 (0.193)
Exhaust mm (in) 4.90...4.94 (0.193...0.194)
Wear limit mm (in) 4.89 (0.193)
Valve stem play - installed clearance
Inlet mm (in) 0.016...0.058 (0.0006...0.0023)
Wear limit mm (in) 0.130 (0.0051)
Exhaust mm (in) 0.031...0.073 (0.0012...0.0029)
Wear limit mm (in) 0.145 (0.0057)
11.6
Page 67
Technical Data F 650 GS / GS Dakar
Valve seat angle
Inlet ° 45
Exhaust ° 45
Included valve angle
Inlet ° 15
Exhaust ° 18
Valve seat width
Inlet mm (in) 1.05...1.35 (0.041...0.053)
Wear limit mm (in) 1.60 (0.063)
Exhaust mm (in) 1.25...1.55 (0.049...0.061)
Wear limit mm (in) 2.2 (0.09)
Valve guide
Inlet intl. dia. mm (in) 5.006...5.018 (0.1971...0.1976)
Wear limit mm (in) 5.080 (0.2000)
Exhaust intl. dia. mm (in) 5.006...5.018 (0.1971...0.1976)
Wear limit mm (in) 5.080 (0.2000)
Bucket tappets (wear limit)
Extl. dia. mm (in) 33.400 (1.3150)
Radial play in cylinder head mm (in) 0.200 (0.0079)
Guide dia. in cylinder head mm (in) 33.600 (1.3229)
Valve spring
On installation (free length) mm (in) min. 40.5 (1.60)
Wear limit mm (in) 39.0 (1.54)
Camshafts
Wear limit
Inlet and exhaust
Bearing journals mm (in) 21.95 (0.864)
Cam height, inlet mm (in) 39.35...39.45 (1.545...1.553)
Cam height, exhaust mm (in) 39.15...39.25 (1.541...1.545)
Wear limit, inlet mm (in) 39.25 (1.545)
Wear limit, exhaust mm (in) 39.05 (1.537)
Bearing bore dia. in camshaft mount mm (in) 22.040 (0.8677)
Oil pressure control valve
Coil spring length, relaxed mm (in) min. 14.0 (0.55)
Oil retaining valve
Coil spring length, relaxed mm (in) min. 14.5 (0.57)
11.7
Page 68
Technical Data F 650 GS / GS Dakar
Piston
Piston dia. “A”
Installed dimension mm (in) 99.975...99.985 (3.9361...3.9365)
Wear limit mm (in) 99.940 (3.9347)
Installed clearance mm (in) 0.015...0.040 (0.0006...0.0016)
Wear limit mm (in) 0.090 (0.0035)
Piston dia. “B”
Installed dimension mm (in) 99.985...99.995 (3.9365...3.9369)
Wear limit mm (in) 99.950 (3.9351)
Installed clearance mm (in) 0.015...0.040 (0.0006...0.0016)
Wear limit mm (in) 0.090 (0.0035)
Piston rings
1st groove rectangular-section ring
Ring thickness mm (in) 1.2 (0.05)
Ring height wear limit mm (in) 1.15 (0.045)
Ring gap mm (in) 0.2...0.4 (0.008...0.016)
Gap wear limit mm (in) 1.0 (0.04)
Groove height wear limit mm (in) 1.30 (0.051)
Ring groove float mm (in) 0.03...0.065 (0.0012...0.0026)
Ring groove float wear limit mm (in) 0.15 (0.045)
2nd groove micro-taper ring
Ring thickness mm (in) 1.5 (0.06)
Ring height wear limit mm (in) 1.45 (0.057)
Ring gap mm (in) 0.2...0.4 (0.008...0.016)
Gap wear limit mm (in) 1.0 (0.04)
Groove height wear limit mm (in) 1.6 (0.06)
Ring groove float mm (in) 0.03...0.065 (0.0012...0.0026)
Ring groove float wear limit mm (in) 0.15 (0.045)
3rd groove spring-steel oil control ring
Ring gap mm (in) 0.2...0.4 (0.008...0.016)
Gap wear limit mm (in) 1.0 (0.04)
Groove height wear limit mm (in) 2.6 (0.10)
Ring groove float mm (in) 0.03...0.065 (0.0012...0.0026)
Ring groove float wear limit mm (in) 0.15 (0.045)
11.8
Page 69
Technical Data F 650 GS / GS Dakar
Piston pin
Piston pin dia.
Wear limit mm (in) 21.98 (0.865)
Piston-pin play
in piston-pin bore mm (in) 0.015...0.029 (0.0006...0.0011)
Wear limit mm (in) 0.050 (0.0020)
in bore (piston) mm (in) 0.012...0.021 (0.0005...0.0008)
Wear limit mm (in) 0.050 (0.0020)
Cylinder
Bore
Cylinder “A” mm (in) 100.000...100.012 (3.9371...3.9376)
Wear limit mm (in) 100.03 (3.9382)
Bore
Cylinder “B” mm (in) 100.012...100.024 (3.9376...3.9380)
Wear limit mm (in) 100.04 (3.9387)
Timing chain
Wear limit
Distance from sealing face of plug to piston
of chain tensioner
Clutch and gearbox
mm (in)
9.0 (0.35)
Clutch friction plates (8)
Installed dimension of each plate mm (in) 3.45...3.55 (0.136...0.140)
Wear limit, height of cluster (total) mm (in) 27.5 (1.082)
Clutch springs
Wear limit at 190 N mm (in) 27.4 (1.079)
Oil pump
Oil pumps primary/secondary
Housing depth (primary) mm (in) 14 (0.6)
Housing depth (secondary) mm (in) 19 (0.7)
Wear limit, installed clearance (radial) mm (in) 0.25 (0.010)
Wear limit, installed clearance (axial) mm (in) 0.25 (0.010)
11.9
Page 70
11.10
Page 71
Cutaway view of engine
11.11
E110550
Page 72
Engine oil circuit
1. Delivery pump
2. Oil tank
3. Check valve
4. Oil filter
5. Control valve
6. Low-pressure line (gearbox)
7. Low-pressure line (clutch)
8. High-pressure line (crankshaft)
9. High-pressure line (big end bearing)
10.High-pressure line (camshafts)
11.Chain tensioner
12.Spray nozzle (for piston)
13.Oil sump
14.Suction pump
11.12
F119109
Page 73
Valve gear
11.13
E110440
Page 74
Valves, components
E110450
11.14
Page 75
Oil pumps, components
11.15
E110460
Page 76
11 12 116 Removing and installing cyl-
inder head, engine installed
L Note:
If an engine failure occurs, the oil tank and oil lines
must be cleaned with the material used for this purpose in the workshop, and then blown through with
compressed air.
Preparatory work
– Remove left, right and centre covers (a 46.5).
– Remove battery (
– Drain coolant (
Drain the engine oil from the oil tank.
•
– Remove engine guard (
– Remove starter (
– Remove exhaust manifold and oxygen sensor
(a 18.6).
– Expose radiator and remove fan (
– Remove intake air pipe (
– Remove intake air silencer (
Remove the battery box.
•
Remove circlip securing throttle cable to throttle
•
valve stub and disengage the throttle cable from
the guide.
Disengage throttle cable from adapter.
•
Disconnect plugs at throttle valve stub.
•
Remove the intake pipe from the cylinder head
•
and lay it carefully to one side, complete with the
throttle valve stub.
Slacken the fastener securing the lid of the elec-
•
tronic equipment box.
Disengage the cover from the anchorages on the
•
main frame on each side and remove.
Disconnect the starter coil at the plug.
•
Remove the fastener securing the ignition-coil
•
bracket and remove the ignition coil complete
with bracket.
a 61.10).
a 00.30).
a 46.8).
a 12.9).
a 17.10).
a 13.5).
a 13.6).
11.16
Page 77
1
3
Remove fastener for oil lines (2) from the cylinder
•
head.
Use pliers, BMW No. 17 5 500, to open the
•
clamp securing the breather hose at the cylinder
head cover.
Remove cylinder head cover (1).
•
Remove spark plug.
•
Remove centre screw plug in engine block cov-
•
er, right.
L Note:
TDC position: marks on the timing-chain sprockets
are parallel with the cylinder head, the bores in the
timing-chain sprockets are at the top.
2
E110070
Turn crankshaft to top dead centre position with
•
an Allen key.
L Note:
Watch out for escaping oil and catch it in a suitable
container.
Remove screw (3) close to the oil feed stub pipe
•
and install locking screw, BMWNo.116570, to
prevent the crankshaft from turning.
11.17
Page 78
11 31 022 Removing camshafts
11 12 116
Removing cylinder head
Remove the cable cover from the right-hand side
•
of the cylinder.
Remove the retainer of the spring-strut adjusting
•
knob from the frame.
2
1
3
E110420
Remove chain guide (1).
•
Remove upper section of camshaft carrier (2).
•
Press chain tensioning rail back against chain
•
tensioner.
Remove camshafts with chain sprockets.
•
Secure timing chain with retaining wire.
•
Remove front chain guide rail (3).
•
Remove lower section of camshaft carrier.
•
E110480
Remove screws securing cylinder head to
•
frame (arrow).
Use pin wrench, BMW No. 11 6 661, to slacken
•
the locknut.
L Note:
Note washers.
Back off the adjuster sleeves.
•
4
5
E110490
Disconnect the coolant hose from cylinder
•
head (4) and drain the last of the coolant from the
radiator.
Disconnect the plug for temperature sensor (5).
•
11.18
Page 79
When looping the timing chain over the camshaft
•
sprockets, make sure that the sprockets are at
the TDC position.
Before installing the cylinder head cover, remove
•
all traces of the gasket and clean the sealing face
with degreasing agent. Also clean the groove
and the seating faces for the gasket.
2
1
E110110
Remove machine screws for chaincase (1).
•
Disconnect plug of oil-pressure sensor.
•
Remove oil pressure switch.
•
Remove rear collar screw (2) from cylinder head.
•
Remove front collar screws from cylinder head.
•
Remove top collar screws from cylinder head.
•
Remove collar nuts from cylinder head.
•
Raise cylinder head clear of stud bolts, turn the
•
cylinder head and lift it toward the rear to
remove.
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
L Note:
Replace cylinder head gasket.
5
9
4
11
8
16
X Tightening torques:
Engine guard to frame.................................... 9 Nm
Footrest plate to frame ................................. 30 Nm
Silencer to exhaust manifold ........................ 55 Nm
Exhaust manifold to cylinder head................ 20 Nm
Intake air silencer to frame ............................. 9 Nm
Intake pipe to cylinder head ......................... 21 Nm
Lid of electronic equipment box to frame ....... 4 Nm
Ignition coil holder.......................................... 9 Nm
Oil lines to cylinder head ................................ 8 Nm
Cylinder head cover to cylinder head ........... 10 Nm
Spark plug in cylinder head.......................... 20 Nm
Rear frame to main frame............................. 21 Nm
Oil line to engine block................................. 35 Nm
Timing-chain tensioner to cylinder head....... 40 Nm
Chain guide to bearing cap
(clean threads + Loctite 243)........................ 10 Nm
Camshaft bearing cap to cylinder head ........ 10 Nm
Cylinder head to frame................................. 41 Nm
Cylinder head to frame, adjuster sleeve
..............................................zero play, max. 5 Nm
Cylinder head to frame, locknut.................. 100 Nm
Machine screws, chaincase ......................... 10 Nm
Collar screws, cylinder head ........................ 33 Nm
Collar nuts, cylinder head................stage 1: 20 Nm
.......................................................stage 2: 60 Nm
Starter to clutch housing.............................. 10 Nm
Oil-pressure switch in engine block
(clean threads + Loctite 243)........................ 12 Nm
Cable cover to engine .................................... 5 Nm
3
14
7
12
Initially tighten the collar nuts of the cylinder head
•
to 20 Nm (3-6) and then tighten to 60 Nm (7-10).
Tighten the fasteners of the cylinder head to cyl-
•
inder in the sequence as shown (11-16) to specified torque.
15
10
13
16
6
E110151
16
11.19
Page 80
11 11 150 Removing cylinder, engine
installed
– Remove cylinder head (a 11.18).
Use pliers, BMW No. 17 5 500, to open the
•
clamp securing the coolant hose to the water
pump (arrow) and disconnect the hose.
E110500
11 6 510
E110520
Oil the piston rings and press the sliding piston
•
ring sleeve, BMWNo.116510, over the piston
rings from above so that the piston projects from
the sliding sleeve by about 2 mm (0.08 in).
Push the timing chain through the chain aperture
•
in the cylinder and secure the chain.
Slip the cylinder over the piston.
•
Remove sliding sleeve.
•
X Tightening torques:
Cylinder to engine block............................... 10 Nm
Ground cable to cylinder................................ 8 Nm
E110510
Disconnect ground cable (arrow) from cylinder.
•
Remove cylinder base screws.
•
Push the rear chain guide forward and carefully
•
lift the cylinder clear.
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
L Note:
When installing, use a new cylinder base gasket.
11.20
Page 81
11 00 050 Removing engine 11 00 050 Preparatory work
– Drain coolant (a 00.30).
– Place motorcycle on its centre stand.
– Secure front wheel in position.
– Remove seat.
– Remove intake air silencer (a 13.6).
Disconnect battery negative terminal.
•
– Remove engine guard (
– Drain engine oil (
– Remove exhaust manifold (
Disconnect oil feed and return lines from oil tank.
•
a 46.8).
a 00.28).
a 18.6).
1
3
5
8
7
6
Remove ground terminal (5) from the engine.
•
Disconnect plug of side-stand switch (6).
•
Unscrew connector for neutral indicator (7).
•
Disconnect the plug of ignition trigger (8).
•
Disconnect plug of oil pressure sensor in oil filter
•
2
housing.
Disconnect positive lead from starter motor.
•
Remove frame truss.
•
E110020
4
E110010
Remove cable cover (1) from the engine.
•
Cut the 2 cable ties (arrow) at the voltage
•
regulator.
Disconnect the plug of the voltage regulator.
•
[GS] Remove voltage regulator (4).
•
Straighten tab (2) and release breather line (3).
•
Remove cover for chain sprocket.
•
L Note:
Do not remove the chain when removing the chain
sprocket. The sprocket complete with chain is
pulled off the main shaft and secured to the frame
with the aid of a cable tie. It is not necessary to
remove the rear wheel and chain.
Remove chain sprocket (a 27.6).
•
10
Cut the cable tie at the adjusting-knob bracket
•
(arrow).
Remove the fastener securing the adjusting-
•
knob bracket (10).
Disconnect the plug for the temperature
•
sensor (9).
Slacken the hose clip at the throttle valve stub
•
and disconnect the throttle valve stub from the
intake pipe.
Disconnect the starter coil at the plug.
•
Pull spark plug connector off spark plug.
•
9
E110030
11.21
Page 82
Remove radiator (a 17.11).
•
Remove the ignition-coil bracket complete with
•
ignition coil from the cylinder head cover.
Disconnect clutch cable from release lever.
•
Disconnect breather hose for oil tank from the
•
cylinder head cover.
Remove the right-hand coolant hose.
•
Remove fasteners for engine shell and remove
•
engine shell with the bracket for the voltage regulator.
L Note:
When locating pin, BMW No. 11 0 661, is inserted
and the floating bearing stud is pulled out 22.5 cm
(8.86 in), the rear swinging fork remains in place in
the frame, but the engine is free.
Slacken nut of swinging-arm bearing.
•
Insert locating pin, BMW No. 11 0 661, to force
•
swinging-arm stud out of frame and pull the stud
22.5 cm (8.86 in) out of the frame.
Remove bottom rear engine mount fastener.
•
Secure the motorcycle by attaching two straps to
•
the front forks.
Remove the brake pedal.
•
Remove the gear shift pedal.
•
E110050
Lower the engine until the cylinder head is rest-
•
ing on the radiator fastening lug (arrow).
Continue lowering the engine; the engine tilts to-
•
ward the rear.
Continue lowering the engine until the fastening
•
lug is above the cylinder head cover.
Turn the engine toward the right and push it clear
•
of the motorcycle.
Transferring engine to assembly frame
11 00 050 Removing engine
Secure adapter, BMWNo.110591, to the plate
•
for the engine lifter.
Place engine lifter, BMW No. 00 1 540, under
•
engine.
1
2
22.5 cm (8.86 in)
E110040
Secure the engine lifter by installing stud bolt (1)
•
through bottom bore in engine block and securing stud (2) in top bore in engine block.
Remove screws securing cylinder head to frame
•
on left and right. Use pin wrench,
BMW No. 11 6 661, to slacken the locknuts and
back off the adjusting sleeves.
11 0 531
E110530
Secure threaded adapter, BMWNo110531, to
•
engine mount.
Detach the engine from the engine lifter, leaving
•
the engine on the lifting platform.
11.22
Page 83
Lay the engine on its left side, as viewed in the
•
forward direction of travel.
Secure engine adapter, BMWNo.110640, to
•
the right side of the engine without a spacer.
Position the assembly stand beside the lifting
•
platform.
Manoeuvre the engine so that the engine adapter
•
is level with the flange of the assembly stand.
2
1
E110060
Secure engine adapter (1) to the flange of the as-
•
sembly stand (2).
Turn engine adapter.
•
11.23
Page 84
1
2
5
4
3
11 00 103 Disassembling engine
e Important:
If there is any mechanical damage, the oil tank and
the oil lines must be cleaned.
11 12 516
– Remove starter (a 12.9)
Remove oil lines.
•
Remove cylinder head cover (1).
•
Remove spark plug.
•
Remove centre screw plug in engine block cov-
•
er, right.
11.24
Removing cylinder head
E110070
Turn crankshaft to top dead centre position with
•
an Allen key.
Remove screws (5) and lock the crankshaft with
•
locating screw, BMWNo.116570.
L Note:
Check for secure seating with Allen key.
11 31 522 Removing camshafts
Only unfasten chain sprockets if they need to be
•
replaced.
Remove chain tensioner (3).
•
Remove chain guide (4) from between the chain
•
sprockets.
Remove fasteners securing camshaft carrier (2).
•
Page 85
Remove camshafts with chain sprockets.
•
Take off the lower camshaft mount.
•
Checking centrifugal decompressor lever
Checking camshaft for wear
00 2 590
F110040
Measure bearing play with Plastigage type PG-1,
•
BMWNo.002590.
Tighten camshaft mount to specified torque.
•
X Tightening torque:
Camshaft mount...........................................10 Nm
Remove camshaft mount and determine bearing
•
clearance using comparative scale.
Wear limits:
Cam height, inlet ..............min. 39.25 mm (1.545 in)
Cam height, exhaust ........min. 39.05 mm (1.537 in)
Bearing journal dia. ........min. 21.950 mm (0.864 in)
Bearing dia. in bearing pedestal
.....................................max. 22.040 mm (0.868 in)
Bearing play ..................max. 0.090 mm (0.0035 in)
L Note:
Never stretch the spring, since this alters the preset
spring force.
When activated, the lever must not project be-
•
yond the cam base circle by less than
distance “B”.
B
E110090
Distance “B”.................................. 0.6 mm (0.02 in)
11 31 530 Disassembling and assembling the
centrifugal decompressor
2
11 31 671 Removing and installing timing-chain
sprockets
Clamp the camshaft in a vise fitted with protec-
•
tive jaws.
Remove the fastener securing the sprocket to
•
the camshaft and remove the camshaft sprocket.
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
Before installing, oil the thread of the chain-
•
sprocket fastener.
X Tightening torque:
Sprocket to camshaft
(thread oiled) ................................................60 Nm
3
1
E110100
L Note:
If the centrifugal decompressor is dismantled,
spring (3) must always be renewed.
Use a suitable punch to press shaft (1) out of
•
centrifugal weight (2).
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
After assembly, check centrifugal weight for ease
•
of movement.
11.25
Page 86
1
3
2
E110111
11 12 116 Removing cylinder head
Remove front chain rail (1).
•
Release the coolant line hose clips with pliers,
•
BMW No. 17 5 500.
Secure timing chain with cable tie.
•
Remove starter (a 12.9).
•
Remove collar nuts from cylinder head.
•
L Note:
If the cylinder head does not have to be dismantled,
do not separate cylinder head from cylinder.
In this case the next six work steps can be omitted.
Remove machine screws for chaincase (2).
•
Remove rear collar screw (3) from cylinder head.
•
Remove front collar screws from cylinder head.
•
Remove top collar screws from cylinder head.
•
Separate the cylinder head from the cylinder.
•
Remove cylinder head.
•
Checking timing chain for wear
A
B
F111060
Push hydraulic chain tensioner (4) in the direc-
•
tion of the tensioner rail in the guide on the cylin-
der, until resistance to movement is felt.
Measure distance (A) from the sealing face to the
•
chain tensioner piston.
4
11.26
Page 87
If the wear limit, distance “B”, is exceeded, first
•
inspect the tensioner rail and the two guide rails
for score-marks and renew them if necessary.
If a part has to be renewed, repeat the measure-
•
ment procedure described above.
If the wear limit has been exceeded, the timing
chain must be renewed.
Distance “B”........................max. 9.0 mm (0.354 in)
11 34 020 Removing valves
Use suction cup, BMW No. 11 3 251, to pull out
•
the bucket-type tappets.
Check that bucket tappets and guides are in per-
•
fect condition.
Bore for bucket tappet
In cylinder head...........max. 33.600 mm (1.3229 in)
Radial clearance of
bucket tappet..............max. 0.200 mm (0.0079 in)
11 12 528 Disassembling and assem-
bling cylinder head
6
5
4
3
2
1
E110120
e Important:
Assign and mark bucket tappets (risk of jamming).
11 5 691
11 5 692
11 0 521
11 0 522
11 0 523
E110130
L Note:
To simplify removal of the valve collets, tap the
valves sharply with a plastic-faced hammer.
Secure the cylinder head to support plate,
•
BMW No. 11 0 523.
Secure adapter plate, BMW No. 11 0 521,
•
support, BMW No. 11 5 691, spindle,
BMW No. 11 5 692, nut, BMWNo.115693,
and thrust plate, BMW No. 11 0 522.
Press down the valves with the thrust plate.
•
Use a screwdriver to press apart and remove the
•
valve collets.
Pull the valves down to remove.
•
1. Valve
2. Lower valve retainer
3. Valve stem seal
4. Valve spring
5. Upper valve retainer
6. Valve collets
11.27
Page 88
Checking valve guide for wear
00 2 510
11 0 571
F110111
Insert new valve from combustion chamber side
•
into valve guide until it reaches the valve stem
seal.
Using dial gauge, BMWNo.002510, posi-
•
tioned vertically on the valve axis, measure maximum tilt clearance across the camshaft axis.
Tilt clearance:
Max. tilt clearance ....................... 0.4 mm (0.016 in)
Intl. dia. of valve guide...max. 5.080 mm (0.2000 in)
11 12 591 Removing valve guide
1
2
F110140
L Note:
To simplify driving out, heat the cylinder head to
100 °C (212 °F).
Use temperature measuring device,
BMW No. 00 1 900, to check the temperature.
Use drift, BMWNo.110571, to drive out the
•
valve guide toward the combustion chamber.
e Important:
If the valve guide bore in the cylinder head is worn,
the cylinder head must be replaced.
F110121
e Important:
Do not damage sliding surfaces on bucket tappets:
risk of jamming.
Pull off valve stem seal (1) with pliers,
•
BMW No. 11 1 250.
Remove valve spring support (2) from cylinder
•
head.
11.28
Page 89
11 12 591 Installing valve guide
1
F110151
Checking valve seat for wear
Apply engineer’s blue or a similar product to the
•
valve seat rings.
Install correct valve and rotate, applying slight
•
pressure.
Heat the cylinder head to 100 °C (212 °F).
•
Using driving-in tool, BMWNo.110571, drive
•
valve guide (1) into the cylinder head until valve
guide projection is as specified.
Projection:
Inlet........................... 9.8...10.2 mm (0.39...0.40 in)
Exhaust..................... 9.8...10.2 mm (0.39...0.40 in)
L Note:
Only use thread-cutting oil to lubricate the reaming
tool.
Only rotate reaming tool in the cutting direction never in the opposite direction!
Withdraw reaming tool at regular intervals for cleaning: always rotate in cutting direction when doing so!
Ream out valve guide with 5H7 reaming tool.
•
A
F110160
Check valve seat width “A” and contact pattern
•
for wear.
Wear limits for valve seat width “A”:
Inlet valve.................................... 1.6 mm (0.063 in)
Exhaust valve.............................. 2.2 mm (0.087 in)
If the wear limit of the seat width has been
•
reached, or the contact pattern is no longer
perfect, the seat can be remachined.
2
E110540
If necessary, remachine valve seat with valve
•
seat turning tool (2).
Valve seat width “B”:
Inlet valve.................................... 1.2 mm (0.047 in)
Exhaust valve.............................. 1.4 mm (0.055 in)
11.29
Page 90
11 34 800 Installing valve stem seal
Checking valve for wear
2
1
Install bottom valve spring retainer (1).
•
Use a drift, BMW No. 11 6 650, to insert valve
•
stem seal (2).
E110120
F110190
Check valve stem diameter and valve head seat
•
width.
Wear dimensions for valve:
Stem diameter
Inlet valve ...........................min. 4.89 mm (0.192 in)
Exhaust valve ..................... min. 4.89 mm (0.192 in)
Check valve for runout.
•
L Note:
Remove oil carbon from valve and deburr grooves
for valve collets with an oilstone.
For wear limits, see Technical Data.
Check grooves for valve collets.
•
11.30
Page 91
11 34 020 Installing valves
11 11 150
Removing cylinder
Install valve with shrink-fit tube.
•
L Note:
Remove the shrink-fit tube.
11 5 691
11 0 521
11 0 523
Install valve spring and valve spring plate.
•
Secure the cylinder head to support plate,
•
BMWNo.110523.
Secure adapter plate, BMW No. 11 0 521,
•
support, BMW No. 11 5 691, spindle,
BMWNo.115692, nut, BMW No. 11 5 693,
and thrust plate, BMW No. 11 0 522.
Press down the valves with the thrust plate.
•
11 5 692
11 0 522
E110130
Separate the cylinder base from the engine
•
block.
e Important:
When removing cylinder, make sure that the piston
does not strike the engine block.
Remove cylinder.
•
Checking cylinder
E110140
Check cylinder face and sealing faces for dam-
•
age and blow out oil ducts for chain tensioner.
L Note:
Coat valve collets with a small amount of grease to
facilitate assembly.
Insert the valve collets.
•
Check bucket tappets for damage and fit to
•
correct valves.
1
2
Measure cylinder bore at distance of 55...65 mm
•
(2.17...2.56 in) from the upper edge with an internal micrometer at three points (1, 2, 3).
Wear limits for cylinder bore:
Cylinder A ...................max. 100.03 mm (3.9382 in)
Cylinder B ...................max. 100.04 mm (3.9387 in)
3
E110150
11.31
Page 92
11 25 050 Removing piston
Remove piston pin circlips.
•
Press out piston pin with drift,
•
BMW No. 11 6 581.
L Note:
Mark exhaust-valve side on piston crown.
Determining clearance of piston in cylinder
1
11 25 671
Remove piston rings with piston ring pliers.
•
Carefully clean piston.
•
Check piston for signs of damage.
•
Disassembling piston
2
Measure cylinder bore at distance of 55...65 mm
•
(2.17...2.56 in) from the upper edge with an
internal micrometer at three points (1, 2, 3).
Make a note of the largest value as
•
dimension “A”.
3
E110150
U
B
E110160
Measure piston diameter “B” at distance
•
H=16 mm (0.63 in) from the lower edge at a right
angle to the piston pin axis.
L Note:
Determine piston clearance:
Dimension “A” minus dimension “B” = piston clearance
Piston clearance:
When new ... 0.024...0.040 mm (0.0009...0.0016 in)
Wear limit ...................... max. 0.100 mm (0.0039 in)
11.32
Page 93
Determining piston ring gaps
12 11 070
Removing ignition magnet
Install piston ring in cylinder and measure 60 mm
•
(2.36 in) from top edge of cylinder with feeler
gauge to determine gap.
Wear dimension:
Ring gap (all piston rings).............. 1.0 mm (0.04 in)
Determining piston pin clearance
Measure diameter of piston pin bores in piston
•
stroke direction using an internal micrometer.
Measure both ends of piston pin with micrometer.
•
Wear limits:
Bore dia. in piston,
vertical ........................max. 22.030 mm (0.8673 in)
Piston pin dia. ..............min. 21.980 mm (0.8654 in)
Radial clearance
in piston ........................max. 0.050 mm (0.0019 in)
11 25 671
Assembling pistons
L Note:
The “Top” must face towards the piston crown.
Install the piston rings with their gaps offset by 120 °.
Remove fastener of right engine block cover.
•
12 5 500
Release the central locking screw, insert and
•
tighten handle, BMW No. 12 5 500.
E110180
1
2
3
E110170
1. Groove for rectangular-section ring
2. Stepped micro-taper ring
3. Groove for spring-steel oil control ring
Use feeler gauge to measure float of piston rings
•
in groove.
Wear limit, ring float in groove . 0.150 mm (0.006 in)
Remove the cover, noting the thrust
•
washer (arrow).
4
E110190
E110200
If necessary, remove ignition trigger (4).
•
11.33
Page 94
12 5 510
E110210
Unscrew hex nut.
•
Heat hub to 80 °C (176 °F).
•
L Note:
Use temperature measuring device,
BMW No. 00 1 900, to check the temperature.
Using puller, BMWNo.125510, pull off magnet
•
rotor.
11 26 500
starter
Removing countershaft for
1
2
4
5
E110230
Remove freewheel gear (5).
•
3
E110220
Remove thrust washer (1) and spacer sleeve (2).
•
Remove double gear (4).
•
Pull off angled gear (3).
•
11.34
Page 95
12 11 077 Disassembling and assem-
bling freewheel
Disassembling freewheel
1. Machine screw
2. Magnet rotor
3. Freewheel
4. Lock ring
5. Freewheel housing
6. Freewheel gear
d Warning:
Securing screws (1) are secured with Loctite 648
and considerable torque is required to release them.
Release securing screws (1).
•
Lift off freewheel housing (5).
•
Remove lock ring (4).
•
Remove freewheel gear (3).
•
Check freewheel housing and freewheel for
•
wear, isolated chatter marks are permissible.
Assembling freewheel
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
Install freewheel with arrow mark (arrow) down.
•
11.35
Page 96
Engage the tabs of the lock ring in the recesses
•
in the freewheel gear.
Clean the threads of the securing screws and
•
freewheel housing, coat threads with
Loctite 648 and install the screws.
Check locking function and locking direction of
•
freewheel.
X Tightening torques:
Machine screw
(clean threads + Loctite 648)........................35 Nm
21 4 600
4
3
21 21 000
Turn engine round in assembly fixture.
•
Remove fastener for left engine block scover and
•
remove cover.
Removing pressure plate
Removing clutch
2
1
E110250
Remove hex screws (2) in diagonally opposite
•
sequence.
Lift off complete pressure plate (1).
•
E110260
Using locating ring, BMW No. 21 4 600, prevent
•
clutch cage (4) and driver (3) from moving and
unscrew hex nut.
Pull off driver.
•
Pull off clutch cage and toothed washer.
•
e Important:
Note the backup washer at the bottom.
Pull off needle cages.
•
Remove the backup washer.
•
Removing clutch plates
e Important:
The topmost clutch plate is offset. Make sure this
plate is installed in the correct position.
Take plate cluster out of clutch cage.
•
11.36
Page 97
11 41 000 Removing and installing oil
pump
Installing oil pump
Removing oil pump
2
Remove circlip (1) from angled gear.
•
Remove the retaining rings of the oil-pump
•
gears (2) and disengage the oil-pump gears.
1
E110270
7
8
11
10
7. Inner rotor
8. Outer rotor
9. Cover
10.Markings
11.Needle roller
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
L Note:
Markings (5) must be visible.
9
F110370
6
5
3
4
E110280
Remove angled gear (3).
•
Remove needle rollers (4).
•
Remove thrust washers (5).
•
Remove countersunk screws from cover and lift
•
off cover (6).
Inspecting oil pump
Using feeler gauges, measure the clearance
•
between the inner and outer rotors and between
the outer rotor and the housing.
Permissible face runouts between:
Inner and outer rotor .........max. 0.25 mm (0.010 in)
Radial clearance................max. 0.25 mm (0.010 in)
Axial clearance between
rotors and cover................max. 0.25 mm (0.010 in)
Oil the inner and outer rotors.
•
Clean the threads of the countersunk screws
•
and coat with Loctite 243.
X Tightening torque:
Countersunk screws in oil-pump cover
(clean threads + Loctite 243).......................... 6 Nm
11.37
Page 98
Removing double drive gear
2
4
1
L Note:
Retaining screw (arrow) must be installed.
Remove hex nut (1).
•
Press chain guide (2) to rear of engine block.
•
Pull off double drive gear with timing chain.
•
11 21 001
ancing shaft
Removing crankshaft and bal-
3
E110290
E110320
Swivel assembly fixture so that clutch side is
•
uppermost.
Remove knurled nuts (4).
•
e Important:
Do not tilt engine housing: this can cause damage
to bearing shell.
Lift off left half of engine block, tapping the main-
•
shaft, countershaft and balancing shaft alter-
nately with light blows of a plastic-faced
hammer, so that these remain in the magnet
side.
Screw knurled nut on to engine support with
•
spacer.
5
E110310
Lever out water-pump drive gear (3) with a
•
screwdriver.
Remove needle roller.
•
Swivel engine in assembly fixture so that magnet
•
side is uppermost.
Remove all fasteners on engine block.
•
Remove oil filter and unfasten two fasteners for
•
engine block in base.
7
Align marks (7) on balancing shaft and crank-
•
shaft (5) with mark on housing (6).
6
E110330
11.38
Page 99
L Note:
Note shims on crankshaft.
First lift out crankshaft, then balancing shaft.
•
Checking crankshaft for wear
Removing and installing crankshaft gear
11 6 502
Check bearing journal on crankshaft and conrod
•
for signs of damage and wear.
Bearing journal dia. ..........min. 45.97 mm (1.810 in)
Radial play, main bearing ..max. 0.10 mm (0.004 in)
Endplay, conrod/crankshaft
webs .................................max. 0.80 mm (0.031 in)
Small end bore dia. .........max. 22.04 mm (0.868 in)
11 27 020
Press off compensating gear with pressure pad,
•
BMWNo.110561.
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
Removing compensating gear
L Note:
Coat the bearing seat for the expander gear on the
compensating gear with Optimoly MP 3.
Heat the compensating gear to 100 °C (212 °F).
•
L Note:
Use temperature measuring device,
BMW No. 00 1 900, to check the temperature.
11 6 501
11 6 503
F110450
Clamp crankshaft into vise with protective jaws.
•
Use yoke, BMWNo.116501, spindle,
•
BMW No. 11 6 502, and pressure pad,
BMWNo.116503, to pull off the crankshaft gear.
A
Use a socket of suitable size or similar adapter
•
to apply pressure to the thrust face of the gear
when installing the compensating gear.
F110460
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
When installing, heat the crankshaft gear to
•
140 °C (284 °F).
L Note:
Use temperature measuring device,
BMW No. 00 1 900, to check the temperature.
e Important:
Pin must not protrude from bore in crankshaft gear
- this is the support face for the thrust washer.
Using a suitable adapter, drive the gear onto the
•
crankshaft.
Projection “A” of pin .............max. 18 mm (0.709 in)
11.39
Page 100
11 11 205 Removing and installing gear-
box mainshaft bearings
11 11 210
Removing and installing gear-
box countershaft bearings
11 6 562
11 6 561
11 6 564
E230040
L Note:
To protect the gasket surfaces of the engine block,
place the old gasket under the bearing puller.
Always renew the mainshaft sealing ring.
Heat the left of the engine block to 80 — 100 °C
•
(176 — 212 °F).
Using bearing puller plate, BMW No. 11 6 561,
•
spindle, BMW No. 11 6 562, and spreader
sleeve, BMW No. 11 6 564, pull off the ball bear-
ing.
Drive out the mainshaft sealing ring from the in-
•
side.
Heat the right of the engine block to 80 - 100 °C
•
(176 - 212 °F).
Working from outside and using a suitable sock-
•
et, press the bearing through to the other side.
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
L Note:
To protect the gasket surfaces of the engine block,
place the old gasket under the bearing puller.
Always renew the mainshaft sealing ring.
Heat the left of the engine block to 80 — 100 °C
•
(176 — 212 °F).
Using bearing puller plate, BMWNo.116561,
•
spindle, BMWNo.116562, and spreader
sleeve, BMWNo.116565, pull off the ball
bearing.
Heat the right of the engine block to 80 - 100 °C
•
(176 - 212 °F).
Using bearing puller plate, BMWNo.116561,
•
spindle, BMWNo.116562, and spreader
sleeve, BMWNo.116564, pull off the ball bear-
ing.
Installation is the reverse of the removal proce-
•
dure: pay particular attention to the following.
L Note:
The sealed ends of the cage must point outwards.
To install the ball bearing, heat the engine block
•
to 80 - 100 °C (176 - 212 °F) and spray the ball
bearing with BMW chilling spray.
Wear limit values for bearing seats in housing:
Magneto side:
Countershaft ............ max. dia. 46.99 mm (1.850 in)
Mainshaft ................. max. dia. 62.02 mm (2.442 in)
Clutch side:
Countershaft ............ max. dia. 51.99 mm (2.047 in)
Mainshaft ................. max. dia. 46.99 mm (1.850 in)
L Note:
The sealed ends of the cage must point outwards.
To install the ball bearing, heat the engine block
•
to 80 - 100 °C (176 - 212 °C) and spray the ball
bearing with BMW chilling spray.
Drive in the shaft sealing ring with sleeve,
•
BMW No. 23 4 540, and drift,
BMW No. 23 4 550.
11.40
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