BMW R1100S Service Manual

Repair Manual

R 1100 S

BMW AG Motorcycle Division
After Sales

Published by: © BMW AG Motorcycle Division

After Sales
UX-VS-2

All rights reserved. Not to be reprinted, translated or duplicated either wholly or in part without prior written
permission.
Errors and omissions excepted; subject to technical amendment.

Produced in Germany 06/99

Introduction

This repair manual will help you to perform all the main maintenance and repair work correctly and efficient­ly. It should be consulted regularly by workshop personnel as an addition to the practical and theoretical
knowledge obtained in Training School courses. It is a contribution towards achieving even higher Service
quality.

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, Dis-

assembly, Repair, Assembly, Installation.

● The entire contents are divided into individual chapters, corresponding to the Construction Groups.

11 . 10

Chap. Page number within chapter

● 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 you to consult the
detailed illustrations on the Parts microfiches as an additional source of information.

BMW AG Motorcycle Division
After Sales

Published by: BMW AG, Sparte Motorrad

Hufelandstr. 6
D - 80937 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

Contents

Group / Chapter

00 Maintenance and general instructions

11 Engine

12 Engine electrics

13 Fuel preparation and control

16 Fuel tank and lines

18 Exhaust system

21 Clutch

23 Gearbox

31 Front fork

32 Steering

33 Rear wheel drive

3

Group / Chapter

34 Brakes

36 Wheels and tyres

46 Frame

51 Equipment

52 Seat

61 General electrical equipment

62 Instruments

63 Lights

5

BMW AG Motorcycle Division
Maintenance schedule
R 1100 S

Customer Licence plate No.

Order No. Mechanic’s signature

Read out the fault memory with the BMW MoDiTeC unit
Change the oil while at regular operating temperature and renew the oil filter

element

if motorcycle is used only for short journeys or at outside temperatures under 0°C, every 3 months,
but at least every 3,000 km (1,800 miles)

)

*

BMW Inspection

at 1,000 km

(600 miles)

BMW Service

every 10,000 km

(6,000 miles)

BMW Inspection

every 20,000 km

(12,000 miles)

BMW

Annual Service

Change the oil in the gearbox while at regular operating temperature

at least every 2 years

every

2 years

Change the oil in the rear wheel drive while at regular operating temperature
Clean the inductive sensor at the rear wheel

every 40,000 km (24,000 miles) or at least every 2 years *

Renew fuel filter *

normally every 40,000 km (24,000 miles), if fuel quality is poor every 20,000 km (12,000 miles)

)

)

40,000

(24,000)

40,000

(24,000)

every

2 years

Check battery acid level, if necessary add distilled water
Clean/grease battery poles if necessary

Renewing intake air cleaner element

in very dusty or dirty operating conditions, renew the intake air cleaner element
every 10,000 km (6,000 miles) or even more often if necessary

Renew Poly-V belt *

Renew Poly-V belt every 60,000 km (36,000 miles); do not adjust

)

Check brake fluid level at front/rear and top up if necessary *
Check operation of brake system and freedom from leaks;

repair/renew items if necessary *

)

Examine brake pads and discs for wear, renew if necessary *

)

*

60,000

(36,000)

)

)

Renew the brake fluid annually

Check clutch operating fluid level

Change clutch fluid

every 40,000 km (24,000 miles) or at least every 2 years *

)

40,000

(24,000)

every

2 years

Check tightness of rear wheel studs
Check rear wheel bearing play by tilting wheel
Check swinging arm bearings (zero play); adjust if necessary *

)

Grease the side (prop) stand pivot
Check function of side (prop) stand contact switch
Check condition of spark plugs
Renew spark plugs *

)

Take up slack at cylinder head nuts
Check/adjust valve operating clearances
Check throttle cable for free movement, abrasion and kinking; renew if necessary *

Check free travel in throttle cable
Check synchronisation and eliminate any leaks *

)

)

Final inspection with road safety and functional check:

– condition of tyres and wheels, tyre pressures
– lights and signalling equipment
– telltale and warning lights
– clutch, gear shift
– handbrake and foot brake, steering
– instruments
– trial run if necessary

)

*

Charged as an additional item

Order No. 01 71 7 654 263 UX-VS-2, 3.99 Printed in Germany

BMW AG Motorcycle Division
Pre-delivery check
R 1100 S

Customer Licence plate No.

Order No. Mechanic’s signature

Checking the shipping crate for damage

Motorcycle:

– unpack
– attach items supplied loose
– inspect for damage
– check that delivery is complete: tools

documentation
keys
correct optional extras

Fill and charge the battery (mark with charging date)

Check engine oil level when cold; add oil if necessary

BMW
Pre-delivery check

Check clutch operating fluid level and brake fluid levels at front and rear

Check headlight beam angle and adjust if necessary

Checking tightness of rear wheel studs
(comply with correct tightening torque)

Check tyre pressures

Add fuel

Final inspection and functional check:

– clutch, gear shift
– handbrake, foot brake
– lighting and signalling equipment, telltale lights, instruments
– check operation of optional extras, ABS
– trial run if necessary

Confirm pre-delivery check in Service and Technical Booklet

Final cleaning

Motorcycle handed over on:

Order No. 01 71 7 654 263 UX-VS-2, 3.99 Printed in Germany

00

00 Maintenance and general instructions

Tightening torques and Table of consumables
Pre-delivery check
Maintenance

Contents Page

Tightening torques ......................................................................................................................5

Table of consumables ..............................................................................................................11

00.1

Pre-delivery check

Contents - Pre-delivery check Page

Pre-delivery check .....................................................................................................................13

General view of crated motorcycle ..................................................................................13

Checking the crate for damage ..........................................................................................14

In case of damage in Germany ...............................................................................................14

In case of damage in importer markets ..............................................................................14

Unpacking the motorcycle ....................................................................................................14

Installing remaining items on

motorcycle .....................................................................................................................................14

Inspecting motorcycle for damage ..................................................................................14

Checking that delivery is complete ..................................................................................14

Filling and charging the battery .........................................................................................15

Disengaging and raising the fuel tank .................................................................................15

Filling and charging the battery ..............................................................................................15

Checking engine oil level when cold, adding oil if necessary ...........................16

Checking clutch fluid level ....................................................................................................17

Checking brake fluid level .....................................................................................................17

Rear brake .......................................................................................................................................17

Front brake ......................................................................................................................................17

Checking headlight beam angle, adjusting if necessary .....................................18

Checking tightness of rear wheel studs ........................................................................18

Checking tyre pressures ........................................................................................................18

Final inspection and function check ...............................................................................19

Final cleaning ...............................................................................................................................19

Handing over the motorcycle ..............................................................................................19

00.2

Maintenance

Contents - Maintenance Page

Maintenance .................................................................................................................................20

Key to maintenance intervals ..............................................................................................20

Reading out MoDiTeC fault memory ...............................................................................20

(Inspections I, II, III and IV)

Changing engine oil, replacing oil filter element ......................................................20

(Inspections I, II, III and IV)

Changing oil in gearbox ..........................................................................................................21

(Inspections III and IV)
or every 2 years at the latest

Changing oil in rear wheel drive; cleaning inductive signal transmitter at

rear wheel .......................................................................................................................................22

(Inspections I, III and IV)
Every 40 000 km (24 000 miles) or every 2 years at the latest

Replacing fuel filter ...................................................................................................................23

(Inspection III)
In normal operating conditions every 40 000 km (24 000 miles); if fuel quality is poor every
20 000 km (12 000 miles)

Checking battery fluid level and

topping up if necessary; cleaning and greasing the battery posts .................25

(Inspections III and IV)

Replacing intake air filter element ....................................................................................25

(Inspection III)
In very dirty and dusty operating conditions, replace every 10 000 km (6 000 miles) or even more fre­quently if necessary

Replacing Poly-V belt ...............................................................................................................26

(every 60 000 km/36 000 miles)
(Inspection III)
Poly-V belt adjusting procedure:

Checking brake fluid level .....................................................................................................27

Front brake ......................................................................................................................................27

Rear brake .......................................................................................................................................27

Checking brake pads and discs for wear/replacing ...............................................28

(Inspections II and III)

Checking front brake pad wear ..............................................................................................28

Checking rear brake pad wear ...............................................................................................28

Checking brake disc wear ........................................................................................................28

Replacing brake pads, front brake .......................................................................................29

Replacing brake pads, rear brake .........................................................................................29

00.3

Contents - Maintenance Page

Changing brake fluid and bleeding brake system ...................................................30

Change the brake fluid annually
(Inspection IV)
[ABS Inspections II and III]

Bleeding front brake circuit/changing brake fluid ..........................................................30

Additional information for [ABS]

Bleeding rear brake circuit/changing brake fluid ............................................................32

Checking clutch fluid level ....................................................................................................33

(Inspections I, II and III)

Changing the clutch fluid .......................................................................................................33

(Inspections III and IV)
Every 40 000 km (24 000 miles) or every 2 years at the latest

Checking tightness of rear wheel studs ........................................................................34

(Inspection I)

Checking rear wheel bearing play by tilting wheel .................................................34

(Inspection III)

Checking swinging arm bearings, adjusting if necessary ...................................34

(Inspections I and III)

Greasing the side stand pivot ..............................................................................................35

(Inspections I, II and III)

Checking function of side stand switch ........................................................................35

(Inspections I, II, III and IV)

Checking/replacing spark plugs ........................................................................................35

(Inspection II) check/(Inspection III) replace

Tightening cylinder heads .....................................................................................................36

(Inspection I)

Checking/adjusting valve

clearances ......................................................................................................................................36

(Inspections I, II and III)

Checking throttle cable for ease of movement, abrasion and kinks; repla­cing if necessary
Checking throttle-cable play

Checking/adjusting idle speed and throttle-valve synchronisation ...............37

(Inspections I, II, III and IV)

Final inspection with road safety and functional check .......................................38

(Inspections I, II, III and IV)
Road safety check
Roadworthiness check

00.4

00

Tightening torques

Model R 1100 S

Connection Nm

11 Engine

Cylinder head

Tightening sequence:

1. Tighten cylinder head nuts (oiled) in diagonally
opposite sequence

1.1 Tighten all nuts to closing torque 20

1.2 Tighten all nuts to wrench angle 90°

1.3 Tighten all nuts to wrench angle 90°

2. M 10 screw 40

3. M 6 screw 9

After 1000 km (600 miles), tighten cylinder head nuts in
diagonally opposite sequence:

1. Slacken one nut

2. Tighten one nut to initial torque 20

3. Tighten nut to wrench angle 180°

4. Slacken and retighten M 10 screw 40

Timing gear carrier to cylinder head
Bearing cap on rocker shaft 15
Locknut, valve adjusting screw 8
Cylinder head cover to cylinder head 9
Camshaft end cover to cylinder head
Air intake connection to cylinder head

Camshaft

Chain sprocket to camshaft 65
Camshaft bearing cap 15

Alternator mount cover

M 6 screw 9
M 8 screw 20

Auxiliary shaft

Chain sprocket to crankshaft 10
Chainwheel to auxiliary shaft 70
Chain tensioner housing to engine block 9

9

9
9

Oil filter

Oil filter 11
Oil drain plug 32

00.5

Model R 1100 S

Connection Nm

11 Engine

Oil pump

Mesh filter basket to engine block 9
Oil pump cover 9
Pressure relief valve 42
Oil pressure switch 30

Oil cooler

Oil cooler pipe to engine block 10

Cooling oil line – banjo screw with oil vent valve 25
Oil cooler to fairing bracket 9
Oil cooler return line to engine block 35
Oil cooler connection to crankcase 9

Cylinders

Tightening sequence:

1. M 8 screw 20

2. M 6 screw 9

3. Chain guide rail pivot screw 18

Timing chain

Chain tensioner 32

Connecting rod

Big end cap Closing torque 20

Wrench angle 80°

Crankcase

Tightening sequence:

1. M 10 screw (oiled) Initial torque 25
Wrench angle 90°

2. M 8 screw (oiled) 22

3. M 6 screw 9

00.6

Model R 1100 S

Connection Nm

12 Engine electrics

Starter motor to engine 20
Starter cover to gearbox housing 7
Alternator to cover mount 20
Tensioning and retaining link to alternator 20
Spacer to alternator 20
Belt pulley to alternator

Series generator 560 W
Option 700 W

Belt pulley to crankshaft 50
Poly-V belt preload 8
Spark plug 20

13 Fuel preparation and control

Temperature sensor, oil, in crankcase 25

Do not release
50

Temperature sensor, air, in air-filter housing 10

16 Fuel tank and lines

Fuel tank to main frame 10

18 Exhaust system

Manifold to cylinder head 21
Clamp for manifold 45 (apply Never Seeze to clamp seat)
Manifold to front silencer 12
Silencer to front-silencer outlet 55 (apply Never Seeze to clamp seat)
Oxygen sensor to silencer 45 (apply Never Seeze to thread)

21 Clutch

Clutch housing Closing torque

Wrench angle 32°

Housing cover 12
Slave cylinder to gearbox 9

40 (oil screw threads lightly)

Clutch line to handlebar fitting 18

00.7

Model R 1100 S

Connection Nm

23 Transmission

Oil drain plug 55
Oil filler plug 23
Gearbox to engine block 22
Foot shift lever to footrest plate 21
Selector lever to selector shaft 9
Gearbox cover to gearbox housing 9

31 Front fork

Quick-release axle clamp screws 22
Clamp, fork fixed tube to fork bridge 22
Slider tube bridge to slider tube 25 (clean thread + Loctite 243)
Ball joint to fork bridge 230 (apply light coat of Never Seeze to thread)
Ball joint to tube slider bridge 230 (apply light coat of Never Seeze to thread)
Leading link tube to ball joint 130 (clean thread + Loctite 2701)
Frame to ball joint 130 (clean thread + Loctite 2701)
Leading link tube to engine right 73
Screw cap to leading link left 42 (apply light coat of Never Seeze to thread)
Suspension strut to front frame
Suspension strut to leading link 50

32 Steering

Handlebar to fixed tube 21
Handlebar to fork bridge 9 (clean thread + Loctite 243)

33 Rear wheel drive

Oil filler plug 23
Oil drain plug 23
Threaded ring 118 (Hylomar SQ 32 M)
Hexagon nut, input bevel gear
Cover to rear-wheel drive housing 35

43

200 (clean thread + Loctite 2701)

Swinging-arm fixed bearing stud bolt to rear frame 9
Swinging-arm floating bearing stud bolt to rear frame 7 (clean thread + Loctite 2701)
Swinging-arm floating bearing stud bolt to rear axle

housing 160 (clean thread + Loctite 2701)
Swinging-arm floating bearing stud bolt to rear-axle

housing 7 (clean thread + Loctite 2701)
Locknut of swinging-arm floating bearing stud bolt 160

00.8

Model R 1100 S

Connection Nm

33 Rear wheel drive

Reaction link to rear wheel drive/main frame 43

Load approx. 85 kg (187 lbs) onto motorcycle and

tighten loose reaction link
Spring strut to main frame 50
Spring strut to rear swinging arm 50

34 Brakes

Brake caliper to fork slider tube 40
Brake caliper to rear wheel drive 40
Brake disc to front wheel 21 (clean thread + Loctite 2701)
Brake disc to rear wheel drive 21 (clean thread + Loctite 2701)
Master cylinder to footrest assembly 8
Brake pedal to footrest assembly
Brake lines/brake hose to brake components 18
Brake hose to brake lever fitting 18
ABS sensor 4 (handtight)
Front brake caliper bleed screw
Rear brake caliper bleed screw 6
Pressure modulator bleed screw
Grubscrew in filler adapter
ABS unit to holder
M6 screw 9

36 Wheels and tyres

Quick-release axle clamp screws 22
Quick-release axle threaded connection 30
Rear wheel to rear wheel drive

Hand-tighten wheel studs, then tighten in diagonally
opposite sequence

Initial tightening 50

21 (clean thread + Loctite 2701)

14

9

10

Final tightening 105

46 Frame

Front frame to engine, M12 bolts 82
Struts to front frame 58

00.9

Model R 1100 S

Connection Nm

46 Frame

Main frame to engine
M 10 screw, top right Initial tightening 13

Final tightening 42
M 10 screw, top left 42
M 10 bolts at top (struts to engine) 50
M 10 screw, long, frame/gearbox 55
M 12 screw, bottom 80
M 8 screw, long, bottom 24
Rear frame to main frame 31
Side stand pivot mount to engine
M 8 screw 21
M 12 screw 80
Side stand to pivot mount 42 (clean thread + Loctite 243)
Centre stand to main frame 42
Footrest assembly to main frame 21
Pillion footrest holder to rear frame 21
Front fairing bracket to front frame 21

51 Equipment

Mirrors 10 (clean thread + Loctite 243)
Ignition/steering lock to fork bridge 15 (microencapsulated)

61 General electrical equipment

Horn to holder 21
Ground (earth) strap to engine block 7

00.10

Table of consumables

Item Use Order number Quantity

Lubricant

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

Staburags NBU 30 PTM High-performance lubricating paste 07 55 9 056 992 75 g tube
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 07 58 1 465 170 90 g tube
Loctite 574 Surface sealant 81 22 9 407 301 50 ml tube
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 retaining agents

Loctite 648 Joint adhesive (low clearance) 07 58 9 067 732 5 g bottle
Loctite 638 Joint adhesive (greater clearance) 07 58 9 056 030 10 ml bottle

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

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

Developer MR 70

Installation aid

BMW cooling spray Cooling spray 83 19 9 407 762 300 ml spray

Crack testing agent for aluminium
housings

Crack testing agent for aluminium
housings

83 19 9 407 855 500 ml spray

81 22 9 407 495 500 ml spray

00.11

00.12

Pre-delivery check

General view of crated motorcycle

00.13

Checking the 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.

•

Immediately notify the freight carrier (e.g. freight

•

forwarder or DB) and
Bavaria Wirtschaftsagentur GmbH
Abteilung ZW - 12

80788 München
Phone [phone]
Fax. [phone]

In case of damage in importer markets

Note the damage on the delivery slip.

•

Comply with specific national market proce-

•

dures.
In case of doubt, please submit enquiries to:
Bavaria Wirtschaftsagentur GmbH
Abteilung ZW - 12

D-80788 München
Tel. [phone]
Fax. [phone]

Immediately notify the freight carrier (e.g. freight

•

forwarder).

Unpacking the motorcycle

Lever off the cover.

•

Take out the separate pack of items:

•

– Spare keys
– Owner's Manual
– Windscreen and securing screws

Pry off the cross struts with a suitable lever.

•

e Caution:

Do not hammer out the cross struts or the motor­cycle may be damaged.

Installing remaining items on motorcycle

Wheel the motorcycle clear of the wooden pallet.

•

S000030

Carefully tighten the securing screws by hand.

•

Inspecting motorcycle for damage

Check for defects.

•

Send an “Urgent notification” to

•

BMW AG, Sparte Motorrad, UX-VS-1
Fax No. [phone]

Rectify the defect.

•

Use the electronic parts list to order parts, if

•

needed.
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 No. [phone]

Checking that delivery is complete

Remove the end panels.

•

Remove the side panels.

•

e Caution:

Remove all nails projecting from the base of the
crate or lying on the floor.

Dispose of the packing materials in an environ-

•

mentally responsible manner as described in
Service Information 23/91 - Sales.

00.14

– All optional extras
– Toolkit
– Documentation

S000020

Filling and charging the battery

Disengaging and raising the fuel tank

Remove seat.

•

Remove right and left side trim panels.

•

e Caution:

Fuel is flammable and a hazard to health. Observe
relevant safety regulations.

Remove the fuel tank.

•

Raise the rear of the fuel tank and prop it in this

•

position on a wooden block or similar.

Filling and charging the battery

d Warning:

Battery acid is severely caustic.
Protect your eyes, face, hands and clothing and the
paintwork.

Disengage the rubber strap holding the battery.

•

Disconnect the battery breather hose.

•

Remove the battery.

•

Add battery acid up to the MAX 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 MAX mark with

•

battery acid.
Charge the battery and allow to stand for

•

24 hours.

Charge current (amps)

......................... 10 % of rated battery capacity (Ah)

If necessary, top up the acid level to the MAX

•

mark with distilled water.
Make a note of the charging date on the battery.

•

00.15

e Caution:

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

Apply acid-proof grease to the battery terminal

•

posts.
Install the battery.

•

Secure the fuel tank in position.

•

Install right and left side trim panels.

•

Install dualseat.

•

Switch on the ignition.

•

Without starting the engine, fully open the throttle

•

once or twice so that the Motronic control unit
can register the throttle-valve positions.

L Note:

Disconnecting the battery deletes all entries (e.g.
faults, settings) stored in the Motronic control unit’s
memory.
Loss of settings can temporarily impair the operat­ing characteristics when the engine is restarted.

X Tightening torque:

Fuel tank to rear frame ................................. 10 Nm

Checking engine oil level when
cold, adding oil if necessary

MAX

MIN

S000040

Check the oil level with the motorcycle upright: if

•

necessary, use stand, BMW No. 00 1 560, to
keep the motorcycle in the upright position.

e Caution:

Never top up the engine-oil level past the MAX mark.

Required level:............................................... MAX

00.16

Checking clutch fluid level

Checking brake fluid level

e Caution:

Keep the brake fluid in the clutch operating system
away from painted surfaces on the motorcycle be­cause brake fluid attacks paint.

Motorcycle upright; if necessary, use stand,

•

BMW No. 00 1 560, to hold the motorcycle up­right.
Turn the handlebar fully to the right.

•

S000050

Check clutch fluid level.

•

e Caution:

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

Rear brake

Motorcycle upright; if necessary, use stand,

•

BMWNo.001560, to hold the motorcycle up­right.

MAX

S000060

Required level with a new clutch liner: ................

...........................................Half way up sight glass

Check the brake fluid level by looking through

•

the opening in the right-hand side panel.

Required level:............................................... MAX

Front brake

Motorcycle upright; if necessary, use stand,

•

BMWNo.001560, to hold the motorcycle up­right.
Handlebar centred.

•

MAX

S000071

Required level:............................................... MAX

00.17

Checking headlight beam angle,
adjusting if necessary

S000240

Motorcycle on level surface.

•

Rider’s weight on motorcycle (approx. 80 kg/

•

176 lbs).
Move swivel lever to horizontal position (basic

•

setting).
Turn the adjusting screw to correct the headlight

•

beam throw.

Checking tightness of rear wheel studs

X Tightening torque:

Rear wheel studs ....................................... 105 Nm

Checking tyre pressures

Check/correct tyre pressures.

•

Tyre pressures:

Solo ..................................... front 2.2 bar (31.3 psi)

.............................................rear 2.5 bar (35.6 psi)

Two-up ................................ front 2.5 bar (35.6 psi)

.............................................rear 2.7 bar (38.4 psi)

Two-up + luggage................ front 2.5 bar (35.6 psi)

.............................................rear 2.9 bar (41.2 psi)

Lateral adjustment:

........................Adjusting screw on left of headlight

Vertical adjustment:

......................Adjusting screw on right of headlight

Turn screw anti-clockwise: ...............longer throw

Turn screw clockwise: .....................shorter throw

S000080

Setting for headlight beam angle adjuster

.... -12 cm (4.7 in) over a distance of 10 m (32.8 ft)

00.18

Final inspection and function check

Handing over the motorcycle

Clutch

•

Check gear shift action.

•

Handbrake and foot brake

•

Check lights and signalling equipment:

•

– Front and rear parking lights
– Instrument lighting
– Low and high headlight beams, headlight flasher
– Brake light (operate front and rear brakes)
– Turn signals left/right
– Hazard warning flashers
–Horn
– Telltale and warning lights
– Instruments

Check function of optional extras:

•

– ABS: perform starting test. When a speed of

5 km/h (app. 3 mile/h) is reached, both
ABS warning lights must go out.

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.

Final cleaning

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.

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/clutch operating fluid
– provision for adjusting handlebar lever positions
– how to adjust the mirrors
– controls
– instruments and telltale lights
– optional equipment and accessories fitted.
– noise during the regular ABS self-diagnosis pro-

cedure

The user must be given the following information:

•

– running-in recommendations and inspection in-

tervals
– safety check
– the clutch fluid level rises gradually as the motor-

cycle is ridden (clutch lining wear)
– before checking the engine oil level, the engine

must be switched off for at least 10 minutes and

the motorcycle must be standing on a flat, level

surface

00.19

Maintenance

Key to maintenance intervals

– BMW Inspection 1000 km/600 miles I
– BMW Service II
– BMW Inspection III
– BMW Annual Service IV

Reading out MoDiTeC fault memory

Changing engine oil, replacing oil filter element

(Inspections I, II, III and IV)

L Note:

If the motorcycle is ridden only for short distances or

outside temperatures are below 0°C (32°F): change
the oil and replace the oil filter element every
3 months or no later than every 3 000 km
(1 800 miles).

(Inspections I, II, III and IV)

Remove seat.

•

Connect the BMW MoDiTeC to the diagnosis

•

connector.
Read out the fault memory.

•

Perform all requisite repair work.

•

Use the auxiliary stand, BMWNo.001560, if

•

necessary.
Change the oil at operating temperature.

•

Remove screw plug.

•

S000040

00.20

11 4 650

C000030

Remove oil drain plug and drain off oil.

•

Fit new seal and screw in drain plug.

•

Use oil filter wrench, BMW No. 11 4 650, to re-

•

move the oil filter.
Coat sealing ring on new oil filter element with oil

•

and install filter.
Refill with oil to correct level.

•

Insert and tighten the screw plug.

•

e Caution:

Never top up the engine oil level past the MAX mark.

X Tightening torque:

Oil filter......................................................... 11 Nm

Oil drain plug................................................ 32 Nm

Engine oil quantities:

With oil filter

change..........3.75 l (6.6 Imp. pints/3.96 US quarts)

Without oil filter

change..........3.50 l (6.2 Imp. pints/3.69 US quarts)

Difference between MIN and MAX

marks............. 0.50 l (0.88 Imp. pint/0.52 US quart)

Engine oil grade:

Brand-name HD oil for spark-ignition engines, API
classifications SF, SG, SH; combination with CD or
CE specification.
Brand-name HD oil of CCMC classification G4, G5;
amendment PD2 is permissible.

Changing oil in gearbox

(Inspections III and IV)
or every 2 years at the latest

Change the gearbox oil at operating tempera-

•

ture.

1

2

23 4 690

S000120

Remove oil filler plug (1).

•

Use socket-head key, BMW No. 23 4 690 and

•

torque wrench, to remove oil drain plug (2) and

drain the oil into a suitable container.

Clean the magnet in the oil drain plug.

•

Fit new seal and reinstall drain plug.

•

Refill with gearbox oil to correct level.

•

Insert oil filler plug with new seal.

•

X Tightening torque:

Oil drain plug................................................ 55 Nm

Oil filler plug ................................................. 23 Nm

Quantity:

Initial filling/oil changes

..........approx. 0.8 l (1.40 Imp. pint, 0.84 US quart)

Oil grade for gearbox:

Brand-name hypoid gear oil, SAE 90, API class GL 5

00.21

Changing oil in rear wheel drive;
cleaning inductive signal transmitter
at rear wheel

(Inspections I, III and IV)
Every 40 000 km (24 000 miles) or every 2 years
at the latest

Change the oil with the rear wheel drive at oper-

•

ating temperature.

1

3

2

S000130

Remove oil filler plug (1).

•

Remove oil drain plug (2) and allow the oil to

•

drain out.
Fit new seal and reinstall drain plug.

•

Refill with gearbox oil to correct level.

•

Insert oil filler plug with new seal.

•

Remove securing screw, pull out inductive signal

•

transmitter (3) and clean it.

X Tightening torque:

Oil drain plug................................................23 Nm

Oil filler plug ................................................. 23 Nm

Quantity:

To bottom edge of the filler opening

..........approx. 0.25 l (0.44 Imp. pint/0.26 US quart)

Oil grade for rear wheel drive:

Brand-name hypoid gear oil, SAE 90, API class GL 5

00.22

13 3 010

Replacing fuel filter

(Inspection III)
In normal operating conditions every 40 000 km
(24 000 miles); if fuel quality is poor every
20 000 km (12 000 miles)

Remove seat.

•

Remove left fairing side section, followed by right

•

fairing side section.
Disconnect air intake pipe from air filter box and

•

remove.

e Caution:

Fuel is flammable and a hazard to health. Observe
relevant safety regulations.

Disengage the fuel tank.

•

Seal the fuel feed and return lines with hose

•

clips, BMW No. 13 3 010, and disconnect.
Pull the plug connector off the fuel pump unit.

•

Remove the fuel tank.

•

S160010

00.23

1

2

Drain fuel tank.

•

Remove fuel pump unit.

•

Disconnect hoses from fuel filter (1).

•

Fit new fuel filter.

•

e Caution:

Note correct direction of flow through fuel filter.

Secure non-reusable hose clips with pliers,

•

BMW No. 13 1 500.

e Caution:

Make sure that O-ring (2) is in perfect condition.

S160020

e Caution:

After installing, check fuel pump unit for leaks.

L Note:

Make sure that breather lines are correctly routed.

X Tightening torque:

Fuel pump unit .............................................. 5 Nm

00.24

S000020

Checking battery fluid level and
topping up if necessary; cleaning and
greasing the battery posts

(Inspections III and IV)

If necessary, disengage fuel tank and lift at rear.

•

Release the rubber strap holding the battery.

•

Check the battery fluid level.

•

Top up the acid level to the MAX mark with dis-

•

tilled water.
Grease the battery posts.

•

Acid-proof battery-post grease:

................................................e.g. Bosch Ft 40 V1

Replacing intake air filter element

(Inspection III)
In very dirty and dusty operating conditions,
replace every 10 000 km (6 000 miles) or even
more frequently if necessary

S000010

Remove top of air-filter housing.

•

Replace air filter element.

•

Install the fuel tank.

•

Make sure that breather lines are correctly rout-

•

ed.

Install right and left side trim panels.

•

X Tightening torque:

Fuel tank to rear frame ................................. 10 Nm

00.25

Replacing Poly-V belt

(every 60 000 km/36 000 miles)

(Inspection III)

If necessary, disengage fuel tank and pull to the

•

rear.

3

12 3 510

C000060

Remove cover to expose spark plug caps.

•

Pull off spark plug caps with special puller,

•

BMWNo.123520.
Use spark plug wrench, BMW No. 12 3 510, to

•

remove the spark plugs.

4

2

1

RS110480

Slacken alternator mounting screws and

•

nuts (1,3,4) and install a new Poly-V belt if neces­sary.

Poly-V belt adjusting procedure:
Poly-V belt installation procedure:

Place the Poly-V belt in position, tension it and

•

turn the engine over once, then release belt ten­sion.

Poly-V belt tensioning procedure:

1. Hand-tighten hex nut (1) on adjusting screw (2)
(do no use tools).

2. Tighten adjusting screw (2) with a torque wrench
and keep preload applied.

3. Tighten upper retaining nut (3), then remove
torque wrench from adjusting screw.

4. Tighten all screws and nuts.

Tightening torque:

Poly-V belt preload......................................... 8 Nm

Alternator to alternator support cover........... 20 Nm

Remove front cover.

•

00.26

RS110490

Checking brake system for correct
operation and freedom from leaks;
repairing/replacing if necessary

(Inspection III)

Checking brake system for leaks.

•

Checking brake fluid level

(Inspections I, II and III)

Rear brake

Motorcycle upright; if necessary, use stand,

•

BMWNo.001560, to hold the motorcycle up-
right.

L Note:

The brake fluid volume (between MIN and MAX) is
sufficient for the complete range of pad wear from
new to the wear limit.
It is not normally necessary to top up the fluid to ac­commodate pad wear.
If the level drops below the minimum mark, this indi­cates some other fault.

Front brake

Motorcycle upright; if necessary, use stand,

•

BMW No. 00 1 560, to hold the motorcycle up­right.

MAX

MIN

MAX

MIN

S000060

Required level

Brake pads new:............................................. MAX

Brake pads worn: not less than........................ MIN

Brake fluid grade.........................................DOT 4

S000070

Handlebar centred.

•

Required level

Brake pads new.............................................. MAX

Turn the handlebar fully to the left.

•

Required level

Brake pads worn: not less than........................ MIN

Brake fluid grade .........................................DOT 4

00.27

Checking brake pads and discs for wear/replacing

(Inspections II and III)

Checking front brake pad wear

S000140

Check/measure thickness of brake pads.

•

e Caution:

Never permit brake pads to wear past the minimum
permissible thickness.
Always replace the brake pads as a complete set.

Checking brake disc wear

S000160

Examine the brake discs carefully for cracks,

•

damage, distortion, wear and score-marks.

Brake disc wear limit:

front:............................................. 4.0 mm (0.16 in)

rear:.............................................. 4.5 mm (0.18 in)

Minimum pad thickness: ............. 1.0 mm (0.04 in)

Checking rear brake pad wear

S000150

Make sure that the brake disc is not visible

•

through the bore (arrow) in the inner brake pad.
If necessary, check/measure thickness of brake

•

pads.

e Caution:

Never permit brake pads to wear past the minimum
permissible thickness.
Always replace the brake pads as a complete set.

Minimum pad thickness: ............. 1.5 mm (0.06 in)

00.28

Replacing brake pads, front brake

Replacing brake pads, rear brake

RS340021

Remove brake caliper.

•

S000170

Remove keeper (arrow) from retaining pin.

•

Drive out retaining pin.

•

Remove brake pads.

•

Installation is the reverse of the removal proce-

•

dure.
Before installing the brake caliper, force the pis-

•

tons fully back with resetting tool,
BMW No. 34 1 500.

S000180

Remove brake caliper.

•

Remove keeper (arrow) from retaining pin.

•

Drive the retaining pin out towards the wheel

•

side.
Remove brake pads.

•

Installation is the reverse of the removal proce-

•

dure.
Before installing the brake caliper, force the pis-

•

tons fully back.

X Tightening torque:

Brake caliper to rear wheel drive.................. 40 Nm

X Tightening torque:

Brake caliper to fork slider tube.................... 40 Nm

00.29

Changing brake fluid and bleeding brake system

Change the brake fluid annually
(Inspection IV)

Bleeding front brake circuit/changing brake fluid

L Note:

This description applies to brake filling and bleeding
devices with vacuum extraction of the brake fluid at
the brake caliper.
If other devices are used, comply with their manu­facturers’ instructions.

Remove brake calipers.

•

KR340280

Top up the brake fluid level to the MAX mark (ar-

•

row).

e Caution:

Keep the brake caliper parallel to the brake disc
when removing and installing.
There is a risk of damage to the brake pads.

Remove the brake pads.

•

34 1 500

S000190

Use resetting tool, BMWNo.341500, to force

•

the pistons of the right-hand brake caliper fully
back.
Turn the handlebars to the left.

•

Release the right handlebar switch.

•

Loosen the clamp screw for the handbrake fitting

•

and turn the fitting until the brake fluid reservoir
is horizontal.
Tighten the clamping screw.

•

Remove reservoir cover with rubber diaphragm.

•

e Caution:

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

e Caution:

When adding brake fluid, do not allow it to enter the
holes for the reservoir cover screws.

[ABS] Begin by bleeding the pressure modula-

•

tor.

a ..............See Additional information for [ABS]

2

1

S000261

Wrap a cloth around the filler adapter in the right

•

brake calliper.
Remove socket-head grub screw (1) from the fill-

•

er adapter in the right brake calliper.
Connect the brake bleeding device to bleed

•

screw (2).
Fully tighten the bleed screw in the filler adapter

•

(valve in filler adapter closed).
Open the bleed screw by half a turn (valve open).

•

Draw off brake fluid until it emerges clear and

•

free from air bubbles.

e Caution:

While bleeding the brakes, do not allow the brake

fluid level to drop below the “MIN” mark, or else air
will be drawn into the brake system.
Bleed the system again if this happens.

00.30

Remove the bleed screw.

•

Disconnect the brake bleeding device from the

•

bleed screw.

Install socket-head grub screw (1) in the filler

•

adapter and tighten.

e Caution:

The motorcycle is not permitted on the road without
the grubscrew in place and secure in the filler adapt­er.

Connect the brake bleeding device to the bleed

•

screw of the left-hand brake caliper.
Open the bleed screw a half turn.

•

Draw off brake fluid until it emerges clear and

•

free from air bubbles.
Close the bleed screw.

•

Assembly is the reverse of the disassembly pro-

•

cedure.
Top up the brake fluid until the level reaches the

•

“MAX” mark.

Wipe the rim of the reservoir, the rubber gaiter

•

and the cover to remove brake fluid, and carefully
re-install the components.
Align the handbrake fitting with the mark on the

•

handlebar.
Recheck the brake-fluid level.

•

Motorcycle upright; if necessary, use stand,

•

BMW No. 00 1 560, to hold the motorcycle up-
right.

Additional information for [ABS]

S000200

Before bleeding the brake caliper, connect the

•

brake bleeding device to the bleed screw on the
pressure modulator for the front brake (arrow)
marked VR (mark for rear brake is HR).
Open the bleed screw by half a turn.

•

Draw off brake fluid until it emerges clear and

•

free from air bubbles.
Close the bleed screw.

•

X Tightening torque:

Bleed screw in pressure modulator................ 9 Nm

MAX

MIN

S000071

Handlebar centred.

•

Required level

Brake pads new.............................................. MAX

Turn the handlebar fully to the left.

•

Required level

Brake pads worn: not less than........................ MIN

Check the function of the brake system.

•

Brake fluid grade .........................................DOT 4

X Tightening torque:

Brake caliper to fork tube............................. 40 Nm

Grubscrew in filler adapter ........................... 10 Nm

Bleed screw in front brake caliper................ 14 Nm

00.31

Bleeding rear brake circuit/changing brake fluid

[ABS] Begin by bleeding the pressure modula-

•

tor.

a ..............See Additional information for [ABS]

Use the auxiliary stand, BMW No. 00 1 560.

•

Remove reservoir cover.

•

MAX

MIN

S000060

Top up the brake fluid level to the “MAX” mark.

•

e Caution:

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

Assembly is the reverse of the disassembly pro-

•

cedure.
Check the function of the brake system.

•

Brake fluid grade .........................................DOT 4

X Tightening torque:

Bleed screw in rear brake caliper ................... 6 Nm

Brake caliper to rear wheel drive.................. 40 Nm

Remove the brake caliper.

•

Remove the inner brake pad.

•

Move the brake caliper to a horizontal position.

•

34 1 500

S000210

Force the pistons fully back with resetting tool,

•

BMWNo. 341500.
Connect the brake bleeding device and open the

•

bleed screw.
Draw off brake fluid until it emerges clear and

•

free from air bubbles.

e Caution:

While bleeding the brakes, do not allow the brake

fluid level to drop below the “MIN” mark, or else air
will be drawn into the brake system.
Bleed the system again if this happens.

Close the bleed screw.

•

Top up the brake fluid level to the “MAX” mark.

•

00.32

Checking clutch fluid level

Changing the clutch fluid

(Inspections I, II and III)

Place the motorcycle on the auxiliary stand,

•

BMW No. 00 1 560.
Turn the handlebars to the right.

•

MIN

S000051

Fluid level:

not below ......................................................... MIN

Required level with a

new clutch liner: ................Half way up sight glass

L Note:

As the clutch lining wears, the fluid level in the res­ervoir rises.

(Inspections III and IV)
Every 40 000 km (24 000 miles) or every 2 years
at the latest

e Caution:

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

L Note:

The description applies to a brake system filling and
bleeding device with vacuum extraction of brake flu­id at the bleed line.
If other devices are used, comply with their manu­facturers’ instructions.

Place the motorcycle on the auxiliary stand,

•

BMW No. 00 1 560, and turn the handlebars fully
to the right.
Remove reservoir cover with rubber diaphragm.

•

Top up the brake fluid.

•

1

3

If necessary, remove reservoir cover with insert.

•

Correct the fluid level. Mark in reservoir: same as

•

brake circuit.

e Caution:

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

Reinstall the reservoir cover with insert.

•

Tighten the reservoir cover without using force.

•

Brake fluid grade ..........................................DOT 4

2

Pull back protective hose (1).

•

Wrap a cloth around the filler adapter.

•

Remove socket-head grubscrew (2) from the fill-

•

er adapter.
Connect the brake bleeding device to bleed

•

screw (3).
Fully tighten the bleed screw in the filler adapter

•

(valve in filler adapter closed).
Open the bleed screw by half a turn (valve open).

•

Draw off brake fluid until it emerges clear and

•

free from air bubbles.

S000251

e Caution:

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

Remove the bleed screw.

•

Disconnect the brake bleeding device from the

•

bleed screw.
Install socket-head grub screw (2) in the filler

•

adapter and tighten.

00.33

e Caution:

The motorcycle is not permitted on the road without
the grubscrew in place and secure in the filler adapt­er.

Correct the fluid level.

•

Place the reservoir cover with rubber diaphragm

•

in position.
Tighten the reservoir cover without using force.

•

Checking tightness of rear wheel studs

(Inspection I)

Check security of the rear wheel studs with a

•

torque wrench.

X Tightening torque:

Rear wheel studs ....................................... 105 Nm

X Tightening torque:

Grubscrew in filler adapter ........................... 10 Nm

Consumables

Brake fluid.....................................................DOT 4

Checking rear wheel bearing play by tilting wheel

(Inspection III)

Tilt the rear wheel to and fro across its axle.

•

If play is detected, fit new shims to rear wheel

•

drive or replace bearings.

Checking swinging arm bearings,
adjusting if necessary

(Inspections I and III)

Grip rear tyre and try to move it sideways, brac-

•

ing against the frame.

00.34

Greasing the side stand pivot

Checking/replacing spark plugs

(Inspections I, II and III)

S000220

Check free movement of side stand and grease

•

if necessary.
Grease pivot point (arrow).

•

Lubricant:

For side stand pivot.....................Shell Retinax EP2

Checking function of side stand switch

(Inspection II) check/(Inspection III) replace

12 3 510

C000060

Remove spark plugs with the spark plug wrench,

•

BMW No. 12 3 510.

e Caution:

Do not bend electrodes – risk of breakage!

Electrode gap: .......................... 0.8 mm (0.031 in)

Gap wear limit:........................... 1.0 mm (0.039 in)

(Inspections I, II, III and IV)

Place the motorcycle on the auxiliary stand,

•

BMW No. 00 1 560.
Select a gear and switch on the ignition.

•

Slowly extend the side stand and watch the neu-

•

tral indicator light.

L Note:

As the stand is extended, the neutral indicator light
must come on briefly.

X Tightening torque:

Spark plug ................................................... 20 Nm

00.35

Tightening cylinder heads

(Inspection I)

Remove cylinder head cover.

•

e Caution:

Catch escaping oil.

C000210

Checking/adjusting valve clearances

(Inspections I, II and III)

RS110980

Check valve clearance with feeler gauge and, if

•

necessary, correct with adjusting screw.

Adjust valve clearances with the engine cold
(max. 35 °C/95 °F):

Inlet........................................... 0.15 mm (0.006 in)

Exhaust..................................... 0.30 mm (0.012 in)

TDC

C000070

Select a gear and turn the rear wheel, or set the

•

piston to TDC on the ignition stroke by turning
the belt pulley.

Top dead centre on ignition stroke:

The TDC mark is visible and the inlet and exhaust

•

valves in the cylinder concerned are closed.

Tighten cylinder head nuts.

•

Tightening procedure after 1 000 km (600 miles)

1. Tighten the cylinder head nuts one after the
other in diagonally opposite sequence

1.1. Slacken off one nut at a time

1.2. Tighten nut to initial torque.................... 20 Nm

1.3. Tighten nut to specified wrench angle ...... 180°

2. Release/retighten M10 screw................ 40 Nm

X Tightening torque:

Locknut.......................................................... 8 Nm

Recheck valve clearances after adjusting. Feeler

•

gauge must pull through between valve stem and
adjusting screw with slight resistance.
Assemble in the reverse of the disassembly pro-

•

cedure.

e Caution:

Make sure that gasket is correctly seated. Gaskets
and sealing faces must be free from oil or grease.

X Tightening torque:

Cylinder head cover ....................................... 9 Nm

00.36

Checking throttle cable for ease of
movement, abrasion and kinks;
replacing if necessary
Checking throttle-cable play
Checking/adjusting idle speed and
throttle-valve synchronisation

Play of throttle cable: .........approx. 2 mm (0.08 in)

Connect hose of BMW Synchro to vacuum

•

adapter and connect cables to BMW MoDiTeC.

Adjust idle speed by turning the air bypass

•

screws while checking that the carburettors are
balanced.

(Inspections I, II, III and IV)

Test-drive the motorcycle until the engine is

•

warm, or allow the engine to idle for approxi­mately 10 minutes.

e Caution:

Do not allow the engine to idle for longer than
20 minutes.

Oil temperature:...................at least 90 °C (194 °F)

Idle speed: ....................................... 1100

±50 min-1

L Note:

Make sure that both throttle valves are closed.

Caution:

Do not tamper with the sealed stop screws of the
throttle valves, as otherwise the idle-speed volume
flow will have to be reset by the manufacturer.

S000100

S000090

Push back rubber cap (arrow) on throttle and

•

choke cables.
Use the adjusting screws to adjust play of throttle

•

and choke cables.

Play of choke cable: .......... approx. 1 mm (0.04 in)

Play of throttle cable: ........ approx. 1 mm (0.04 in)

Remove right and left fairing panels.

•

S000100

Carefully turn the adjusting screw of the left throt-

•

tle valve and reduce play until the reading of the
Synchro tester changes.
Turn the adjusting screw very slightly in the op-

•

posite direction until the reading returns to its
original value.
Tighten the locknut to secure.

•

L Note:

Make sure that the reading does not change when
you tighten the locknut.

Adjust the right throttle valve in the same way.

•

L Note:

Zero play can cause the throttle valves to rattle.

Turn the adjusting screws to adjust the play of

•

the cables for the left and right throttle valves.

00.37

S000090

Use the adjusting screws (arrow) to adjust play of

•

the throttle cables.
Push the rubber cap into position over the ad-

•

justing screw.

Play of throttle cable: ..... approx. 0.5 mm (0.02 in)

Final inspection with road safety
and functional check

(Inspections I, II, III and IV)

Road safety check

Check wheels and tyres.

•

Check/correct tyre pressures.

•

Wait at least 10 minutes after the trial run/road

•

test before checking/correcting engine oil level.

Tyre pressures:

Solo ..................................... front 2.2 bar (31.3 psi)

.............................................rear 2.5 bar (35.6 psi)

Two up................................. front 2.5 bar (35.6 psi)

.............................................rear 2.7 bar (38.4 psi)

Two up + luggage ................ front 2.5 bar (35.6 psi)

.............................................rear 2.9 bar (41.2 psi)

Roadworthiness check

Lights

•

Telltale/warning lights

•

Horn

•

Instruments

•

Special equipment

•

Clutch

•

Gear shift

•

Steering

•

Foot brake and handbrake

•

If necessary, take the motorcycle for a test ride.

•

S000110

Use the adjusting screw (arrow) to adjust play of

•

the choke cable to zero.
Push the rubber cap into position over the ad-

•

justing screw.
Move the handlebars all the way from left to right

•

and check the settings. Make sure that engine
speed does not vary when the handlebars are
moved in this way.
Repeatedly open the throttle gradually and in-

•

crease engine speed from idle to approximately
n = 2500 min
sation. (Readings shown by Synchro tester must
increase and decrease together). If necessary,
correct by turning the adjusting screws of the
connecting cable.

-1

to check throttle-valve synchroni-

L Note:

Make sure that when the throttle grip is released
both throttle valves return to their fully closed posi­tions.

Tighten the locknuts and recheck carburettor

•

balance.
Seal off the vacuum bores.

•

00.38

11

11 Engine

Contents Page

Technical Data ...............................................................................................................................5

Cutaway drawing of engine

Lubricating-oil circuit ...............................................................................................................11

Cooling-oil circuit .......................................................................................................................13

Removing engine ........................................................................................................................15

Disassembling engine ..............................................................................................................17

Removing cylinder head cover ...............................................................................................18

Locking the engine at TDC .......................................................................................................19

Firing TDC .........................................................................................................................................19

Removing and installing chain

tensioner ...........................................................................................................................................20

Work instructions, timing-chain tensioner ..........................................................................................20

Removing valve gear holder ....................................................................................................21

Disassembling/assembling valve gear holder ..................................................................22

Removing cylinder head ............................................................................................................24

Disassembling, checking, repairing and reassembling cylinder head ..................25

Removing and installing valves ..........................................................................................................25

Removing valve stem seals ...............................................................................................................25

Checking valves for wear ..................................................................................................................26

Remachining valve seat .....................................................................................................................26

Checking and repairing cylinder head ...............................................................................................26

Checking valve guide for wear ...........................................................................................................26

Replacing valve guides ......................................................................................................................27

Installing valve and valve stem seal ...................................................................................................28

Removing cylinder ........................................................................................................................29

Removing and disassembling piston ...................................................................................29

Checking pistons and cylinders .............................................................................................30

Assembling pistons .....................................................................................................................30

Removing and installing conrod .............................................................................................31

Removing and installing alternator mount cover with engine installed .................32

Removing alternator mount cover .........................................................................................32

Replacing radial shaft seal in alternator mount cover ..................................................32

11.1

Contents Page

Removing auxiliary shaft drive ................................................................................................33

Removing oil pump ......................................................................................................................34

Removing radial shaft seal from

crankshaft with engine installed .............................................................................................35

Disassembling crankcase .........................................................................................................36

Removing crankshaft, auxiliary shaft

and timing chain tensioning and slide rails .......................................................................38

Removing and installing oil intake strainers ......................................................................39

Replacing oil level sight glass .................................................................................................39

Removing and installing oil thermostat ...............................................................................39

Removing conrods .......................................................................................................................39

Checking conrods ........................................................................................................................39

Measuring crankshaft bearing play .......................................................................................40

Measuring radial bearing play ............................................................................................................40

Installing main bearings .....................................................................................................................41

Measuring axial bearing play .............................................................................................................41

Measuring big end bearing play .............................................................................................42

Assembling engine ....................................................................................................................43

Installing conrods .........................................................................................................................43

Installing crankshaft .....................................................................................................................44

Installing timing chain tensioning and slide rails .............................................................44

Installing auxiliary shaft/timing chains .................................................................................44

Assembling engine block ..........................................................................................................45

Installing radial shaft seals on crankshaft ..........................................................................48

Installing the crankshaft-end radial shaft seal ....................................................................................48

Installing the clutch-end radial shaft seal ...........................................................................................48

Installing clutch housing ............................................................................................................49

Installing oil pump .........................................................................................................................50

Installing auxiliary shaft drive ...................................................................................................51

Installing piston ..............................................................................................................................52

Installing cylinder ..........................................................................................................................53

Installing cylinder head ...............................................................................................................54

11.2

Contents Page

Adjusting valve clearances .......................................................................................................55

Installing right cylinder head ....................................................................................................56

Adjustment specification ...................................................................................................................56

Installing left cylinder head .......................................................................................................57

Adjustment specification ...................................................................................................................57

Installing alternator mount cover ...........................................................................................59

Installing magnetic gate/belt pulley ......................................................................................59

Timing the ignition .............................................................................................................................60

Installing alternator .......................................................................................................................61

Installing engine ..........................................................................................................................62

11.3

11.4

11

Technical Data R 1100 S

Engine, general

Engine design Four-stroke flat twin, air-cooled with oil-

cooled exhaust ports, installed longitudinal­ly, 4 valves per cylinder, two overhead cam-

shafts, electronic fuel injection.
Location of engine number Crankcase
Cylinder bore mm (in) 99 (3.9)
Stroke mm (in) 70.5 (2.78)
Effective displacement cc 1085
Compression ratio 11.3 : 1
Power output kW(bhp)/min
Max. torque Nm/min

-1

72(98)/7500

-1

97/5750
Permissible maximum engine speed min-18210
Idle speed min

-1

1100

±50

Direction of rotation Clockwise, looking at ignition system
Compression test pressure

good
normal
poor

bar (psi)
bar (psi)
bar (psi)

above 10 (142)

8.5...10 (121...142)

below 8.5 (121)
Intake port dia./cylinder head mm (in) 45 (1.8)

Lubrication system

Theoretical volume in circulation at 6000 min

Lubricating oil

Cooling oil

-1

l (Imp. gal/

US gal)

30 (6.6/7.9)

l (Imp. gal/

US gal)

33 (7.3/8.7)
Oil filter Full-flow type
Pressure differential needed to open

bypass valve bar (psi) 1.5 (21.3)
Oil pressure warning light comes on below bar (psi) 0.3 (4.2)
Pressure relief valve opens at bar (psi) 5.5 (78.3)
Operating pressure bar (psi) 3.5...6.0 (49.8...85.4)
Oil capacity Without filter change

With filter change

min/max

l (Imp. pints/

US quarts)

l (Imp. pints/

US quarts)

l (Imp. pints/

US quarts)

3.50 (6.16/3.70)

3.75 (6.60/3.96)

0.5 (0.88/0.53)

Permissible oil consumption
l/1000 km (miles per Imp. pint/miles per US quart) 1.0 (350/390)

Oil pump

Oil pump 2 Duocentric pumps
Housing depth Cooling oil

lube oil

Height of rotor Cooling oil

lube oil

mm (in)
mm (in)

mm (in)
mm (in)

11.02...11.05 (0.434...0.435)

10.02...10.05 (0.394...0.396)

10.95...10.98 (0.431...0.432)

9.95...9.98 (0.392...0.393)

Axial play mm (in) 0.04...0.1 (0.002...0.004)

Wear limit mm (in) 0.25 (0.010)

11.5

Technical Data R 1100 S

Valves

Included valve angle °41
Valve clearances with engine cold (max. 35 °C/95 °F)

Inlet valve mm (in) 0.15 (0.059)
Exhaust valve mm (in) 0.30 (0.012)

Valve timing without valve clearance, 3 mm (0.12 in) valve lift

Inlet opens 5° after TDC
Inlet closes 33° after BDC
Exhaust opens 27° before BDC
Exhaust closes 5° before TDC

Tolerance ± 3°

Valve head dia.

Inlet mm (in) 34 (1.3)
Exhaust mm (in) 29 (1.1)

Stem dia.

Inlet mm (in) 4.966...4.980 (0.1955...0.1960)
Wear limit mm (in) 4.946 (0.1947)
Exhaust mm (in) 4.956...4.970 (0.1951...0.1956)
Wear limit mm (in) 4.936 (0.1943)

Valve head edge thickness

Inlet mm (in) 1.00

±0.2

(0.039

±0.008

)
Wear limit mm (in) 0.5 (0.02)
Exhaust mm (in) 1.00

±0.2

(0.039

±0.008

)
Wear limit mm (in) 0.5 (0.02)

Max. runout of valve head at valve seat

Inlet, exhaust mm (in) 0.035 (0.0014)

Valve seat ring

Valve seat angle

Inlet °45

Exhaust ° 45

Valve seat width

Inlet mm (in) 1.1

±0.15

(0.043

±0.006

)
Wear limit mm (in) 2.5 (0.10)
Exhaust mm (in) 1.4

±0.15

(0.055

±0.006

)
Wear limit mm (in) 3.0 (0.12)

Valve seat extl. dia. (dimension for machining seat)

Inlet mm (in) 33.4
Exhaust mm (in) 28.4

±0.1

±0.1

(1.315
(1.118

±0.004

±0.004

)
)

Seat ring dia. (oversize +0.2 mm/+0.008 in)

Inlet mm (in) 36.617...36.633 (1.4416...1.4422)
Exhaust mm (in) 32.134...32.150 (1.2651...1.2658)

Seat dia. in cylinder head (oversize +0.2 mm/+0.008 in)

Inlet mm (in) 36.500...36.525 (1.4370...1.4380)
Exhaust mm (in) 32.000...32.025 (1.2599...1.2608)

11.6

Technical Data R 1100 S

Valve guide

Valve guide Extl. dia. mm (in) 12.533...12.544 (0.4934...0.4939)
Bore in cylinder head mm (in) 12.500...12.518 (0.4921...0.4928)
Overlap mm (in) 0.015...0.044 (0.0006...0.0017)
Repair stages
Replacement valve guide Extl. dia. mm (in) 12.550...12.561 (0.4941...0.4945)
Oversize valve guide Extl. dia. mm (in) 12.733...12.744 (0.5013...0.5017)
Valve guide Intl. dia. mm (in) 5.0...5.012 (0.1969...0.1973)
Radial clearance

Inlet mm (in) 0.020...0.046 (0.0008...0.0018)

Wear limit mm (in) 0.15 (0.006)
Exhaust mm (in) 0.030...0.056 (0.0012...0.0022)
Wear limit mm (in) 0.17 (0.007)

Valve spring

Spring length, off-load mm (in) 41.1 (1.62)

Wear limit mm (in) 39.0 (1.54)

Rocker

Bore mm (in) 16.016...16.027 (0.6306...0.6310)
Rocker shaft dia. mm (in) 15.973...15.984 (0.6289...0.6293)
Radial clearance mm (in) 0.032...0.054 (0.0016...0.0021)

Wear limit mm (in) 0.1 (0.004)

Axial play min. mm (in) 0.05 (0.002)

max. mm (in) 0.40 (0.016)

Camshaft

Opening angle, inlet/exhaust cams 300°
Cam spread, inlet/exhaust 109°/106°
Marking Mark in

position 4

Inlet valve lift mm (in) 9.7 (0.38) (valve clearance = 0)
Exhaust valve lift mm (in) 9.3 (0.36) (valve clearance = 0)
Camshaft bearing bore mm (in) 21.02...21.04 (0.8276...0.8284)
Camshaft dia. mm (in) 20.97...21.00 (0.8256...0.8268)
Radial clearance mm (in) 0.02...0.07 (0.0008...0.0028)

Wear limit mm (in) 0.15 (0.006)
Width of guide bearing mm (in) 15.92...15.95 (0.6268...0.6280)
Width of camshaft bearing mm (in) 16.0...16.05 (0.6299...0.6319)
Axial play mm (in) 0.08...0.13 (0.0031...0.0051)

Wear limit mm (in) 0.25 (0.010)

11.7

Technical Data R 1100 S

Bucket-type tappet

Extl. dia. mm (in) 23.947...23.960 (0.9428...0.9433)
Bore in cylinder head mm (in) 24.000...24.021 (0.9449...0.9457)
Radial clearance mm (in) 0.040...0.074 (0.0016...0.0029)

Wear limit mm (in) 0.18 (0.007)

Auxiliary shaft

Bore in crankcase

front/back mm (in) 25.020...25.041 (0.9851...0.9859)

Auxiliary shaft dia.

front/back mm (in) 24.959...24.980 (0.9827...0.9835)

Radial clearance mm (in) 0.040...0.082 (0.0016...0.0032)

Wear limit mm (in) 0.17 (0.007)

Crankshaft

Marking of main bearing and crankpin on front crank
web

no paint mark Grinding stage 0
paint mark Grinding stage 1 (-0.25 mm/-0.010 in)

Grinding stage 0

(grinding stage 1 = —0.25 mm/–0.01 in)
Guide bearing bore mm (in) 64.949...64.969 (2.5571...2.5579)
Guide bearing dia. mm (in) Green: 59.964...60.003 (2.3609...2.3624)

mm (in) Yellow: 59.974...60.013 (2.3612...2.3628)

Main bearing journal dia. mm (in) Green: 59.939...59.948 (2.3598...2.3602)

mm (in) Yellow: 59.949...59.958 (2.3602...2.3606)

Radial clearance mm (in) 0.016...0.064 (0.0006...0.0025)

Wear limit mm (in) 0.1 (0.004)
Main bearing bore mm (in) 60.000...60.019 (2.3622...2.3629)
Main bearing dia. mm (in) Green: 54.998...55.039 (2.1653...2.1669)

mm (in) Yellow: 55.008...55.049 (2.1657...2.1673)

Main bearing journal dia. mm (in) Green: 54.971...54.980 (2.1643...2.1646)

mm (in) Yellow: 54.981...54.990 (2.1646...2.1650)

Radial clearance mm (in) 0.018...0.068 (0.0007...0.0028)

Wear limit mm (in) 0.13 (0.005)
Width of guide bearing mm (in) 24.890...24.940 (0.9799...0.9819)
Width of main bearing journal mm (in) 25.020...25.053 (0.9851...0.9864)
Axial play mm (in) 0.080...0.163 (0.0031...0.0064)

Wear limit mm (in) 0.2 (0.008)
Grinding stage 0 (grinding stage 1 = –0.25 mm/–0.01 in)
Crankpin dia. mm (in) 47.975...47.991 (1.8888...1.8894)
Width of crankpin mm (in) 22.065...22.195 (0.8687...0.8738)

11.8

Technical Data R 1100 S

Connecting rod

Big-end bore mm (in) 51.000...51.013 (2.0079...2.0084)
Big end bearing dia. mm (in) 48.016...48.050 (1.8904...1.8918)
Radial clearance mm (in) 0.025...0.075 (0.010...0.0030)

Wear limit mm (in) 0.13 (0.005)
Width of big end bearing eye mm (in) 21.883...21.935 (0.8616...0.8636)
Conrod end float mm (in) 0.130...0.312 (0.0051...0.0123)

Wear limit mm (in) 0.5 (0.02)
Small-end bore mm (in) 22.015...22.025 (0.8664 ... 0.8671)
Radial clearance mm (in) 0.015...0.030 (0.0006...0.0012)

Wear limit mm (in) 0.06 (0.002)
Distance between centers mm (in) 125 (4.92)
Max. deviation from parallel of conrod bores

at distance of 150 mm (5.90 in) mm (in) 0.07 (0.003)

Cylinders

Bore (20 mm/0.79 in from top edge)

A mm (in) 98.992...99.000 (3.8974...3.8977)

Wear limit mm (in) 99.050 (3.8997)

B mm (in) 99.000...99.008 (3.8977...3.8980)

Wear limit mm (in) 99.058 (3.9000)
Total wear clearance of piston and cylinder mm (in) 0.12 (0.005)
Permitted out-of-round of cylinder bore
20 mm (0.79 in) from the top edge mm (in) 0.03 (0.001)
100 mm (3.94 in) from the top edge mm (in) 0.04 (0.002)

Pistons

Piston dia. (Measuring plane A — see Checking pistons and

cylinders)
A mm (in) 98.971...98.983 (3.8966...3.8970)
Wear limit mm (in) 98.895 (3.8936)
B mm (in) 98.983...98.995 (3.8970...3.8975)
Wear limit mm (in) 98.905 (3.8940)
AB mm (in) 98.979...98.987 (3.8969...3.8972)
Wear limit mm (in) 98.900 (3.8938)

Installed clearance mm (in) 0.005...0.029 (0.0002...0.0011)
Total wear clearance of piston and cylinder mm (in) 0.12 (0.005)
Piston pin bore mm (in) 22.005...22.011 (0.8664...0.8666)
Weight classes + and —
Weight difference in one class grammes

(oz.) 10 (0.353) (complete with pins and rings)

Direction of installation Arrow on piston crown pointing to exhaust side

Production locating point towards exhaust side

(see Installing piston)

11.9

Technical Data R 1100 S

Piston rings

1st groove Piston ring

asymmetric, convex oval
Thickness mm (in) 1.170...1.190 (0.0461...0.0469)
Wear limit mm (in) 1.1 (0.04)

End gap mm (in) 0.1...0.3 (0.004...0.012)

Wear limit mm (in) 0.8 (0.03)

Side clearance mm (in) 0.030...0.070 (0.0012...0.0027)

Wear limit mm (in) 0.15 (0.006)

2nd groove Micro-taper compression ring

Thickness mm (in) 1.175...1.190 (0.0463 ...0.0469)
Wear limit mm (in) 1.1 (0.04)

End gap mm (in) 0.1...0.3 (0.004...0.012)

Wear limit mm (in) 0.8 (0.03)

Side clearance mm (in) 0.030...0.065 (0.0012...0.0026)

Wear limit mm (in) 0.15 (0.006)

3rd groove 3 - S ring

Height mm (in) 2.0 (0.078)
Wear limit mm (in) 1.9 (0.075)

End gap mm (in) 0.30...0.60 (0.012...0.024)

Wear limit mm (in) 1.20 (0.047)

Side clearance mm (in) 0.020...0.055 (0.0008...0.0022)

Wear limit mm (in) 0.15 (0.006)

Installed direction of piston rings “Top” marking uppermost

Piston pin

Piston pin dia. mm (in) 21.995...22.000 (0.8664...0.8662)

Wear limit mm (in) 21.960 (0.8646)
Bore in piston mm (in) 22.005...22.011 (0.8664...0.8666)
Radial clearance in piston mm (in) 0.005...0.016 (0.0002...0.0006)

Wear limit mm (in) 0.070 (0.0028)

11.10

Cutaway drawing of engine

11.11

Lubricating-oil circuit

11.12

Cooling-oil circuit

11.13

11.14

Removing engine

L Note:

Auxiliary shaft, timing chains, chain tensioner/guide
rails and crankshaft can only be disassembled after
the engine has been removed. All other components
can be disassembled with the engine installed.

Drain engine oil.

•

[ABS] Fully drain the brake system.

•

00 1 520

S110010

Secure stand, BMW No. 00 1 520, to motorcy-

•

cle.
Remove seat.

•

Remove left side trim.

•

Remove right side trim.

•

Remove the intake air pipe.

•

Disengage the fuel tank.

•

e Caution:

Fuel is flammable and a hazard to health. Observe
relevant safety regulations.

Seal the fuel feed and return lines with hose

•

clips, BMW No. 13 3 010, and disconnect.
Pull the plug connector off the fuel pump unit.

•

Lift off fuel tank.

•

Remove the battery.

•

[ABS] Disconnect plug from pressure modulator.

•

[ABS] Disconnect brake lines from pressure

•

modulator.

S340071

[ABS] Remove cover and disconnect cables.

•

e Caution:

Comply exactly with the instructions in the Repair
Manual.
aGroup 34/Removing ABS unit

[ABS] Remove the pressure modulator.

•

Remove the rear side panel on the right.

•

Disconnect plug for rear wiring harness.

•

[ABS] Disconnect sensor plug.

•

Disconnect plug for brake-light switch.

•

Disconnect plug for inductive sensor, speedom-

•

eter.
Release right footrest plate.

•

[ABS] Remove rear brake lines.

•

Disconnect gearshift linkage at ball head.

•

Disconnect plug for lambda sensor.

•

Disconnect rear silencer from front silencer.

•

Remove lambda sensor.

•

Disconnect main frame and use workshop crane,

•

BMWNo.465640, to lift main frame.

e Caution:

Disconnect negative terminal first, then positive ter­minal.

Remove the rear brake caliper.

•

[ABS] Remove rear sensor.

•

Remove inductive sensor from rear wheel drive.

•

The motorcycle is heavy at the rear; use a ratch-

•

et-lock belt to pull the motorcycle down at the
nose on the lifting platform.
Remove rear wheel.

•

Remove retainer from rubber bellows of swinging

•

arm at rear wheel drive.
Swinging-arm bearing studs are secured with

•

Loctite: heat to max. 120 °C (248 °F) to release.

Slacken nut of swinging-arm floating bearing.

•

Loosen the floating bearing stud bolt.

•

Loosen the fixed bearing stud bolt.

•

Disengage reaction link from rear wheel drive.

•

Remove fixed and floating bearing stud bolts and

•

remove rear wheel drive.
Remove screw at top of suspension strut.

•

S330170

Use a screwdriver to press out the universal

•

shaft.
Disconnect plug for air-temperature sensor from

•

air filter box.
Release hose clips at the air intake necks.

•

Push the air intake necks into the air filter box.

•

11.15

Use pliers, BMW No. 17 5 500, to release hose

•

clip securing breather hose to air filter box.
Remove air filter box.

•

Remove starter-motor cover.

•

Remove the starter motor.

•

Disconnect plug for gearshift switch.

•

Release the clutch slave cylinder and pull it out

•

of the housing.
Release the battery carrier can pull it up and out

•

of the rubber mount.
Remove the fuel distributor with injectors.

•

Remove the gearbox securing screws.

•

23 1 820

Remove front silencer.

•

Use a strap with ratchet latch to secure bottom

•

fork bridge to top fork bridge.

L Note:

This precaution is necessary, as otherwise the fork
would fall apart.

Use workshop crane to raise the entire front end

•

of the motorcycle.
Installation is the reverse of the removal proce-

•

dure.

23 1 820

Always use guide pins, BMW No. 23 1 820, when

•

removing or installing the gearbox.
Remove the windshield.

•

Secure the top fork bridge to workshop crane,

•

BMWNo.465640.
Disconnect suspension strut from leading link.

•

Heat the ball joint mount at the leading link to

•

max. 120 °C (248 °F) and disengage.

Release throttle flap stub pipes.

•

Remove the leading link caps.

•

Remove the left screw cap.

•

Remove the circlip at the right and the safety

•

cap.
Remove the screw at the right and pull the shaft

•

out to the left.

RS230010

e Caution:

Do not scratch the surface of the leading link.

Pull telescopic fork forwards.

•

Remove the leading link.

•

Disconnect oil cooler return line from oil cooler.

•

Remove screws securing oil cooler return line to

•

fairing bracket.
Disconnect oil cooler supply line from engine.

•

Disconnect plug for oil-temperature sensor.

•

Disconnect plug for oil-pressure switch.

•

Disconnect cables from three-phase generator.

•

Disconnect cables from cable guide/engine.

•

Disconnect plug from Hall sensor.

•

Remove bolts from front frame.

•

Pull off spark plug caps with special puller,

•

BMW No. 12 3 520.
Disconnect Motronic control unit.

•

Remove battery carrier.

•

Disconnect ground cable from engine.

•

Disconnect plug for side stand.

•

Remove side stand with retaining plate.

•

Remove manifolds.

•

11.16

Disassembling engine

Secure engine mount, BMW No. 11 0 630, to the

•

engine block.
Transfer engine to assembly frame.

•

00 0 630

RS110010

11 4 650

Drain engine oil.

•

Remove the oil filter, using oil filter wrench,

•

BMW No. 11 4 650.

RS110950

11.17

12 3 510

RS110020

Removing cylinder head cover

Remove spark plugs with the spark plug wrench,

•

BMW No. 12 3 510.
Remove cylinder head cover.

•

e Caution:

Catch escaping oil.

11.18

TDC

11 5 640

RS110030

Locking the engine at TDC

Remove front cover.

•

Turn the belt pulley to bring the piston to firing

•

TDC.

Firing TDC

1. TDC mark is visible, and

2. The inlet and exhaust valves of the cylinder in
question are closed.

Lock the clutch housing with special tool,

•

BMW No. 11 5 640.

11 2 650

TDC

RS110461

L Note:

The engine can be locked at TDC by inserting locat­ing pin, BMW No. 11 2 650, through the hole in the
clutch housing and the engine block.

11.19

Removing and installing chain tensioner

e Caution:

Do not mix up the chain tensioner pistons. When in­stalling, fit a new seal.

Work instructions, timing-chain tensioner

Removing:

Remove timing chain tensioner, then remove

•

camshaft sprocket from camshaft.

Installing:

First install camshaft sprocket, then timing chain

•

tensioner.

e Caution:

Failure to observe this sequence can cause the
chain tensioner piston on the left to drop into the
timing-chain chamber.

X Tightening torque:

Chain tensioner............................................ 32 Nm

RS110060

11.20

2

M6 x 60

M6 x 30

Removing valve gear holder

M6 x 30

M6 x 30

1

S110110

Remove valve gear holder.

•

Secure rockers with a rubber band (2).

•

L Note:

If no work is carried out on the valve gear holder, re­move it together with the cylinder head.

RS110051

Remove camshaft sprocket cover.

•

Remove/pull off camshaft sprocket.

•

L Note:

If the camshaft sprocket (1) is not removed after
loosening, it must be held firmly and prevented from
falling into the engine block (e.g. with a cable strap).

11.21

M8 x 40

M8 x 30

M8 x 40

RS110080

Disassembling/assembling valve gear holder

Remove bearing cap.

•

Insert a suitable pin into the bore (arrow) of the

•

rocker shaft, and turn the shaft back and forth to
remove it from its bearing.
Remove pushrods.

•

e Caution:

Do not mix up the rocker shafts and pushrods.

11.22

1

M8 x 65

3

2

Remove camshaft bearing cap (1).

•

Remove camshaft and bearing (2).

•

Remove bucket-type tappets.

•

e Caution:

Do not mix up the bucket-type tappets.

Assembly is the reverse of the disassembly pro-

•

cedure.

e Caution:

Note direction of installation (3) for camshaft bearing
cap. Rocker-shaft recess must be aligned with the
bores.

L Note:

Locate pushrods in ball cups of rockers and hold the
rockers together with a rubber band to secure the
pushrods in position.

X Tightening torque:

M 8 screw, rocker shaft bearing cap ............ 15 Nm

M 8 screw for camshaft bearing cap ........... 15 Nm

RS110090

RS110100

Adjust the holder for minimum end float.

•

End float of rockers:

min............................................ 0.05 mm (0.002 in)

max. ......................................... 0.40 mm (0.016 in)

11.23

M6 x 30

M10 x 70

Removing cylinder head

M6 x 30

M6 x 30

RS110110

11.24

11 5 690

Disassembling, checking, repairing
and reassembling cylinder head

11 1 250

RS110130

Removing and installing valves

e Caution:

Do not scratch sealing face on cylinder head. Place
the head on a clean, non-scratching surface.

Mount valve spring compressor,

•

BMW No. 11 5 690, on cylinder head.
Compress the valve springs.

•

Gently tap valve head to release collets from

•

spring retainer.
Remove valve collet sections.

•

Relieve tension on valve springs.

•

Remove top and bottom spring retainers, valve

•

springs and valves.

Removing valve stem seals

Pull off valve stem seal with pliers,

•

BMW No. 11 1 250.

L Note:

If a valve is removed, the valve stem seal must be re­placed.

11.25

Checking valves for wear

Clean combustion residue from valves.

•

Check valve dimensions.

•

a ............................................see Technical Data

Remachining valve seat

D

B

RS110890

e Caution:

Width (B) and diameter (D) must always be main­tained if valve seat is machined.

a ............................................see Technical Data

Checking and repairing cylinder head

Remove combustion residues from combustion

•

chamber.
Check sealing face for damage/distortion, and

•

skim flat if necessary.

Skimming sealing

face: ........... max. 0.2 mm (0.008 in) metal removal

Checking valve guide for wear

Check valve guide bore.

•

a ............................................see Technical Data

11.26

Replacing valve guides

Heat cylinder head slowly and uniformly to

•

200 °C (392 °F) in a suitable oven.

e Caution:

Wear protective gloves when handling heated parts.

Drive out valve guides with 5 mm (0.20 in) dia.

•

drift, BMW No. 11 5 674, from the combustion
chamber side.
Allow cylinder head to cool down to room tem-

•

perature (app. 20 °C/68 °F).
Examine valve guide bore for:

•

–wear,
– widening taper and
– correct dimensions in H7 tolerance range

(12.500...12.518 mm/0.4921...0.4928 in).

L Note:

Valve guides are press-fitted in the cylinder head
with an interference fit of 0.015...0.044 mm
(0.0006...0.0017 in).

If valve guide bore is undamaged and dimen­sions are within correct 12.5 H7 tolerance range:

Use original 12.5 U6 (12.533...12.544 mm/

•

0.4934...0.4939 in) valve guide.
Measure valve guides with micrometer.

•

Slowly heat cylinder head to 200 °C (392 °F) in a

•

suitable oven.
Immerse valve guide in liquid grinding paste.

•

Chill valve guide with dry ice.

•

e Caution:

Immediately before pressing in, the temperature

must be –40 °C (–40 °F).

Place heated cylinder head flat on workbench or

•

a similar surface.

Mount the chilled valve guide on Ø 5 mm (0.20 in)

•

drift, BMW No. 11 5 673.

Drive valve guides into cylinder head with no de-

•

lay.
Allow cylinder head to cool down to room tem-

•

perature, app. 20 °C (68 °F).
Inspect bores of valve guides.

•

L Note:

Valve guides for repair purposes are produced with
an internal diameter of 5.01 mm (0.1972 in) H7.
In most cases, the bore is within the 5.00 mm
(0.1969 in) H7 tolerance range after pressing in.
If the bore is too narrow, ream it out to size.

If valve guide bore is undamaged but slightly
larger than the 12.5 H7 tolerance range:

Use replacement valve guide

•

12.550...12.561 mm (0.4941...0.4945 in).

If valve guide bore is damaged or not to correct
dimensions in 12.5 H7 tolerance range:

Use an oversize 12.7 U6 (12.733...12.744 mm/

•

0.5013...0.5017 in) valve guide.

Repair method 1 – ream out the bore
(if bore is damaged or not to correct dimensions)

Determine actual diameter of valve guide using

•

micrometer.

Ream bore with Ø12.7 H7 mm

•

(12.700...12.718 mm/0.5000...0.5007 in) ream­er.

Repair method 2 – turn the valve guide on a lathe
(bore must not be damaged)

Measure bore with internal measuring tool.

•

Calculate the nominal diameter of the valve

•

guide:

Required diameter of valve guide = bore dia. + inter­ference-fit value (0.015...0.044 mm/

0.0006...0.0017 in).
Use an oversize 12.7 U6 (12.733...12.744 mm/

•

0.5013...0.5017 in) valve guide.
Machine oversize valve guide to required diame-

•

ter.

11.27

11 5 690

11 5 602

RS110160

Installing valve and valve stem seal

L Note:

If a valve was removed, the valve stem seal must be
replaced.

Oil the stem before installing the valve.

•

Shrink a short length of tube (arrow) on to the end

•

of the valve stem.
Install the valve stem seal with a 5 mm (0.20 in)

•

dia. drift, BMW No. 11 5 602.

e Caution:

Remove the shrink-fit tube.

Install lower spring retainer, valve spring and up-

•

per spring retainer.
Compress the valve springs with the valve spring

•

compressor, BMW No. 11 5 690.

L Note:

Apply grease to valve collets (to facilitate installation)
and install.

e Caution:

Make sure that valve collets are correctly seated in
the valve stem grooves.

Relieve tension on valve springs.

•

Check valves for leakage (blow-by).

•

11.28

1

Removing cylinder

Remove guide rail bearing screws (1).

•

Remove cylinder retaining screws, and remove

•

cylinder.

e Caution:

When removing cylinder, make sure that the piston
does not strike the engine block.

Removing and disassembling piston

Remove both retaining rings from piston pin.

•

Press out piston pin by hand.

•

Remove piston.

•

Carefully remove piston rings with piston ring pli-

•

ers.
Remove combustion residues from piston crown

•

and clean piston.

RS110170

e Caution:

Do not mix up pistons, piston pins and piston rings.

11.29

Checking pistons and cylinders

Reference temperature for measurements:

...........................................................20 °C (68 °F)

20

100

RS110180

Measure cylinder bore with internal probe at

•

20 mm (0.79 in) and 100 mm (3.94 in) from the
top in direction of piston pin, and again at a right
angle to the first measurement.

a ............................................See Technical Data

A

Assembling pistons

1.

TOP

2.

3.

S110170

Carefully fit piston rings to piston in the following

•

sequence, using piston ring pliers:
3rd groove - 3-S ring
2nd groove - micro-chamfer ring
1st groove - asymmetric piston ring, oval section

a ............................................See Technical Data

L Note:

Make sure that the gap of the spring in the 3-S ring

is offset approximately 180° from the gaps of the oil
control rings.

RS110970

Measuring plane A: .........................6 mm (0.24 in)

a ............................................See Technical Data

Install piston rings in cylinder.

•

RS110200

Measure end gap using feeler gauge.

•

a ............................................See Technical Data

11.30

TDC

11 2 500

11 5 640

Removing and installing conrod

Turn crankshaft to TDC position.

•

Lock the clutch housing with special tool,

•

BMW No. 11 5 640.
Remove conrods.

•

L Note:

Conrods can also be removed and installed with the
crankshaft removed.

e Caution:

Make sure that conrods and bearing shells are rein­stalled in their original positions.
Use a felt-tipped pen or similar to mark the installed
positions on the conrods.

RS110210

e Caution:

Oil the bearings.

Screw the big end bolts in by hand, then tighten

•

them with a tightening angle indicator,
BMW No. 11 2 500.

e Caution:

Never re-use the big end bolts.

X Tightening torque:

Big end bolts oiled

Joint torque.................................................. 20 Nm

Wrench angle.................................................... 80°

Install conrods.

•

11.31

11 5 640

3

2

1

S110020

Removing and installing alternator mount
cover with engine installed

e Caution:

Disconnect earth (ground) lead from battery.
Insulate earth (ground) lead.

Remove the horn.

•

Remove the oil cooler line.

•

Disconnect the Hall sensor.

•

Remove the starter motor.

•

Remove rear leading link mount.

•

Removing alternator mount cover

Remove the alternator.

•

Lock the clutch housing with special tool,

•

BMW No. 11 5 640.
Remove pulley (1).

•

Remove magnetic gate (2).

•

L Note:

It is not necessary to remove magnetic gate (2) when
removing the alternator mount cover as a unit.

Remove alternator mount cover (3).

•

Replacing radial shaft seal in alternator
mount cover

11 5 680

RS110240

Carefully lever out radial shaft seal, using a

•

screwdriver.
Drive in the new radial shaft seal with drift and

•

sliding sleeve, BMW No. 11 5 680.

L Note:

Slide new radial shaft seal over taper on sliding
sleeve, pre-shape and pull off.

11.32

11 5 640

2

3

4

Removing auxiliary shaft drive

8

1

6

5

7

S110030

Align marks (arrows) on timing pinion and chain

•

sprocket.
Remove banjo bolt of cooling oil pipe (1) and

•

swing the pipe forwards.
Remove chain tensioner (2).

•

Remove chain tensioning rail (3).

•

Remove chain guide rail (4).

•

Lock the clutch housing with special tool,

•

BMW No. 11 5 640.
Remove chain sprocket retaining bolt (5).

•

Remove sprocket (6) and timing chain (7).

•

If necessary, remove chain sprocket (8).

•

S110120

11.33

3

1

M6 x 45

Removing oil pump

Remove oil pump cover (1).

•

Remove complete oil pump (2) together with

•

cooling oil pipe (3), and disassemble.

e Caution:

Check installed positions of parts which have al­ready been run together.

2

M6 x 50

M6 x 45

M6 x 50

M6 x 45

RS110410

11.34

Removing radial shaft seal from
crankshaft with engine installed

Lock clutch housing with special tool,

•

BMW No. 11 5 640.
Remove the clutch.

•

S110040

11 5 640

S210010

00 8 582

00 8 581

00 8 583

S110100

Using awl, BMW No. 00 8 583, carefully punch a

•

hole in the shaft sealing ring.
Screw the pull rod, BMW No. 00 8 581, into the

•

hole and use impact weight, BMW No. 00 8 582,
to remove the shaft sealing ring.

Carefully lever out radial shaft seal, using a

•

screwdriver.

e Caution:

Take care not to damage the sealing faces of crank­case and crankshaft.

L Note:

The radial shaft seals can be removed when the
crankcase is disassembled.

11.35

M8 x 80

M8 x 80

M10 x 100‹

M10 x 100‹

M8 x 35

M8 x 35

RS110261

Disassembling crankcase

Turn engine on to its side.

•

Remove screws on right side.

•

11.36

M6 x 50

M6 x 35

M10 x 100‹

M6 x 35

M6 x 35

M6 x 50

M6 x 25

M10 x 100‹

M6 x 50

M6 x 50

M6 x 50

M6 x 50

M6 x 25

M6 x 25

M6 x 35

M6 x 35

M6 x 35

Turn engine on to its side.

•

Remove screws on left side.

•

Remove upper section of crankcase.

•

M6 x 50

M6 x 35

M6 x 50

M6 x 50

RS110260

11.37

Removing crankshaft, auxiliary shaft
and timing chain tensioning and slide
rails

11.38

S110050

Removing and installing oil intake strainers

S110060

X Tightening torque:

M 6 screw ......................................................9 Nm

e Caution:

Make sure that the O-ring is not omitted, and is in­stalled undamaged.

Removing conrods

Clamp crankshaft in a vise with protective jaws.

•

Remove conrod.

•

e Caution:

Do not mix up the conrods.

Checking conrods

Check conrod dimensions.

•

a ........................................... See Technical Data

e Caution:

Do not attempt to straighten the sintered conrods –
risk of fracture.

Replacing oil level sight glass

Pierce the plastic disc with a large screwdriver

•

and lever out the oil level sight glass.
Coat the sealing face of the new oil level sight

•

glass with engine oil and drive it in with drift,
BMW No. 00 5 550.

Removing and installing oil thermostat

1

3

2

S110070

Remove screws securing oil cooler line to fairing

•

bracket.
Disconnect oil cooler line from crankcase.

•

Remove support plate (1), control element (2)

•

and spring (3).
Installation is the reverse of the removal proce-

•

dure.

X Tightening torque:

M 6 screw ......................................................9 Nm

11.39

Measuring crankshaft bearing play

Measuring radial bearing play

Measure main bearing journal with an external

•

micrometer in two planes, A and B, at right an­gles.
Enter measured values on record sheet.

•

a ........................................... See Technical Data

e Caution:

The crankshaft can only be reground in grinding
stage 0; after this it must be rehardened and fin­ished. Grinding stages are identified by a paint mark
on the front crank web.

a ................................ See Technical Data

When replacing the bearing shells, make sure that
the colour marks on the crankpins and big end bear­ings match.

RS110310

11.40

1

RS110320

Installing main bearings

Insert tensioner rail/slide rail pivot pin (1) for

•

centering purposes.
Tighten M 8 and M 10 crankcase screws.

•

X Tightening torque/tightening order:

1. M 10 screw (oiled) Initial torque ......... 25 Nm

Wrench angle............ 90°

2. M 8 screw (oiled)......................................22 Nm

Measure front and rear main bearings in the load

•

direction.
Enter measured values on record sheet and cal-

•

culate main bearing play.

a ........................................... See Technical Data

Measuring axial bearing play

Place crankshaft in crankcase.

•

Insert tensioner rail/slide rail pivot pin (1) for

•

centering purposes.
Tighten crankcase screws.

•

00 2 500

00 2 510

RS110910

Screw measuring device, BMW No. 00 2 500,

•

with dial gauge, BMW No. 00 2 510, into tapped
hole for alternator carrier cover.
Move crankshaft forwards and backwards and

•

read axial play from dial gauge.

a ........................................... See Technical Data

11.41

Measuring big end bearing play

Measure crankpin with an external micrometer in

•

the thrust direction and at right angles to the
thrust direction.

11 2 210

RS110350

Install bearing shells and assemble conrods.

•

Using tightening angle indicator,

•

BMW No. 11 2 210, tighten the big end bolts.

RS110340

RS110360

Measure big end bearing with internal gauge in

•

thrust direction.
Enter measured values on record sheet and cal-

•

culate big end bearing play.

a ........................................... See Technical Data

X Tightening torque:

Big end bolts oiled

Joint torque..................................................20 Nm

Wrench angle.................................................... 80°

11.42

Assembling engine

Installing conrods

11 2 500

RS110370

Clamp crankshaft in a vise with protective jaws.

•

Oil the big end bolts, screw them in by hand and

•

tighten with tightening angle indicator,
BMW No. 11 2 500.

e Caution:

Oil the bearings.
Make sure that conrods and bearing shells are re­installed in their original positions.
Always use new big end bolts.
Use a felt-tipped pen or similar to mark the installed
positions on the conrods.

X Tightening torque:

Big end bolts (oiled)

Joint torque.................................................. 20 Nm

Wrench angle.................................................... 80°

11.43

u

2

3

Installing crankshaft

e Caution:

Oil the bearings.

Installing timing chain tensioning and
slide rails

Seal pivot pin for tensioner rail/slide rail at clutch

•

side (arrow) with 3-Bond 1209.
Insert pivot screw (1) into chain tensioner rail, us-

•

ing a new seal.

X Tightening torque:

Chain guide rail pivot pin..............................18 Nm

1

S110080

Installing auxiliary shaft/timing chains

When installing the auxiliary shaft, make sure that

•

the bore in the auxiliary shaft (2) facing the crank­shaft is in line with the crankcase mating face.

e Caution:

Timing chains (3) must mesh fully with auxiliary shaft
sprockets.

11.44

u

M10 x 100‹

M6 x 50

M6 x 50

M6 x 50

M6 x 50

M6 x 50

M6 x 25

M6 x 25

M6 x 35

M6 x 35

M6 x 35

M6 x 50

1

M10 x 100‹

M6 x 35

M6 x 35

M6 x 35

M6 x 50

M6 x 25

M6 x 35

M6 x 50

M6 x 50

Assembling engine block

Clean and degrease sealing faces (arrow) and

•

coat with 3-Bond 1209.
Secure the timing chain with rubber band (1) to

•

the timing chain tensioner and slide rail.

RS110920

11.45

M8 x 80

M8 x 80

M10 x 100‹

M10 x 100‹

M8 x 35

M8 x 35

RS110391

Bolt the crankcase sections together.

•

X Tightening torque/tightening order:

1. M 10 screw (oiled) Initial torque .......... 25 Nm

Wrench angle............. 90°

2. M 8 screw (oiled)......................................22 Nm

3. M 6 screw .................................................. 9 Nm

11.46

11 5 702

11 5 703

11 5 703

11 5 701

11 5 702

11 5 703

11 5 703

11 5 703

11 5 662

11 5 661

00 5 500

11 5 662

00 5 500

11 5 661

11 5 661

00 5 500

11.47

Installing radial shaft seals on crankshaft

Installing the crankshaft-end radial shaft seal

Shape the lip of the radial shaft seal carefully by

•

hand (1).
Oil the radial shaft seal at the sealing/contact

•

surface.
Using assembly sleeve, BMW No. 11 5 702,

•

mount the radial shaft seal with the closed side
toward the clutch onto sleeve,
BMWNo.115703, (2).
Remove assembly sleeve (3).

•

Mount sleeve complete with radial shaft seal on

•

crankshaft (4).
Use drift, BMW No. 11 5 701, together with the

•

sleeve (5) to drive the radial shaft seal onto the
crankshaft.
Remove sleeve (6).

•

Installing the clutch-end radial shaft seal

Shape the lip of the radial shaft seal carefully by

•

hand (7).
Oil the radial shaft seal at the sealing/contact

•

surface.
Using assembly sleeve, BMW No. 11 5 662,

•

mount the radial shaft seal with the closed side
toward the clutch onto drift, BMW No. 11 5 661,
with handle, BMW No.005500, (8).
Remove assembly sleeve (9).

•

Using the drift, drive the radial shaft seal

•

home (10).

11.48

2

1

Installing clutch housing

e Caution:

Always use new screws for housing and cover.

11 5 640

S210010

Install clutch housing with mark (1) aligned with

•

crankshaft mark (2).
Lock the clutch housing with special tool,

•

BMW No. 11 5 640.
Insert all screws by hand and tighten down.

•

X Tightening torque:

Clutch housing to crankshaft

(screw threads oiled) ...................................40 Nm

Wrench angle.................................................... 32°

11.49

1

2

3

M6 x 45

4

5

5

6

7

M6 x 45

M6 x 50

Installing oil pump

e Caution:

Oil the friction faces.

Install outer rotor (1) of oil pump in pump hous-

•

ing.
Install oil pump housing with cooling oil pipe (2).

•

e Caution:

O-ring (3) must be in perfect condition.

Install Woodruff key (4), outer rotor (5) and inner

•

rotor (6) in cooling oil pump.
Secure housing cover (7) to oil pump.

•

e Caution:

Note different lengths of screws.

X Tightening torque:

M 6 screw ...................................................... 9 Nm

Pressure relief valve ..................................... 42 Nm

Oil pressure switch....................................... 30 Nm

M6 x 50

M6 x 45

RS110411

11.50

11 5 640

5

4

1

3

6

2

S110030

Installing auxiliary shaft drive

Align crankshaft mark with mark on auxiliary

•

shaft.

e Caution:

Adjust according to the adjusting instructions.

b ............................................ See Technical Data

Lock the clutch housing with special tool,

•

BMW No. 11 5 640.
Install chain sprocket (1).

•

X Tightening torque:

M 6 screw .................................................... 10 Nm

Install drive-shaft chain with chainwheel (2).

•

X Tightening torque:

Securing screw in chainwheel...................... 70 Nm

Install and secure chain guide rail (3).

•

Install and secure chain tensioner rail (4).

•

Install chain tensioner housing (5) with piston and

•

spring.

X Tightening torque:

M 6 screw ......................................................9 Nm

Tighten down cooling oil line (6).

•

e Caution:

Use a new sealing ring.

X Tightening torque:

M 6 screw.................................................... 10 Nm

Banjo bolt for cooling oil line

with oil vent valve ......................................... 25 Nm

11.51

Installing piston

X

RS110430

Turn oil scraper ring so that gap (arrow) is at top.

•

Install piston rings with gaps offset by 120°.

•

Production locating point X = install on exhaust side.

e Caution:

Make sure that retaining rings are properly seated
on piston pin.
Oil the friction faces.
Always use pistons of the same weight class in any
one engine.

Markings: .................................................... + or —

a ........................................... See Technical Data

e Caution:

Always install pistons and cylinders in pairs.
Do not mix up pistons and piston pins.

Piston size identification:

On piston crown A, B, AB (for either A or B cylinder),
and on cylinder A, B.

11.52

1

Installing cylinder

Clean and de-grease cylinder base sealing face

•

(arrow) and apply 3-Bond 1209.
Oil the cylinder wall.

•

Compress the piston rings with a clamping strap,

•

BMW No. 11 2 900.
Install the cylinder and at the same time pass the

•

timing chain and the tensioner and guide rails
through the timing case cavity.
Tighten cylinder securing screws.

•

Fit new seals to pivot pins for chain guide rail (1).

•

Install chain sprocket.

•

u

11 2 900

RS110420

X Tightening torque/tightening sequence:

1. M 8 screw ................................................ 20 Nm

2. M 6 screw .................................................. 9 Nm

3. Pivot screw for chain guide rail.................... 18 Nm

11.53

2

M6 x 60

M6 x 30

M6 x 30

1

Installing cylinder head

Install cylinder head gasket.

•

Fit cylinder head and insert correctly positioned

•

camshaft chain sprocket (1) and timing chain into
chain cavity.
Install valve gear holder (2).

•

Tighten cylinder head securing screws and nuts.

•

e Caution:

Install cylinder head nuts with collar (arrow) toward
cylinder head.

X Tightening torque/tightening sequence:

1. Tighten cylinder head nuts (oiled) in diagonally
opposite sequence

1.1 Tighten all nuts....................................... 20 Nm

1.2 Tighten all nuts to correct angle.................. 90°

1.3 Tighten all nuts to correct angle.................. 90°

2. M 10 screw ............................................ 40 Nm

3. M 6 screw ................................................ 9 Nm

M6 x 30

S110130

Fit camshaft chain sprocket in accordance with

•

adjustment specification.
Lock the clutch housing with special tool,

•

BMW No. 11 5 640.
Tighten camshaft chain sprocket.

•

X Tightening torque:

Camshaft sprocket retaining screw.............. 65 Nm

Insert the left-side camshaft sprocket with pin

•

into the camshaft and set the left cylinder to firing
TDC.
Fit camshaft chain sprocket in accordance with

•

adjustment specification.
Tighten camshaft chain sprocket.

•

Install chain tensioner.

•

Check that marks on camshaft sprockets are in

•

accordance with adjustment specification.

X Tightening torque:

Chain tensioner............................................ 32 Nm

X Tightening torque:

Retighten after 1000 km (app. 600 miles)
Tighten cylinder head nuts in diagonally opposite
sequence

1. Slacken one nut

2. Tighten nut to initial torque......................20 Nm

3. Tighten nut to wrench angle...................... 180°

4. Slacken and retighten M10 screw ...........40 Nm

11.54