Maintenance BMW Integral ABS

R 1150 RT

BMW Motorrad After Sales

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© BMW Motorrad 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 01/01

BMW Motorrad Maintenance schedule R 1100 S EVO / R 1150 R / R 1150 RT
BMW Inspection at 1,000 km (600 miles) BMW Inspection every 20,000 km (12,000 miles)
40,000 40,000 60,000
Customer Registration No.

Order No.

Mechanic’s signature

Read the fault code memory with the BMW MoDiTeC [Integral ABS] perform bleed test with BMW MoDiTeC Change oil while at regular operating temperature and replace the oil filter element If the motorcycle is ridden only for short distances or outside temperatures are below 0 °C: at the latest every 3,000 km (1,800 miles)*) Change oil in gearbox while at operating temperature every 2 years*) at the latest Change oil in rear wheel drive while at operating temperature if necessary, clean inductive sensor on rear wheel every 40,000 km (24,000 miles) or at the latest every 2 years*) Replace fuel filter *) Normally every 40,000 km (24,000 miles), if fuel is of poor quality every 20,000 km (12,000 miles) Check the battery fluid level, if necessary top up with distilled water Clean and grease battery poles if necessary Replace intake air filter element In very dirty and dusty operating conditions, replace every 10,000 km (6,000 miles) or even more frequently if necessary *) Replace Poly-V belt *) Replace the Poly-V belt every 60,000 km (36,000 miles); do not adjust it Check brake fluid level at front and rear Check operation of brake system and freedom from leaks; repair/replace items if necessary*) Examine brake pads and discs for wear, replace as necessary*) [Without ABS] change brake fluid every twelve months [Integral ABS] change bake fluid in wheel circuit every 12 months [Integral ABS] change brake fluid in control circuit every 2 years*)

every 2 years

every 2 years

every 2 years

[Integral ABS] perform bleed test with BMW MoDiTeC Check clutch fluid level Change the clutch fluid*) every 2 years at the latest Check tightness of rear wheel studs Check rear wheel bearing play by tilting wheel Check swinging arm bearings (freedom from play), adjust if necessary *) Grease the side stand pivot Check function of side stand contact switch Check condition of spark plugs Replace spark plugs Tighten cylinder head nuts Check/adjust valve clearances Check that the throttle cable moves freely and is free of kinks and chaffing, replace if necessary *) Check throttle-cable play check synchronisation, repair leaks if necessary *) Final inspection with road safety and functional check: – Condition of tyres and wheels, tyre pressures – Lights and signalling equipment, telltale and warning lights, instruments, – clutch, gearshift mechanism, hand brake and foot brake, steering, – if necessary, test drive

every 2 years

*)

Charged as an additional item UX-VS-2, 12.2000 Printed in Germany

Order No. 01 71 0 029 614

BMW Annual Service

BMW Service 10,000 km (6,000 miles)

Check operation of optional extras If necessary. BMW Pre-delivery check Order No. 01 71 0 029 614 UX-VS-2. Mechanic’s signature Check the shipping crate for damage Motorcycle: – – – – unpack install remaining items inspect for damage check that delivery is complete: Toolkit On-board literature Ignition keys Scope of optional extras Fill and charge the battery (mark with charging date) Check engine oil level when cold and correct if necessary. gear shift Handbrake and foot brake Lights and signalling equipment. Final cleaning Motorcycle handed over on: Order No. 12. test drive Confirm pre-delivery check in “Service and Technical Booklet”. telltale and warning lights.2000 Printed in Germany .BMW Motorrad Pre-delivery check R 1100 S EVO / R 1150 R / R 1150 RT Customer Registration No. instruments. Check tightness of rear wheel studs (note correct tightening torque) Check tyre pressures Fill up with fuel [Integral ABS] perform bleed test with BMW MoDiTeC Final inspection as functional check: – – – – – Clutch. Check headlight setting and adjust if necessary.

6) 3. pints) Brand-name hypoid gear oil.25 (0.15) Unit of measurement/specification litres (Imp.039) 1.5 (0.9 – 36. 1.177) 4. pints) litres (Imp.5 (0.006) Exhaust: 0.012) adjust at TDC 0. pints) Brand-name hypoid gear oil.75 (6. 11. SF SG.15 (0. 0. pints) litres (Imp.5 (0. rear Rear wheel studs Tightening cylinder heads Nut M 10 screw Locknut.039) (wear mark) 4. 35 °C/95 °F) Ignition timing static setting Spark plugs Electrode gap Wear limit Idle speed Throttle cable setting for cold-start (increased idle) speed for throttle (twistgrip) cable for divider cable Brakes Colour of identification mark on brake calipers/brake pads.8 (1. with CC or CD specification Transmission Initial filling Oil changes approx.0 (0. 0.00 mm (in) free travel DOT 4 brake fluid mm mm mm mm (in) (in) (in) (in) bar (psi) bar (psi) Tightening torques: Oil filter Engine oil drain plug Gearbox oil filler plug Gearbox oil drain plug Rear wheel drive oil filler/drain plug Fuel tank to rear frame Fuel pump assembly to tank Poly-V belt preload Alternator to cover mount Brake caliper fasteners.0 (0. SAE class GL 5 SAE 90 Valve clearances measured cold (max. 01 71 0 029 621 Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm ° tightening angle Nm Nm Nm Nm Printed in Germany .41) of oil to bottom edge of filler neck litres (Imp. pints) [SI 11 048 90] Engine oil grade: brand-name HD oil for four-stroke spark-ignition engines.5 (31. combination .26 – 42. 0.50 (6.9 (36.177) front: 2. valve adjusting screw Cylinder head cover Spark plugs NGK BKR 7 EKC Order No.02) zero play white 1.2 – 2.26) rear: 2.76) approx.0315) 1.100 ±50 mm (in) mm (in) mm (in) mm (in) rpm zero play approx.0 (1.039) 1.0 (0.5 – 2. API classes SE.44) of oil to bottom edge of filler neck litres (Imp.BMW Motorrad Service data R 1150 RT Item Oil capacities Engine (with filter) (without filter) Desired value 3. front Brake caliper fasteners.30 (0.06) 11 32 30 30 23 22 5 8 20 30 40 105 unscrew/20 180 unscrew/40 8 8 25 UX-VS-2. SAE class GL 5 SAE 90 Rear wheel drive Initial filling/oil change approx. front Minimum front pad thickness Minimum rear pad thickness Minimum front disc thickness Minimum rear disc thickness Tyre pressures depending on load Inlet: 0.8 (0.

...6 23 Transmission ...................................................................................................................................................................1 ............................................................................................7 32 Steering ...................................3 12 Engine electrics ............................................................................................................................................................................ 11 61 General electrical equipment ................................................................................................................................................................................................................................................................................................................00 00 Tightening torque Table of operating fluids Contents Page Tightening torque .............8 34 Brakes ....................................................................................... 11 Table of operating fluids ..............................................................................................................................................................................7 33 Rear wheel drive ....................................................6 31 Front forks ..................................................................................................................................................................................................................................................5 16 Fuel tank and lines ........................................................................................................................................................................................................................................................................................................................................9 46 Frame ......................9 36 Wheels and tyres ...........................................................12 00...........................................................................................................5 21 Clutch .......................................................... 10 51 Equipment ................5 13 Fuel preparation and control .....................................................................5 18 Exhaust system .................3 11 Engine .........................................................................

2 .00.

1 Tighten all nuts to closing torque 1.000 km (600 miles).3 Tighten all nuts to correct wrench angle 2 M 10 screw 3 M 6 screw After 1. valve adjusting screw Cylinder head cover to cylinder head Camshaft end cover to cylinder head Air intake connection to cylinder head Camshaft Chain sprocket to camshaft Camshaft bearing cap Alternator mount cover M 6 screw M 8 screw Auxiliary shaft Chain sprocket to crankshaft Chainwheel to auxiliary shaft Chain tensioner housing to engine block Nm Nm Nm 10 70 9 Nm Nm 9 20 Nm Nm 65 15 Nm ° Nm Nm Nm Nm Nm Nm Nm 20 180 40 9 18 8 8 9 9 Nm ° ° Nm Nm 20 90 90 40 9 R 1150 RT 00.3 .2 Tighten all nuts to correct wrench angle 1.00 Tightening torque Model Connection 11 Engine Cylinder head Tightening sequence: 1 Tighten cylinder head nuts (oiled) in diagonally opposite sequence 1. tighten cylinder head nuts in diagonally opposite sequence: 1 Slacken one nut 2 Tighten nut to initial torque 3 Tighten nut to wrench angle 4 Slacken and retighten M 10 screw Timing gear carrier to cylinder head Bearing cap on rocker shaft Locknut.

4 .Model Connection 11 Engine Oil filter Oil filter Oil drain plug Oil pump Mesh filter basket to engine block Oil pump cover Pressure relief valve Oil pressure switch Oil cooler Cooling oil line to engine block Cooling oil line banjo screw with oil vent valve Oil cooler to bracket Oil cooler return line to engine block Oil cooler connection to crankcase Cylinders Tightening sequence: 1 M 8 screw 2 M 6 screw 3 Chain guide rail pivot screw Timing chain Chain tensioner Connecting rod Big end cap Closing torque Wrench angle Crankcase Tightening sequence: M 10 screw (oiled) to initial torque Wrench angle M 8 screw M 6 screw Nm ° Nm Nm Nm ° Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm R 1150 RT 11 32 10 9 42 30 10 25 9 35 9 20 9 18 32 20 80 25 90 22 (oiled) 9 00.

Model Connection 12 Engine electrics Starter motor to engine Positive lead to starter motor Alternator to generator support cover Tensioning and retaining link to alternator Spacer to alternator Positive lead to alternator Belt pulley to alternator Belt pulley to crankshaft Poly-V belt preload NGK BKR 7 EKC spark plug Model Connection 13 Fuel preparation and control Oil temperature sensor to crankcase Air temperature sensor to air-filter housing Model Connection 16 Fuel tank and lines Fuel tank to rear frame Fuel pump assembly to tank Model Connection 18 Exhaust system Manifold to cylinder head Clamp for manifold Silencer to footrest plate Oxygen sensor to silencer Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm R 1150 RT 20 10 20 21 21 15 50 50 8 25 R 1150 RT 25 10 R 1150 RT 22 5 R 1150 RT 21 45 (apply Optimoly TA to clamp seat) 35 45 (apply Optimoly TA to thread) 00.5 .

6 .Model Connection 21 Clutch Clutch housing Initial tightening torque + additional wrench angle Housing cover to housing Clutch line to handlebar fitting Slave cylinder to gearbox Grub screw in filler adapter Model Connection 23 Transmission Oil drain plug Oil filler plug Gearbox to engine block Shift lever to footrest plate Selector lever to selector shaft Housing cover to housing Frame tube to gearbox 1. to gearbox and right footrest plate Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm ° Nm Nm Nm Nm R 1150 RT 40 (oil screw threads lightly) 32 12 14 9 10 R 1150 RT 30 30 22 35 9 9 42 (clean thread + Loctite 243) 9 42 (clean thread + Loctite 243) 00. to gearbox and left footrest plate 2. terminal block. frame tube to transmission 3.

Model Connection 31 Front forks Quick-release axle clamp screws Sliding tube bridge to slider tube Threaded connection. handlebar lever Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm R 1150 RT 22 25 (clean thread + Loctite 243) 45 (free from oil and grease) 130 (clean thread + Loctite 243) 230 (lightly grease threads with Optimoly TA) 80 130 (clean thread + Loctite 2701) 73 42 (lightly grease threads with Optimoly TA 43 50 R 1150 RT 21 21 11 (Tuflok-Blau thread-locking compound. screw can be released and tightened a number of times) 00. fork fixed tube to fork bridge Threaded stud to frame Ball joint to sliding tube bridge Leading link Leading link to ball joint Initial tightening Final tightening Leading link to engine Right Left-hand screw cap Spring strut Spring strut to front frame Spring strut to leading link Model Connection 32 Steering Handlebars to fork bridge Handlebar weight to handlebars Pivot screw.7 .

Swinging arm to left of transmission 1. initial torque 2. Swinging arm to left of transmission Spring strut Spring strut to rear frame Spring strut to rear swinging arm Hydraulic spring adjustment on rear frame Nm Nm 9 Nm Nm Nm 7 (clean thread + Loctite 2701) 160 160 (clean thread + Loctite 2701) Nm 9 Nm Nm 7 (clean thread + Loctite 2701) 160 Nm Nm Nm 50 58 (clean thread + Loctite 243) 22 00. Swinging arm to right rear axle housing Floating bearing stud bolt. input bevel gear Cover to rear-wheel drive housing Swinging arm Reaction link to rear wheel drive / gearbox Nm Nm Nm Nm Nm Nm R 1150 RT 23 23 160 (clean thread + Loctite 577) 200 (clean thread + Loctite 2701) 35 43 (load approx. floating bearing stud bolt. final torque Lock nut.8 . 85 kg (187 lbs) onto motorcycle and tighten loose reaction link) 160 (clean thread + Loctite 2701) Fixed bearing stud bolt.Model Connection 33 Rear wheel drive Rear axle differential Oil filler plug Oil drain plug Threaded ring Hexagon nut. Swinging arm to left rear axle housing Fixed bearing stud bolt. Swinging arm to right of transmission Floating bearing stud bolt. final torque Lock nut. slacken 3. floating bearing stud bolt. initial torque 2. Swinging arm to left rear axle housing 1. slacken 3.

screw can be released and tightened a number of times) Rear brake Brake caliper to rear wheel drive Rear brake caliper bleed screw Brake disc to rear wheel drive Master cylinder to footrest plate Brake pedal to footrest plate Footbrake-lever stop Brake lines Brake lines/brake hose to brake components Brake hose to brake lever fitting Filler adapter to brake line Bracket to front frame Retainer to rear frame BMW Integral ABS ABS pressure modulator on retainer ABS pressure modulator on battery carrier Model Connection 36 Wheels and tyres Quick-release axle clamp screws Quick-release axle threaded fastener Rear wheel to rear wheel drive screw wheel bolts finger-tight in a crosswise pattern Nm Nm Nm 22 30 105 Nm Nm 7 10 R 1150 RT Nm Nm Nm Nm Nm 18 18 18 9 9 (clean thread + Loctite 2701) Nm Nm Nm Nm Nm Nm 40 5 21 (clean thread + Loctite 2701) 9 21 (clean thread + Loctite 2701) 9 00.Model Connection 34 Brakes Front brake Brake caliper to EVO brake sliding tube Front brake caliper bleed screw Brake disc to front wheel Pivot screw.9 . handlebar lever Nm Nm Nm Nm R 1150 RT 30 7 21 (clean thread + Loctite 2701) 11 (Tuflok-Blau thread-locking compound.

left M 12 screw M 8 screw Pivot mount of main (centre) stand (stud bolt) Pivot mount of main (centre) stand (machine screw) Side stand to pivot mount Footrest plate Footrest plate to left/right transmission Footrest plate to left of rear frame M 10 screw M 8 screw Footrest plate to right of rear frame M 10 screw M 8 screw Shift lever to footrest plate Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm R 1150 RT 82 58 58 (clean thread + Loctite 2701) 42 (clean thread + Loctite 2701) 42 (clean thread + Loctite 2701) 20 72 (clean thread + Loctite 2701) 72 (clean thread + Loctite 2701) 21 (clean thread + Loctite 2701) 21 (clean thread + Loctite 243) 21 58 (clean thread + Loctite 2701) 19 36 19 36 19 35 00.Model Connection 46 Frame Frame Frame to engine Struts to frame Strut to engine Rear frame to left/right of engine Rear frame with footrest plate to left/right of transmission Fairing bracket to frame Side stand Mounting bracket to right of engine.10 . M 12 screw Pivot mount to engine.

Model Connection 51 Equipment Ignition/steering lock to fork bridge Model Connection 61 General electrical equipment Horn to holder Horn to fairing bracket Ground (earth) strap to engine block Battery carrier to rubber-metal element Strut to battery carrier Nm Nm Nm Nm Nm Nm R 1150 RT 20 (micro-encapsulated) R 1150 RT 8 (clean thread + Loctite 243) 10 9 8 10 00.11 .

12 .Table of operating fluids Item Lubricant Use Order number Quantity Staburags NBU 30 PTM Optimoly MP 3 Optimoly TA Silicone grease 300. steering head and taper roller 83 22 9 407 845 100 g tube bearing grease Contact spray Drive chain 81 22 9 400 208 300 ml spray 72 60 2 316 676 50 ml spray 72 60 2 316 667 300 ml spray 3-Bond 1110 B 3-Bond 1209 OMNI VISC 1002 Loctite 574 Loctite 577 Curil K 2 Surface sealant Surface sealant Surface sealant Surface sealant Thread locking compound Heat-conductive sealant 07 58 9 056 998 5 g tube 07 58 9 062 376 30 g tube 07 58 1 465 170 90 g tube 81 22 9 407 301 50 ml tube 07 58 2 328 736 5 g tube 81 22 9 400 243 250 g can Adhesives and retaining agents Loctite 648 Loctite 638 Loctite 243 Loctite 270 Loctite 2701 Loctite 454 Cleaners Joint adhesive (narrow gap) Joint adhesive (wide gap) Thread retainer. strong Thread retainer. heavy Retinax EP2 Contact spray Chain spray Sealants High-performance lubricating paste High-performance lubricating paste High-temperature assembly paste Damping grease 07 55 9 056 992 75 g tube 07 55 9 062 476 100 g tube 18 21 9 062 599 100 g tube 07 58 9 058 193 10 g tube Wheel. strong Cyanacrylate adhesive (gel) 07 58 9 067 732 5 g bottle 07 58 9 056 030 10 ml bottle 07 58 9 056 031 10 ml bottle 81 22 9 400 086 10 ml bottle 33 17 2 331 095 10 ml bottle 07 58 9 062 157 20 g tube Brake cleaner Metal Polish Testing agents Brake cleaner Polish for chrome-plated parts 83 11 9 407 848 600 ml spray 82 14 9 400 890 100 g tube Penetrant MR 68 Developer MR 70 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 Installation aids BMW cooling spray Cooling spray 83 19 9 407 762 300 ml spray 00. medium-strength Thread retainer.

...........................................................24 00...............................21 ..............................20 ..............21 Inspecting motorcycle for damage Checking that delivery is complete Checking engine oil level when cold...............................................................................13 .....23 [Integral ABS] Performing bleed test with BMW MoDiTeC Final inspection and function check .................................................................................................................................00 00 Pre-delivery check Contents General view of crated motorcycle Page ................................................21 Checking headlight beam angle................23 Final cleaning .......16 ...................................23 Handing over the motorcycle ................18 Installing cover for windscreen adjuster and installing windscreen Installing mirrors Assembling case ................................................................................................................................................................................. adding oil if necessary Checking tightness of rear wheel studs .............................................................................................................................................21 Checking tyre pressures ..............16 In case of damage in importer markets Unpacking the motorcycle ............................15 .....................................17 ..........................................................................................................................................................................................................................................................................................20 ................................................................................................................................................ adjusting if necessary ..17 Filling and charging the battery ..............................................................................................................................16 .........................................................21 .....................................................................................................................................17 Assembling the motorcycle Installing the front wheel Installing front mudguard ...................................................16 Checking the crated motorcycle for damage In case of damage in Germany ...........22 .....................................................................................................................................................20 .......................

14 .00.

15 .00 General view of crated motorcycle W BM B M W R22009010 00.

freight company or DB) and also Bavaria Wirtschaftsagentur GmbH Abteilung ZW .g. +49 89/14327-632 Fax. examine the contents for consequential damage. +49 89/14327-709 • • Lever off the cover. Read the information sheet on damage in transit. Take out the separate pack of items: Front wheel Case lid Aerial Windscreen Covers Engine spoiler Cover for windscreen adjuster Front mudguard Mirrors Small parts/fasteners Documentation Remove the set of keys from the left rear footrest.Checking the crated motorcycle for damage Unpacking the motorcycle • When the motorcycle arrives. Force off cross-struts with a suitable lever. freight company) without delay. please submit enquiries to: Bavaria Wirtschaftsagentur GmbH Abteilung ZW . e • • Remove the end-walls. • • • – – – – – – – – – – – In case of damage in Germany • • • Note the damage on the delivery slip. In case of damage in importer markets • • • Note the damage on the delivery slip. e • Dispose of the packing materials in an environmentally responsible manner as described in Circular 23/91 . +49 89/14327-632 Fax. Remove plastic covers. 00. if necessary.Sales. Notify the supplier without delay (e.16 . Attention: Remove any nails projecting from the base of the crate or lying on the base or on the floor. Remove the side-walls.g. In case of doubt.12 80788 München Tel. Comply with specific national market procedures. check the crated motorcycle immediately for damage and. +49 89/14327-709 Notify the supplier (e.12 D-80788 München Tel. Attention: Do not knock the cross-struts out or the motorcycle may be damaged.

..... BMW No. e Attention: the brake lines. carefully force back the pistons only far enough to ensure that the wheel-circuit reservoir does not overflow. Using the assembly crane. secure the front of the motorcycle to the assembly crane... 46 5 640. carefully push the motorcycle forward off the pallet. 30 Nm Installing front mudguard Warning: Integral ABS When removing and installing the brake calipers...Assembling the motorcycle Installing the front wheel 1 3 2 A e Attention: • Degrease all brake discs..... Tighten the clamp screws. B R22000020 • Install the front wheel with spacer (1) and speedometer drive (2).. 46 5 640.... R22000030 Lnot apply handbrake lever or footbrake lever with Note: Do brake calipers removed/front wheel removed. 00...17 ......... e Attention: R22000010 Locate stop on slider tube (A) in recess in speedometer drive (B)..... 22 Nm Brake caliper to fork slider ...... • Raise the front of the motorcycle... BMW No.. Install the front brake calipers.. The brakes are not ready for use until the brake pads have been bedded against the brake discs with the ignition switched on... Remove rear straps.... e Attention: • • • Make sure that the motorcycle cannot topple sideways.. BMW No... • • • • • Tighten the retaining screw (3). 46 5 640. Extend the main stand and lower the motorcycle until it is resting firmly on the main stand and the rear wheel... Compress the front fork firmly several times... Bowden cables and d Warning: Do not damage fairing panels. If fluid escapes... X of quick-release axle .. top up the level in the wheel-circuit reservoir to “MAX” mark. Remove front straps. Release the motorcycle from the assembly crane. • Using the straps. d • Remove screws securing the front brake calipers.... 30 Nm Tightening torque: Bolt Clamping screws of quick-release axle ..

Pull the battery to the left to remove. Warning: Battery acid is highly caustic. face hands. Disengage the rubber strap holding the battery.18 .28 to the upper mark. Remove the air filter cover. Allow the battery to stand for approximately 30 minutes. Remove air intake pipe. clothing or the motorcycle’s paintwork. 00. Remove left side fairing panel. R22000040 • • Disconnect the battery breather hose.4x 2x 4x 3x 4x R22460020 Filling and charging the battery • • • • • Remove seat. It must not contact the eyes. d • • Fill all the cells with pure battery acid of density 1.

. Install the battery..... Install the covers. bed in the brake pads against the brake discs..26-1..... Install the engine spoiler... Reinstall the plugs... L Note: Acid density Battery full charged . • Battery charge can be measured by checking the density of the battery acid..... • • • • Shake the battery slightly to allow the gas bubbles to escape.. 00... Follow the instructions for use supplied with the battery charger..... 1... • Switch on the ignition.. then the negative terminal......... so it has to be charged with a battery charger............19 .. Install the left side fairing panel. Connect the positive cable..... top up the acid to the max... mark. Wait until the battery acid has settled. Charge current (amps) .. check that no more bubbles rise and if necessary.... Make a note of the charging date on the battery.30 at a temperature of 20 °C (68 °F) Disconnecting the battery means that the entries in the fault memory of the Motronic MA2. Without starting the engine.. always wait for the After switching BMW Integral ABS to complete its self-diagnosis...... coat with acid-proof grease and install the protective cap..4 control unit are deleted and the adaptation values are reset..10 % of rated battery capacity (Ah) Charging time .. L Note: L Note: on the ignition........ 5-10 hours • • With the ignition switched on. R22000050 e Attention: • • • • • • • Connect the positive battery terminal first... fully open the throttle once or twice so that the Motronic control unit can register the throttle-valve positions..... This can temporarily impair the operating characteristics when the engine is restarted...• The battery does not achieve full charge capacity from being filled.. Do not operate the brake lever until self-diagnosis has completed......... Assembly is the reverse of the disassembly procedure. Connect the negative cable and coat with acidproof grease.....

Oil the seal in the bottom of the case.Installing cover for windscreen adjuster and installing windscreen Assembling case R22000070 R22000060 • • • Install the cover for the windscreen adjuster.20 . • • • Connect the turn indicators. Engage by pressing at the front first. Install the aerial. Engage riveting tool on rivets. 00. 2x short rivets in hinge at front. e • • RT460280 • Carefully close the case. Insert the lock cylinder into the case with the key in the lock and turn the lock. as viewed in forward direction of travel. 2x long rivets in hinge at rear. Install windscreen with washers. hold the hinge at the outside to keep it in position and secure all four rivets. as viewed in forward direction of travel. Open the hinges of the lid and guide them into the base with the guide hook. then the rear. using the sponge provided for the purpose. Affix the stickers. Attention: Make sure that the seal is not squeezed out of shape and that the lid closes without catching. insert the pop rivets into the base and the hinges. Position the mirror at the 3 attachment points. • • – – Installing mirrors • • Position the lid on the case for alignment. From the inside.

front 2............21 ..5 bar (36....... Defect codes: Parts missing 10 01 00 00 00 Parts damaged 10 02 00 00 00 Incorrect parts delivered 10 03 00 00 00 Checking tightness of rear wheel studs Tightening torque: Securing screws for rear wheel .......5 bar (36...... rear 2...Inspecting motorcycle for damage • • • • • – – – Check for defects... front 2............26 psi) .. Required level:......06 psi) two-up + luggage ..... UX-VS-1 Fax: + 49 89-382-33220 Rectify the fault.......................... rear 2....2 bar (31....... e Attention: Never top up the engine-oil level past the “MAX” mark....3937 in)........ order them through the usual channel. rear 2............. R22000080 • Check oil level with the motorcycle upright......5 bar (36......... Costs are to be processed by the warranty claim system (stage 4).... MAX BMW recommends Castrol 00................... If parts are needed......................26 psi) ...9 bar (42..06 psi) Checking that delivery is complete – – – All optional extras Toolkit Documentation Checking engine oil level when cold...........26 psi) two-up ..................90 psi) ....... Use the “express handling service” to notify BMW Motorrad..................... adding oil if necessary L Note: The difference between the oil level indicated when the engine is at operating temperature and the oil level indicated when the engine is very cold due to extremely low outdoor temperatures can be as much as 10 mm (0......................... front 2.... 105 Nm X • Checking tyre pressures Check/correct tyre pressures...... Tyre pressures: one-up .9 bar (42...........

... right.. adjusting if necessary 1 2 R22000110 R22000090 • Turn screw (2) to adjust beam throw.......... left .....-10 cm (-3. Direction of rotation. • • • • Motorcycle on level surface....shorter/deeper R22000100 Setting for headlight beam angle adjuster ...... if necessary.. 85 kg/187. Check headlight beam throw.Checking headlight beam angle. .. Turn knob (1) counter-clockwise as far as it will go...8 ft) 00....22 ...937 in) at a distance of 10 m (32. Rider’s weight on motorcycle (approx.4 lbs).....further/higher Direction of rotation.

....... never pump quickly or vigorously.....Integral ABS Performing bleed test with BMW MoDiTeC Final inspection and function check Warning: Self-diagnosis is not performed unless both brake levers are in their fully released positions........ Perform BMW Integral ABS pull-away test: When a speed of 5 km/h (3 mph) is reached....... OFF – Self-diagnosis successfully completed. d • • • Perform bleed test. headlight flasher Fog lamps Brake light (operate brake at front and rear) Turn signals left/right Hazard warning lights Horn Telltale and warning lights Instruments Check operation of optional extras........ Perform all requisite repair work. Final cleaning • Clean the motorcycle...... Handbrake and foot brake Check lights and signalling equipment: Front and rear parking lights Instrument lighting Low and high headlight beams.. bed in the brake pads against the brake discs.................. Perform BMW Integral ABS self-diagnosis: • Release the brake levers...flashes at 4 Hz General warning light ... • With the ignition switched on... the hydraulic system or electrical components.......... Warning: When performing maintenance and repair work on BMW Integral ABS... L Note: The ABS warning light and the general warning light must both be OFF after successful self-diagnosis and the pull-away test... If necessary............ ON – Self-diagnosis is in progress d – – – – – – – – – – • • • • • • • • Clutch Check gear shift action.... • Switch on the ignition... • Connect the BMW MoDiTeC to the diagnosis connector................ only RESIDUAL BRAKING FUNCTION is available. See “Checking motorcycle for damage” if defects are found.... The Note: Do high steam or water pressure could damage seals.. ABS warning light.... Prior to conclusion of the self-diagnosis........... Perform bleed test with BMW MoDiTeC: • Remove front and rear seats.. Lnot use a steam or high-pressure water jet..... Confirm pre-delivery check in Service and Technical Booklet. take the motorcycle for a test ride.23 ... ABS warning light... the ABS warning light must go out.. 00.. if necessary.flashes at 1 Hz General warning light ..

After switching off the engine at operating temperature. residual braking function. • – – – – – – – – – – – 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 handlebars lever positions procedure for adjusting seat how to adjust the mirrors controls instruments and telltale lights optional equipment and accessories fitted features of BMW Integral ABS: brake servo. because the difference between the oil level indicated when the engine is at operating temperature and the oil level indicated when the engine is very cold due to extremely low outdoor temperatures can be as much as 10 mm (0. wait at least 5 minutes for the oil to drain back into the sump.Handing over the motorcycle This is the ideal opportunity to familiarise the customer with the motorcycle in order to ensure the customer’s satisfaction and safety.24 . pump noises. Checking the oil level just after the engine has been run or when it is not properly warm will falsify the reading. • – – – – – 00.3937 in). The user must be given the following information: running-in recommendations and inspection intervals safety check features of BMW Integral ABS: fully integral brake. brake-fluid levels in the control circuits remain constant despite brake-pad wear. the clutch fluid level rises gradually as the motorcycle is ridden (clutch lining wear) Always check the oil level when the engine is at operating temperature. self-diagnosis with pull-away test.

......................................................................................29 Reading the BMW MoDiTeC fault code memory .................30 ....... replace every 10............36 (Inspection III) ......................................31 every 40.............................................................................................................................................................000 km (24..............................................................................000 miles) ....................................................................................................................31 (Inspections III and IV) ............... II........................................35 every 60...................................31 Changing the oil in the rear wheel drive ..................................................35 (Inspection III) .......................................................................36 00.......35 (Inspection III) .............................29 Changing engine oil.....000 km (24......................................................................................................................................................................34 Replacing intake air filter element .............32 Replacing fuel filter Checking battery fluid level and topping up if necessary........................................................ II.......................................................................................................................................................... replacing oil filter element Changing oil in gearbox ......................................................29 (Inspections I.............................................................................................................................................................. II...........29 Integral ABS: Performing bleed test with BMW MoDiTeC .........32 (Inspection III) ...................................................................30 (Inspections I.........................................................................000 miles) or even more frequently if necessary .......................................................................................................................................................................................................................................... if fuel quality is poor every 20...........................................................................................36 Replacing Poly-V belt Checking brake fluid level Front brake Rear brake Checking brake system for correct operation and freedom from leaks.........................................29 (Inspections I...........................................................................................................................31 ....................................36 (Inspections II and III) ...000 miles) ..................................35 ......000 km (6............34 (Inspections III and IV) ................36 ...................................................................................31 (Inspections I................................................................................................................................................................................................................000 km (36.........................31 or at the latest every 2 years ............................................................................................... III and IV) ..........................35 .........................000 km (12...................................000 miles)............................... III and IV) ...............................................................35 in very dirty and dusty operating conditions..........................25 ................................. cleaning and greasing the battery posts.................................................................32 In normal operating conditions every 40.......36 ....................000 miles) or at the latest every 2 years ..............................................................................................................................................00 00 Maintenance Contents Page Key to maintenance intervals ...................... III and IV) ................................................. III and IV) ...................................................... repairing/replacing if necessary .................................

..............................................38 Brake pads...........................................................52 (Inspection IV) ................................................................................................53 (Inspections I........53 (Inspections I...............................................................26 .................................................................................................................................................................46 Changing/bleeding brake fluid in control circuit .........................53 Checking swinging arm bearings........Contents Checking brake pads and discs for wear/replacing Checking brake pads for wear Page ..................................................................................................................................................................................................................48 (Inspection IV) ..............................................................................................51 (Inspections II and III) .................................48 Change brake fluid in control circuit every 2 years ...........................................................................................................................54 (Inspection II) check/(Inspection III) replace ........................................53 Checking tightness of rear wheel studs Checking rear wheel bearing play by tilting wheel ..................39 ................................................................................................................. III and IV) ........................................................................... front brake .............................................44 Instructions for filling rear wheel circuit reservoir .................53 ...................................40 Changing/bleeding brake fluid in wheel circuit Bleeding/changing brake fluid in front wheel circuit ..............................................................................................52 ...................................50 ............................................................................................... II.................52 every 2 years at the latest ..................................................... rear brake .....................................................................................................................................................53 Checking function of side stand contact switch Checking/replacing spark plugs Tightening cylinder heads ..........................................48 Bleeding/changing brake fluid in front control circuit Bleeding/changing brake fluid in rear control circuit Checking clutch operating fluid level Changing the clutch fluid ........51 .........42 Bleeding/changing brake fluid in rear wheel circuit ...............................................37 Brake pads........................37 Checking brake disc wear ........................................................48 ........................................40 Change brake fluid in wheel circuit once a year ...............................................................54 (Inspection I) ......................................... rear brake ............................................... II and III) ....................................................................................................................................................................................................................................................................................................................................................................................................................................53 (Inspection III) ................................................54 00......................................................................................40 Instructions for filling front wheel circuit reservoir .................................................................38 Replacing brake pads ...............53 (Inspection I) .....53 (Inspections I and III) ...............40 (Inspection IV) ...............................38 Brake pads................................................................................53 .......37 (Inspections II and III) ............................................................................................................................................................................................................................................................................. adjusting if necessary Greasing the side stand pivot ................................................................................................................................................................................................................................................................................................................................................................................................................. front brake ..........................................................................54 ................................37 ..................................................................................37 Brake pads...........................

.............55 (Inspections I..........................................................................................................................................57 (Inspections I..27 .......... checking for chaffing and kinks..........Contents Checking/adjusting valve clearances Page .............................55 Checking freedom of throttle cable............................................................................. II and III) ................................................. II....................................................................................57 Road safety check ..................................55 .................................................. replacing if necessary..............................57 00...................................... III and IV) .................................. Checking throttle-cable play Checking and adjusting idle speed and throttle-valve synchronisation Final inspection with road safety and functional check ........................55 (Inspections I........................................................................................57 Roadworthiness check .... II and III) .........

28 .00.

never pump quickly or vigorously.000 km (600 miles) BMW Service every 10. Connect the BMW MoDiTeC to the diagnosis connector. Integral ABS: Performing bleed test with BMW MoDiTeC (Inspections I.000 km (6.000 miles) BMW Inspection every 20.000 miles) BMW Annual Service I II III IV 00 13 624 Reading the BMW MoDiTeC fault code memory (Inspections I. III and IV) • • • • Remove front and rear seats.000 km (12. II. Perform bleed test.29 . 00.00 Key to maintenance intervals – – – – BMW Inspection at 1. Connect the BMW MoDiTeC to the diagnosis connector. Perform all requisite repair work. II. d Warning: • • When performing maintenance and repair work on BMW Integral ABS. Read all fault memories. Perform all requisite repair work. III and IV) • • Remove front and rear seats.

.800 miles)...16 Imp.... 11 Nm Oil drain plug.... to remove the oil filter....... BMW recommends Castrol 00. Refill with oil to correct level.. pints/3.60 Imp. BMW No.96 US quarts) without oil filter renewal ...50 l (0....... 0. • Change the oil at operating temperature... III and IV) • Insert and tighten the screw plug.. API classifications SF. 3....... Reinstall the oil drain plug with a new sealing ring.. SH... G5...50 l (6. e X Tightening torque: Oil filter.. R22000080 • • Remove screw plug......................... combination with CD or CE specification.. amendment PD2 is permissible.. Brand-name HD oil of CCMC classification G4.. pints/3....000 km (1.75 l (6.......... 32 Nm Engine oil capacities: with oil filter renewal ..... Remove oil drain plug and drain off oil........ pints/0...... SG....... 11 4 650 C000030 • • • • Use oil filter wrench.30 ..... 3... L Note: is ridden only for short distances or If the motorcycle outside temperatures are below 0°C (32°F) change the oil and replace the oil filter element every 3 months....... Attention: Never top up the engine-oil level past the “MAX” mark....... or not later than every 3.52 US quarts) Engine oil grade: Brand-name HD oil for spark-ignition engines....... II... replacing oil filter element (Inspections I.. 11 4 650.... Coat sealing ring on new oil filter element with oil and install filter......69 US quarts) Quantity of oil between MIN and MAX marks ..00 11 209 Changing engine oil.....88 Imp..................

.. 0. Reinstall the oil drain plug with a new sealing ring...... Fill with gearbox oil....... Reinstall the oil drain plug with a new sealing ring.. Fill with gearbox oil......25 l (0....... III and IV) every 40...26 US quarts) Oil grade for rear wheel drive: Brand-name hypoid gear oil. SAE 90........................... Remove oil drain plug (2) and allow the oil to drain out.....41 Imp...... • Change the gearbox oil at operating temperature.. pints/0............44 Imp.8 l (1. approx.......... SAE 90....00 11 229 Changing oil in gearbox 00 11 229 (Inspections III and IV) or at the latest every 2 years Changing the oil in the rear wheel drive (Inspections I. 23 Nm Oil filler plug ......000 km (24..... 23 Nm Quantity: to bottom of thread in oil filler hole ..85 US quarts) Oil grade for gearbox: Brand-name hypoid gear oil.......... pints/0.. and turn it to the right.....31 ....000 miles) or at the latest every 2 years • Change the gearbox oil at operating temperature..... Remove oil filler plug (1)..... BMW No. Insert oil filler plug with new seal....... Tightening torque: Oil drain plug.. API class GL 5 X X Tightening torque: Oil drain plug.... R28000100 e Attention: • • • • • Do not allow oil to drip onto the rear tyre...... Push in oil drain tube....... Remove oil drain plug (2) and allow the oil to drain out. 1 1 2 2 R22000250 • • • • • • Remove oil filler plug (1)....... 0.. Insert oil filler plug with new seal.......... API class GL 5 00............. approx....... 30 Nm Quantity: to bottom edge of filler neck .... 30 Nm Oil filler plug .............. 23 4 680...........

00. Remove left and right side sections of fairing. Use a cable tie to secure the stowage compartment to the motorcycle.000 miles). Remove fuel pump unit. Disconnect the plug of the fuel pump. lay a cloth between the fork bridge and the fuel tank.R22160010 16 12 008 Replacing fuel filter (Inspection III) In normal operating conditions every 40. Warning: Fuel is flammable and a hazard to health.32 . • • • • Remove front and rear seats.000 km (12. if fuel quality is poor every 20. Drain fuel tank.000 km (24. Disengage stowage compartment and lift it up to remove. Disconnect quick-connect adapters of the fuel lines.000 miles) • • • • Disconnect breather and overflow hoses. • • Pull fuel tank up and to the rear to remove. L Note: To avoid damaging the paintwork of the fuel tank. d • Remove screw securing fuel tank. Observe relevant safety regulations.

........ Note correct direction • Secure non-reusable hose clips with pliers.. BMW No.... Install new fuel filter.33 .... L Note: that breather lines are correctly routed.... AfMake sure O-ring ter installing. check fuel pump unit for leaks. 5 Nm Tightening torque: Fuel Fuel tank to rear frame .R22160021 • • Disconnect hoses from fuel filter....... 13 1 500.. Make sure X pump unit to fuel tank ......... 22 Nm e Attention: (arrow) is in perfect condition. e Attention: of flow through fuel filter........ • Installation is the reverse of the removal procedure.................... 00..

.. Pull the battery to the left to remove..34 ... e Acid proof battery-post grease: ... Bosch Ft 40 V1 00.R22000120 61 20 029 Checking battery fluid level and topping up if necessary..... This can temporarily impair the operating characteristics when the engine is restarted.. Installation is the reverse of the removal procedure.g....e. then the negative terminal. Disconnect the negative terminal of the battery. It must not contact the eyes. Disengage the rubber strap holding the battery. Remove air intake pipe. Attention: Connect the positive battery terminal first..... Clean and grease the battery terminals. Check the battery fluid level.. Remove the left side case. cleaning and greasing the battery posts (Inspections III and IV) L Note: Disconnecting the battery means that the entries in the fault memory of the Motronic MA2. fully open the throttle once or twice so that the Motronic control unit can register the throttle-valve positions... Disconnect the battery breather hose. If necessary.. Switch on the ignition... then the positive terminal... Disconnect the positive terminal of the battery. Remove the air filter cover. Without starting the engine.. Remove left cover and side trim panel....... L Note: • • • • • • Remove the battery if the acid level is incorrect or cannot be read correctly.. top up the acid level to the “MAX” mark with distilled water. face hands.. Warning: Battery acid is highly caustic.. clothing or the motorcycle’s paintwork.....4 control unit are deleted and the adaptation values are reset. e Attention: Disconnect the negative battery terminal first.... d • • • • • • • • • • Remove front and rear seats....

....4).. Remove front intake pipe...... Poly-V belt adjusting procedure: Place the Poly-V belt in position.000 km (6..........000 miles) • • • Remove left side fairing panel...000 km (36. • • Install new Poly-V belt. 50 Nm Belt pulley to crankshaft . Disengage fairing bracket from end cover on left...... 00.. replace every 10..000 miles) or even more frequently if necessary 3 4 1 RS110480 2 • • Slacken alternator securing screws (1.. Remove old Poly-V belt.... L Note: R22000130 Loop Poly-V belt over crankshaft belt pulley first... 3 Tighten upper retaining nut (3).. then relieve belt tension.......3........ then over alternator belt pulley. 2 Tighten adjusting screw (2) with a torque wrench and keep preload applied...... 8 Nm Belt pulley to alternator ..... tension it and turn the engine over once........... X Tightening torque: Preload for Poly-V belt .. Replace air filter element.... 12 31 240 Replacing Poly-V belt (Inspection III) every 60... Poly-V belt tensioning procedure: 1 Slightly tighten hex nut (1) on adjusting screw (2) by hand (do not use tools).35 .Replacing intake air filter element 13 72 000 (Inspection III) in very dirty and dusty operating conditions. 4 Tighten all screws and nuts..... 50 Nm Alternator to alternator support cover... Close air filter cover.................. then remove torque wrench from adjusting screw. 20 Nm R22110010 • Remove front cover.. • • • Open clips securing air filter cover.........

Turn the handlebars fully to the left.. never pump quickly or vigorously...... Brake fluid.......... repairing/replacing if necessary (Inspection III) • Front brake • • • • • Place the motorcycle on its centre stand...... always wait for the After switching BMW Integral ABS to complete its self-diagnosis................ Warning: When performing maintenance and repair work on BMW Integral ABS. Checking brake system for correct operation and freedom from leaks......... Check brake fluid level at sight glass................................. Remove case and right trim panel.... R22000150 Required level not below ..... Check the brake fluid level. If the level drops below the MIN mark... L Note: on the ignition......... this indicates some other fault. MIN (top edge of the marking ring) Warning: Defective lines and threaded unions in the brake system must always be replaced without delay.........Checking brake fluid level (Inspections II and III) • Correct the fluid level if necessary....... Brake fluid ....................... d • Correct the fluid level if necessary. Switch on the ignition......... Wipe down all threaded unions on the brake lines and check them..36 . MIN 00...................... Do not operate the brake lever until self-diagnosis has completed..........DOT 4 L Note: The brake fluid level in the sight glass/brake fluid reservoirs of control circuits remains constant despite wear of the brake pads.... Required level not below ....DOT 4 Rear brake • • • Place the motorcycle on its centre stand. inspect the brake lines for leaks............ d • R22000140 • Apply the brake hard and hold on in this position for a short time.......... Check all brake lines and their holders for damage and correct positioning........ After this..............

Checking brake pads and discs for wear/replacing
(Inspections II and III)

Brake pads, rear brake

Checking brake pads for wear
Brake pads, front brake

1 2

R22000170

• •

R22000160

Visually inspect the brake pads. 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.


Visually inspect the brake pads. Wear indicators (1) must be clearly visible. If necessary, check/measure thickness of brake pads.

e Attention:

Do not permit brake pad thickness to fall below the minimum value. Always replace the brake pads as a complete set.

e Attention: pad thickness to fall below the minDo not permit brake
imum value. Always replace the brake pads as a complete set. Minimum pad thickness: ......... 1.0 mm (0.0393 in)

Minimum pad thickness: ........ 1.0 mm (0.0393 in) – If the brake disc is visible through the bore in the wheel-side brake pad, the brake lining is worn to its minimum permissible thickness.

Check that colour codes of brake pads and brake calipers (2) match.

Colour code: ................................................. white

00.37

Checking brake disc wear

Remove grub screw (2) and spring (3).

Carefully check the brake discs for cracks, damage, deformation and scoring.

Attention: Integral ABS Press back pistons on only one side of the brake caliper. Allow the brake pad on the opposite side to remain in the caliper during this process. Make sure that the fluid level in the wheel-circuit reservoir does not rise above “max”. Risk of fluid escaping. If fluid escapes, proceed in accordance with “instructions for filling reservoir”.

e

• •
R22000260

• •

Measure the thickness of the brake discs at several points with a caliper gauge.

Press back piston with inner brake pad only far enough to allow the new brake pad to be slipped into position. Remove remaining old brake pad and insert new brake pad. Press back piston with outer brake pad only far enough to allow the new brake pad to be slipped into position. Remove remaining old brake pad and insert new brake pad.

Brake disc wear limit: front:........................................... 4.5 mm (0.177 in) rear: ............................................ 4.5 mm (0.177 in)

L Note:

Replacing brake pads
34 11 008 Brake pads, front brake

After switching on the ignition, always wait for the BMW Integral ABS to complete its self-diagnosis. Do not operate the brake lever until self-diagnosis has completed. After replacing the pads of a caliper, always bed in the new brake pads with the ignition switched on.

Attention: Integral brakes, the rear brake must be ready for use.

e

L Note: and arrow (4) of spring (3). Note position
• • •
Install grub screw (2) and spring (3). Reinsert the split-pin keeper (1) in the groove in grub screw (2). Check operation of the brake system with the ignition switched on.

4

2 3

Tightening torque: Grub screw in front brake caliper ................... 7 Nm Colour code: Brake pads/brake calipers ..............................white

X

1
R22000270

Remove the split-pin keeper (1) from grub screw (2).

00.38

34 21 200 Brake pads, rear brake

• •

e Attention: the front brake must be ready for Integral brakes,
use.

Installation is the reverse of the removal procedure. Check operation of the brake system with the ignition switched on.

X Tightening torque: drive .................. 40 Nm Brake caliper to rear wheel

R22000180

• • • •

Remove keeper (arrow) from retaining pin. Drive the retaining pin out towards the wheel side. Remove brake caliper. Remove brake pads.

e Attention: back pistons in brake caliper Integral ABS Press
brake pad only far enough to allow the brake disc to the slipped in. Make sure that the fluid level in the wheel-circuit reservoir does not rise above “max”. Risk of fluid escaping. If fluid escapes, proceed in accordance with “instructions for filling reservoir”.

Force back the pistons.

R22000280


Check that spring is correctly positioned and secure. Engraved arrow (arrow) points in direction of travel.

00.39

e Attention: • 1 R28340110 • Open front wheel-circuit reservoir (1). d Attention: Install piston resetting tool. (a 00. and locator. [Bleeding only] Bleed the front wheel circuit. only when the cap has been removed from the wheel-circuit reservoir. 34 1 531. e L Note: 34 1 531 This description applies for the brake filling and bleeding unit with extraction of the brake fluid by partial vacuum. the rear brake must be ready for use. 34 00 070 Bleeding/changing 34 1 532 R22000290 brake fluid in front wheel circuit Integral brakes.34 00 090 Changing/bleeding brake fluid in wheel circuit • • Draw off the old brake fluid from the wheel-circuit reservoir. Remove fuel tank.40 . 00. Comply with all maintenance and repair instructions and always work through the various steps in the correct order. Do not scrape • • – Use resetting tool. BMW No. Use only new brake fluid from freshly opened containers. Wrap cloths around the left and right brake calipers.43) Draw off the old brake fluid from the wheel-circuit reservoir. 34 1 531. e Attention: • e Attention:the wheel – mask it off if necessary. If other devices are used. BMW No. Remove front brake pads (left and right). qualified specialists. Do not allow brake fluid to come into contact with painted parts of the motorcycle as brake fluid destroys paint. to force the pistons in the left and right brake calipers all the way back and hold them in this position. BMW No. 34 1 532. comply with their manufacturers’ instructions. Change brake fluid in wheel circuit once a year (Inspection IV) Warning: All repair and maintenance work on the BMW Integral ABS must be performed by trained.

Release the brake and switch off the ignition. L Note: • • • • • The higher the brake pressure the faster the fluid is pumped through the system. When the brake fluid is clear and free of bubbles. Connect the brake bleeding device to the bleed screw of the left brake caliper. with new brake fluid until it is approximately 1/2 full. Connect the brake bleeding device to the bleed screw of the right brake caliper. L Note: After switching on the ignition. which means that the level in the wheel-circuit reservoir drops all the more rapidly. 34 1 581. Do not operate the brake lever until self-diagnosis has completed. Close the bleed screw. • • • R22000340 Very gently pull the handbrake lever until the pump just starts up. BMW No. while topping up the container with new brake fluid if necessary.34 1 581 e Attention: The brake fluid must always be visible in the container. Switch on the ignition. because the piston in the base of the wheel-circuit reservoir must always be covered by the fluid. but do not switch on the device. use a cable tie to secure the bleed hose to the bleed screw. Pump off brake fluid until it emerges clear and free from air bubbles. BMW No. Close the bleed screw. Disconnect the brake bleeding device from the bleed screw. L Note: • If necessary. • • • Screw container. use a cable tie to secure the bleed hose to the bleed screw. Disconnect the brake bleeding device from the bleed screw. always After changing top up the fluid in the wheel-circuit reservoir to the correct level in accordance with the instructions. then vary the brake pressure. but do not switch on the device. MAX MIN R28340090 e Attention:and/or bleeding the brakes. 34 1 581. The procedure for changing the brake fluid in the right brake caliper is the same as that for the left caliper. 00. Slowly fill container. Disconnect the container from the wheel-circuit reservoir. Open the bleed screw. Pump out the brake fluid with virtually no pressure to begin with. always wait for the BMW Integral ABS to complete its self-diagnosis. L Note: • • • • • • If necessary. The procedure must be repeated if the fluid drops below the “min” level.41 . Release the brake. onto front wheel circuit reservoir. continue pumping until the fluid in the container just disappears from view.

... and force back pistons far enough to allow the brake pads to be fitted. the rear brake must be ready for use. Install front brake pads.... Top up the fluid in the wheel-circuit reservoir until one of the three protrusions in the filler neck just touches the surface of the fluid (arrow).. and tighten the resetting tool until the adapters are secure........ bed in the brake pads against the brake discs... Hand-tighten cap of front wheel-circuit reservoir.. Disconnect the container from the wheel-circuit reservoir. e MAX MIN 34 1 533 34 1 531 R28340090 • 34 1 532 R22000300 • • • • • • • • • Top up fluid in front wheel-circuit reservoir to “MAX” mark if necessary Install adapters 22... Screw container. BMW No......DOT 4 After switching on the ignition. 34 1 533.... Remove adapter. Attention: The piston in the base of the wheel-circuit reservoir must always be covered by the fluid. Bleed the system again if this happens.42 .. for both front brake calipers..........Instructions for filling front wheel circuit reservoir Attention: Integral brakes. as otherwise air can be drawn into the brake system. Tightening torque: Bleed screw in front brake caliper .. BMW No.. Pull handbrake lever until the pistons of the front brake calipers are in contact with resetting tool. in resetting tool.... onto front wheel circuit reservoir... e • Attention: After all the work on the brake system has been completed. L Note: • Brake fluid . Do not operate the brake lever until self-diagnosis has completed........ BMW No. always wait for the BMW Integral ABS to complete its self-diagnosis.. 34 1 533.. 34 1 531/532... run a bleed test using the BMW MoDiTeC and check the fault code memory! e • Switch on the ignition..... BMW No... Install fuel tank. Check the function of the brake system. 34 1 531. 34 1 581.... 7 Nm X 00.. With the ignition switched on... BMW No.

. L Note: • • • • • Brake fluid . use. always top up the fluid in the wheel-circuit reservoir to the correct level in accordance with the instructions. 34 2 541... Remove left and right brake pads..43 . • • • • 34 1 561 • • • • 34 2 541 • Pump brake fluid through the system until it is clear and free from air bubbles.. 34 1 561....5 m (4... then vary the brake pressure. Release the brake and switch off the ignition..... Fill front wheel-circuit reservoir with brake fluid up to “MAX” mark and install cap.. BMW No.. from bleed screw and drain the hose. Pump the brake fluid with virtually no pressure until the hose is full of brake fluid. BMW No...DOT 4 After switching on the ignition.5m (4.. Connect end of hose to cap... • • Fill front wheel-circuit reservoir with brake fluid up to “MAX” mark and install cap... • • Fill front wheel-circuit reservoir with brake fluid in accordance with instructions. 7 Nm 00...... 34 1 561..42) Check operation of the brake system with the ignition switched on. (a 00..40) e Attention: the rear brake must be ready for Integral brakes. Very gently pull the handbrake lever until the pump just starts up.Only bleeding the front wheel circuit – – Draw off the old brake fluid from the wheel-circuit reservoir. e Attention: R28000220 After changing and/or bleeding the brakes....... Do not operate the brake lever until self-diagnosis has completed. BMW No. d Warning: – Check that the brake fluid in the hose does not foam.. Connect 1. If the fluid foams.9214 ft) silicon hose.. BMW No... X Tightening torque: Bleed screw in front brake caliper . to the bleed screw of the left brake caliper....... Switch on the ignition... to the bleed screw of the right brake caliper... force back the brake pistons and secure the pistons in this position. 34 2 541. (a 00. 34 2 541. 7 Nm Grub screw in front brake caliper .... 34 1 561. Disconnect silicon hose. 34 2 541.... use a cable tie to secure the bleed hose to the bleed screw. e Attention: After all the work on the brake system has been completed.. L Note: • If necessary. run a bleed test using the BMW MoDiTeC.. BMW No...... The procedure for bleeding the right brake caliper is the same as that for the left caliper. BMW No........ Remove cap..... BMW No.. BMW No. proceed as described in the section on bleeding and changing brake fluid in front wheel circuit.. Close the bleed screw.... always wait for the BMW Integral ABS to complete its self-diagnosis. 34 1 561. Wrap cloths around the left and right brake calipers.. Pump the brake fluid with virtually no pressure to begin with.. Open the bleed screw.. Connect 1.9214 ft) silicon hose... Release the brake and disconnect silicon hose..

44 .34 00 080 Bleeding/changing brake fluid in rear wheel circuit Attention: Integral brakes. Draw off the old brake fluid from the wheel-circuit reservoir. 34 1 581. BMW No. (a 00.47) Draw off the old brake fluid from the wheel-circuit reservoir. BMW No. manually push back brake piston far enough to permit installation of resetting tool. 34 1 531 only when the cap has been removed from the wheel-circuit reservoir. 34 1 581. Connect the brake bleeding device to the bleed screw. 34 1 531. Remove rear brake pads. BMW No. e Attention: 34 1 531 R28000170 • • • – Install adapter. but do not switch on the device. use a cable tie to secure the bleed hose to the bleed screw. e • 34 1 536 Remove fuel tank. 34 1 581 Attention: Install piston resetting tool. Install resetting tool. press the pistons fully back and secure them in this position. onto rear wheel circuit reservoir. [Bleeding only] Bleed the rear wheel circuit. e R22000350 • • • Screw container. the front brake must be ready for use. If necessary. with new brake fluid until it is approximately 1/3 full. Wrap a cloth around the brake caliper. • 1 R28340110 • • • • Open rear wheel-circuit reservoir (1). with the handle toward the outside in the rear brake caliper. Slowly fill container. BMW No. Do not allow brake fluid to come into contact with painted parts of the motorcycle as brake fluid destroys paint. BMW No. instead of the outboard brake pad. L Note: If necessary. 34 1 536. 00. 34 1 531. BMW No.

• When the brake fluid is clear and free of bubbles. then vary the brake pressure. Disconnect the container from the wheel-circuit reservoir. Release the brake and switch off the ignition. e Attention:and/or bleeding the brakes. Pump out the brake fluid with virtually no pressure to begin with. always After changing top up the fluid in the wheel-circuit reservoir to the correct level in accordance with the instructions. because the piston in the base of the wheel-circuit reservoir must always be covered by the fluid. • • • • Close the bleed screw. MAX MIN R28340090 e Attention: The brake fluid must always be visible in the container.45 . continue pumping until the fluid in the container just disappears from view. always wait for the After switching BMW Integral ABS to complete its self-diagnosis. while topping up the container with new brake fluid if necessary. Open the bleed screw. The procedure must be repeated if the fluid drops below the “min” level. L higher the brake pressure the faster the fluid is Note: The pumped through the system. Do not operate the brake lever until self-diagnosis has completed. 00. • • • Very gently press the footbrake lever until the pump just starts up.• Switch on the ignition L Note: on the ignition. Disconnect the brake bleeding device from the bleed screw. which means that the level in the wheel-circuit reservoir drops all the more rapidly.

..... Check operation of the brake system with the ignition switched on..29) Install fuel tank.... Remove resetting tool. Disconnect the container from the wheel-circuit reservoir.... BMW No.... always wait for the BMW Integral ABS to complete its self-diagnosis.. e • Install rear brake pads and brake caliper.. as otherwise air can be drawn into the brake system.....Instructions for filling rear wheel circuit reservoir Attention: Integral brakes.. BMW No. Perform bleed test with BMW MoDiTeC..... d • • • • Attention: The piston in the base of the wheel-circuit reservoir must always be covered by the fluid.. 34 1 531. 34 1 536..... Hand-tighten cap of rear wheel-circuit reservoir.DOT 4 • Operate the footbrake lever until the pistons of the rear brake caliper are in contact with resetting tool... Do not operate the brake lever until self-diagnosis has completed.. and adapter.... Tightening torque: Bleed screw in rear brake caliper ... 40 Nm X 00... and adapter. 34 1 531... (a 00............ 34 1 531....... 34 1 536.. BMW No.. the front brake must be ready for use...46 . L Note: Attention: After all the work on the brake system has been completed.... and adapter. Warning: Make sure that the wheel-circuit reservoir does not overflow when the brake pads/brake calipers are installed. e MAX MIN 34 1 536 R28340090 • 34 1 531 • R28000170 Top up the fluid in the wheel-circuit reservoir until one of the three protrusions in the filler neck just touches the surface of the fluid (arrow)... run a bleed test using the BMW MoDiTeC.. 34 1 536.. BMW No. e • • After switching on the ignition.... 5 Nm Brake caliper to rear wheel drive . Fully tighten resetting tool. • • Top up fluid in rear wheel-circuit reservoir to “MAX” mark if necessary.. Switch on the ignition..... BMW No.. Bleed the system again if this happens.. BMW No... Brake fluid ...

... e Attention: on the brake system has been After all the work completed... to the bleed screw....... 34 1 561..9214 ft) silicon hose... BMW No. Wrap a cloth around the rear brake caliper... Release the brake and switch off the ignition.. 34 1 561. run a bleed test using the BMW MoDiTeC. Connect 1. Do not operate the brake lever until self-diagnosis has completed. BMW No. (a 00.DOT 4 • Switch on the ignition.. 34 2 541.44) • 34 1 561 • • • • 34 2 541 Pump brake fluid through the system until it is clear and free from air bubbles...... 34 2 541. (a 00.. Remove cap...47 .. Pump the brake fluid with virtually no pressure until the hose is full of brake fluid. L Note: • • • • • After switching on the ignition........ Close the bleed screw.... Connect end of hose to cap. BMW No. force back the brake pistons and secure the pistons in this position..5m (4. If the fluid foams.. hose to the bleed screw.46) Check operation of the brake system with the ignition switched on. 34 2 541........ then vary the brake pressure.. always wait for the BMW Integral ABS to complete its self-diagnosis.... R28000230 • • • • Fill rear wheel-circuit reservoir with brake fluid up to “MAX” mark and install cap........ from bleed screw and drain the hose..... Remove rear brake pads. Disconnect silicon hose. d Warning: Check that the brake fluid in the hose does not foam. Open the bleed screw... always After changing top up the fluid in the wheel-circuit reservoir to the correct level in accordance with the instructions.. e Attention:and/or bleeding the brakes...... X Tightening torque: Bleed screw in rear brake caliper . L Note: use a cable tie to secure the bleed If necessary.Only bleeding the rear wheel circuit – – – Draw off the old brake fluid from the wheel-circuit reservoir.. proceed as described in the section on bleeding and changing brake fluid in rear wheel circuit.. BMW No.. Very gently press the footbrake lever until the pump just starts up.. BMW No... Pump the brake fluid with virtually no pressure to begin with.... Fill rear wheel-circuit reservoir with brake fluid in accordance with instructions.... 40 Nm 00. 6 Nm Brake caliper to rear wheel drive . Brake fluid .....

in front control circuit 1 3 2 When performing maintenance and repair work on BMW Integral ABS. R28340110 • Attention: Do not allow brake fluid to come into contact with painted parts of the motorcycle as brake fluid destroys paint. Wrap cloths around the reservoir. Place the motorcycle on its main stand. Turn the front wheel to a position in which the brake fluid reservoir is horizontal and secure the handlebars in this position. draw off the old brake fluid and clean the reservoir.34 00 091 Changing/bleeding brake fluid in control circuit Change brake fluid in control circuit every 2 years (Inspection IV) Warning: All repair and maintenance work on the BMW Integral ABS must be performed by trained. d 00. d R21000020 • 34 00 072 Bleeding/changing brake fluid Top up the brake fluid level to the “MAX” mark (arrow). Repeatedly and slowly pull front brake lever lightly to expel air from brake master cylinder. Warning: Do not use vacuum extraction to change the brake fluid in the control circuits or bleed the control circuits. qualified specialists. Comply with all maintenance and repair instructions and always work through the various steps in the correct order. Remove fuel tank. Use only new brake fluid from freshly opened containers.48 . d Warning: • • • • • Place the motorcycle on its side stand and turn the handlebars all the way to the left. Remove front reservoir cap with rubber diaphragm. e • • Connect the brake bleeding device to bleed screw (1) of the front metering cylinder. never pump quickly or vigorously. but do not switch on.

......... never pump quickly or vigorously.. Repeat steps 1 to 4 until the bake fluid is clear and free of bubbles.. • Set the handbrake lever to position 4... – front integral circuit (2) – front control circuit (3) and – front metering cylinder (1) for the second time using ring spanner. Brake fluid ........ 4.. 5.. Top up the brake fluid until the level reaches the “MAX” mark................... Slowly pull brake lever until brake-light switch clicks (blow-by bore closed).. and carefully reassemble the components. the rubber diaphragm and the cover to remove brake fluid.......DOT 4 • In the following sequence.... Open the bleed screw. Slowly pull brake lever to full extent of its travel and close the bleed screw.49 . 34 2 532. • • • Recheck the brake-fluid level...... Turn the handlebars to the left... 00.. or else air will be drawn into the brake system...e Attention: During the fluid-change and bleeding procedure. BMW No... Bleed the system again if this happens....... make sure that the fluid replenishing hole is always below the level of the brake fluid.. MIN (top edge of the marking ring) e Attention: R28340110 After all the work on the brake system has been completed.... Instructions for bleeding: 1... d 1 3 2 R22000140 Required level not below . 2.. Slowly release the brake lever............ run a bleed test using the BMW MoDiTeC....... Place the motorcycle on its centre stand.. Warning: When performing maintenance and repair work on BMW Integral ABS. bleed: – front metering cylinder (1). 3.... • • • Fit the protective caps on the bleed screws.... in accordance with instructions for bleeding... Wipe the rim of the reservoir......

Open the bleed screw. – rear control circuit (3) and – rear metering cylinder (1) for the second time using ring spanner. R22000151 • • Top up the brake fluid level to the “MAX” mark. Remove rear reservoir cap with rubber diaphragm. as otherwise air will be drawn into the brake system. Fuel tank removed. BMW No. Warning: Do not use vacuum extraction to change the brake fluid in the control circuits or bleed the control circuits. draw off the old brake fluid and clean the reservoir. Repeat steps 1 to 4 until the bake fluid is clear and free of bubbles. Bleed the system again if this happens. Connect the brake bleeding device to bleed screw (1) of the rear metering cylinder. 2 3 1 R28340110 • In the following sequence. Instructions for bleeding: 1. d • Fit the protective caps on the bleed screws. Slowly depress brake lever until brake-light switch clicks (blow-by bore closed). 2. e • • • Remove right case. do not allow the brake fluid level to drop below the “MIN” mark.34 00 082 Bleeding/changing brake fluid in rear control circuit – – Place the motorcycle on its main (centre) stand. never pump quickly or vigorously. in accordance with instructions for bleeding. Remove small right side fairing panel. Warning: When performing maintenance and repair work on BMW Integral ABS. if necessary. Slowly depress brake lever to full extent of its travel and close the bleed screw.50 . but do not switch on. 34 2 532. Attention: While bleeding the system. – rear integral circuit (2). 4. Slowly release the brake lever. 5. 3. bleed: – rear metering cylinder (1). d Attention: Do not allow brake fluid to come into contact with painted parts of the motorcycle as brake fluid destroys paint. e 00.

..... Move the handlebars to the straight-ahead position.. Checking clutch operating fluid level (Inspections II and III) e Attention: fluid in the clutch operating system Keep the brake away from painted surfaces on the motorcycle because brake fluid attacks paint...... the fluid level in the reservoir rises... the rubber diaphragm and the cover to remove brake fluid.....51 ................ MIN e Attention: • • After all the work on the brake system has been completed. Place the motorcycle on its centre stand..... (a 00...DOT 4 00.................... • • Place motorcycle on its centre stand. Reinstall the reservoir cap with insert. Mark in reservoir: same as brake circuit.............DOT 4 L Note: – As the clutch lining wears.... Wipe the rim of the reservoir.............. run a bleed test using the BMW MoDiTeC..29) Install fuel tank................................... • • • • If necessary. Half way up sight glass Brake fluid........• • – Correct the brake fluid level. Perform bleed test with BMW MoDiTeC................... remove reservoir cap with insert.... Correct the fluid level.. Tighten the reservoir cap carefully and without using force............... Brake fluid ..... R22000190 Required level with a new clutch liner: ... R22000150 Required level not below .............. and carefully reassemble the components..................

.. 3 Attention: The motorcycle is not permitted on the road without the grub screw in place and secure in the filler adapter. e • • • • • • • Place the motorcycle on its main (centre) stand... • Reinstall socket-head grub screw (2) in the filler adapter. Tighten the reservoir cap carefully and without using force.......... do not allow the brake fluid level to drop below the bottom edge of the ring mark... Open the bleed screw by half a turn (valve open). Top up the brake fluid.... e Attention: • • • . Draw off brake fluid until it emerges clear and free from air bubbles..... Laccount of the vacuum extraction process... 10 Nm Consumables Brake fluid. Attention: While bleeding the system.. In this case bleed the system manually... Disconnect the brake bleeding device from the bleed screw.... R22210010 Tightening torque: Grubscrew in filler adapter .... Remove the bleed screw. If other devices are used.. e • • 1 2 • • Correct the fluid level. Recheck the fluid level......... Turn the handlebars to a position in which the clutch fluid reservoir is horizontal. it Note: On might not be possible to tell whether there is brake fluid in the hose of the brake bleeding device when it is free of bubbles. Wrap a cloth around the filler adapter.. Remove socket-head grub screw (2) from the filler adapter.21 52 005 Changing the clutch fluid • Screw the bleed screw all the way into the filler adapter (valve in filler adapter closed). comply with their manufacturers’ instructions...... as otherwise air will be drawn into the clutch system.. Reinstall the reservoir lid with rubber diaphragm in position...52 ......DOT 4 X • • • • Pull back protective hose (1)... Keep the brake fluid in the clutch operating system away from painted surfaces on the motorcycle because brake fluid attacks paint.... Connect the brake bleeding device to bleed screw (3).. Bleed the system again if this happens.. 00........... Remove reservoir cap with rubber diaphragm..... (Inspection IV) every 2 years at the latest L description applies to a brake system filling and Note: The bleeding device with vacuum extraction of brake fluid at the bleed line. Draw off the brake fluid and clean the reservoir. Secure front wheel in position..

............. If play is perceptible...Checking tightness of rear wheel studs (Inspection I) Greasing the side stand pivot (Inspections I........ 00. Grease pivot point (arrow)....... bracing against the frame....... Start the engine....... fit new shims to rear wheel drive or replace bearings.. Disengage the clutch and select a gear........ 105 Nm X Checking rear wheel bearing play by tilting wheel (Inspection III) • – a Tilt the rear wheel to and fro across its axle.. adjusting if necessary (Inspections I and III) Check free movement of side stand and grease if necessary....... Tightening torque: Securing screws for rear wheel . without releasing the clutch lever........53 ..... if extended.............. Lubricant: .......... .... remove fixed-bearing stud and floating-bearing stud of the bearing in question.... II and III) • Tighten the rear wheel studs with a torque wrench... Extend the side stand... III and IV) • • • • • Place the motorcycle on its centre stand..... Shell Retinax EP2 • – a Grip rear tyre and try to move it sideways..... Retract the side stand. L side-stand switch is in correct working order if Note: The the engine stops when the side stand is extended.. II...... If play is detected.... clean the threads and reinstall............................. ...... see Group 33 Checking function of side stand contact switch (Inspections I......... see Group 33 R22000310 • • Checking swinging arm bearings..............

........0393 in) Tightening torque: Spark plug NGK BKR7EKC .2.....12 12 011 Checking/replacing spark 11 12 009 Tightening cylinder heads plugs (Inspection II) check/(Inspection III) replace (Inspection I) 12 3 510 12 3 520 R21000330 R21000190 • • Pull off spark plug caps with special puller..... Slacken/retighten M10 screw.. Top dead centre on ignition stroke: The TDC mark is visible and the inlet and exhaust valves in the cylinder concerned are closed............... or set the piston to TDC on the ignition stroke by turning the belt pulley...risk of breakage! Spark plug:...3... Slacken off one nut at a time 1...... 1... • Remove cylinder head cover................000 km (600 miles) 1........ 12 3 510..... e Attention: Catch escaping oil.......... Remove spark plugs with the spark plug wrench......... 0.....8 mm (0.. 25 Nm X R21000370 • Select a gear and turn the rear wheel. Tighten nut to specified wrench angle........ 180° 2.... 20 Nm 1..... 12 3 520....... e Attention: Do not bend electrodes ..54 .......... Tighten nut to initial torque. Tighten the cylinder head nuts one after the other in diagonally opposite sequence 1. BMW No...1.. • Tighten cylinder head nuts.. 40 Nm 00...... NGK BKR 7 EKC Electrode gap: ..0314 in) Wear limit: ....... • Tightening procedure after 1.. BMW No......0 mm (0........

.... Tightening torque: Cylinder head cover ....... II and III) • • • Test-drive the motorcycle until the engine is warm. 8 Nm 00... Remove the flap in the right side panel................... 1 mm (0.15 mm (0............. correct with adjusting screw..........approx... if necessary............. 0.......... Use the adjusting screws to adjust play of throttle and choke cables..... Valve clearances with engine cold (max. Feeler gauge must pull through between valve stem and adjusting screw with slight resistance..............0059 in) Exhaust .... Assembly is the reverse of the disassembly procedure....... 8 Nm X • • R22000320 Recheck valve clearances after adjusting....approx... 0........... • • Push back rubber cap (arrow) on throttle and choke cables....... II and III) 13 60 110 Checking freedom of throttle cable.....Checking/adjusting valve clearances 11 34 004 (Inspections I.... 35 °C/95 °F): Inlet .... Seals and sealing faces must be free from oil and grease.30 mm (0....... replacing if necessary Checking throttle-cable play Checking and adjusting idle speed and throttle-valve synchronisation (Inspections I................. Oil temperature: .. checking for chaffing and kinks.....55 .. 1 mm (0.......0393 in) Play of throttle cable: .at least 90 °C (194 °F) R21000340 • Check valve clearance with feeler gauge and.0393 in) Make sure that all seals are correctly seated.....0118 in) Tightening torque: Locknut ...... Remove the left side panel................... e Attention: X Play of choke cable: .....

..0787 in) L Note: Zero play can cause the throttle valves to rattle. but the throttle valve reliably contacts the stop screw (no strain on cable).. Tighten the locknut to secure.. • Turn the adjusting screws to adjust the play of the cables for the left and right throttle valves.... Play of throttle cable: ....... as otherwise the idle-speed volume flow will have to be reset by the manufacturer... • • Connect hose of BMW Synchro to vacuum adapter and connect cables to BMW MoDiTeC... • Use the adjusting screws (arrow) to adjust play of the throttle cables.. Turn the adjusting screw very slightly in the opposite direction until the reading returns to its original value....56 ... 0.......0197 in) • Push the rubber cap into position over the adjusting screw.....5 mm (0.... Attention: Do not allow the engine to idle for longer than is necessary.approx. 00... ±50 rpm Idle speed: ...... approx..... 2 mm (0......... 1... because the trim panels near the exhaust could be damaged..... Play of throttle cable: .. e • Adjust idle speed by turning the air bypass screws while checking that the carburettors are balanced.• • • Carefully turn the adjusting screw of the left throttle valve and reduce play until the reading of the Synchro tester changes..... • Adjust the right throttle valve in the same way. Adjust throttle cable play at throttle valve so that no play is perceptible.. Start the engine... e Attention: Do not tamper with the sealed stop screws of the throttle valves..100 L Note: R22000320 Make sure that both throttle valves are closed....... L Note: S000100 Make sure that the reading does not change when you tighten the locknut...

Seal off the vacuum bores............ Integral ABS • If necessary. Tighten the locknuts and recheck carburettor balance........ front .... correct by turning the adjusting screws of the throttle-valve Bowden cable........5 2............. Push the rubber cap into position over the adjusting screw.......2 2...5 2............06 psi) psi) psi) psi) psi) psi) Roadworthiness check • Lights • Telltale/warning lights • Horn • Instruments • Special equipment • Clutch • Gear shift • Steering • Footbrake and handbrake..... • Wait at least 10 minutes after heating the engine to operating temperature in the trial run/road test before checking/correcting engine oil level....9 2. Assembly is the reverse of the disassembly procedure.... rear two-up ..........26 (42..... II.. Make sure that engine speed does not vary when the handlebars are moved in this way.... • Check/correct tyre pressures.............. Repeatedly open the throttle gradually and increase engine speed from idle to approximately n = 2. III and IV) Road safety check • Check wheels and tyres. Tyre pressures: one-up .......26 (36.... If necessary.......06 (36.5 2......... (Readings shown by Synchro tester must increase and decrease together)...90 (36..... take the motorcycle for a test ride... 00..500 rpm to check throttle-valve synchronisation..26 (42............9 bar bar bar bar bar bar (31......... L Note: • • • Make sure that when the throttle grip is released both throttle valves return to their fully closed positions........ rear two-up + luggage ....... front .Final inspection with road safety and functional check (Inspections I......57 ....... Move the handlebars all the way from left to right and check the settings... front .. 2........ rear R22000330 • • • • Use the adjusting screw (arrow) to adjust play of the choke cable to zero................

00.58 .

.............. 11 ...................................8 Removing and installing front brake discs Removing and installing rear brake disc ............................................................. 12 Checking blow-by clearance of piston rod ........... 14 ........9 ...................................................................................... 13 ......................................................................................................................................................................................7 ...................................................... 13 Checking setting of brake light switch........................................................................................................... 13 Adjusting brake light switch.......5 Disassembling and assembling front brake caliper Removing and installing rear brake caliper ......................................34 Brakes 34 Contents Page Technical Data 34 Brakes ....................................................................7 Disassembling and assembling rear brake caliper Disassembling rear brake caliper Assembling rear brake caliper ...............................................................................................................................................................6 ....................................................... 11 Removing and installing rear brake master cylinder Checking and adjusting blow-by clearance of piston rod .............................................................................................................................................................................. 12 ............................................................ 13 ........................................................................1 ................................7 ..................................................................................... 15 34...........................9 .............. 10 Removing and installing Integral ABS sensor Removing and installing front Integral ABS sensor Removing and installing rear Integral ABS sensor Removing and installing footbrake lever ............................................. rear ...................................................................4 ........ 3 Removing and installing front brake caliper ................................. 12 Adjusting blow-by clearance at piston rod .............. rear ............................8 .................................................................... 14 Checking and adjusting setting of rear brake light switch Removing and installing piston in brake-lever fitting Removing and installing Integral ABS pressure modulator Removing Integral ABS pressure modulator Installing Integral ABS pressure modulator .......................

29 Integral ABS Removing and installing bleed lines.............. 19 Bleeding front control circuit .............................................................................................................................21 Bleeding the rear control circuit ...................................... 18 Draining rear control circuit ................................................... 17 ......................31 ................................................................................................................... 19 Draining control circuits Filling and bleeding Integral ABS system Filling and bleeding control circuits ........................................................................................................................................................................................................................................................................32 ............................................................................................ 16 ................................................................................................30 ......... wheel circuit reservoirs Integral ABS: Removing and installing brake lines Installed position of front brake line Installed position of rear brake line .......21 Filling and bleeding wheel circuits ..................................................23 Filling and bleeding front wheel circuit ...........26 Instructions for filling rear wheel circuit reservoir ............................................................................................................................................................................................................23 Instructions for filling front wheel circuit reservoir ....................33 34........................................ 18 Draining front control circuit ..............20 Filling the rear control circuit .......Contents Draining the Integral ABS brake system Drain both wheel circuits Page ................................................................................................ 19 Filling the front control circuit ...........................................2 ...........29 .........................................................................................28 Integral ABS Reading fault memory with BMW MoDiTeC Integral ABS Performing bleed test with BMW MoDiTeC .................................................................................... 16 Draining rear wheel circuit ............................................................................................................................................................................................................... 16 Draining front wheel circuit ...............................................................................................25 Filling and bleeding rear wheel circuit .... 18 .........................................................................................................................................................................................................................................................................................................................................

1772) mm (in) 0.34 Technical Data 34 Brakes Brake fluid Front wheel Type Colour of identification mark on brake calipers/brake pads Brake pad lining Minimum lining thickness Brake pad surface area Brake disc dia. Brake disc thickness Minimum thickness of brake discs Permissible lateral runout Piston dia. rear mm (in) 276 (10..0 (0.15 (0.1969) mm (in) 4.1772) mm (in) 0..0236/1.15 (0.23) (sq in) Brake pad surface area Brake disc dia.0..0079.8661) mm (in) 5.0079.7 (0.4173) mm (in) 16 (0.2.. in brake caliper Piston dia.0 (0. Brake disc thickness Minimum thickness of brake disc Permissible lateral runout Piston dia. front Sensor gap. in brake caliper Piston dia.0670) (active sensor) 34.33) mm (in) 320 (12.1. in handlebar lever cylinder Rear wheel Type Brake pad lining Minimum lining thickness R 1150 RT DOT 4 Hydraulically operated twin disc brake with 4-piston fixed calipers and floating brake discs white Sintered metal mm (in) 1.3 .0 (0.5 (0.8 (5..0.0393) (If the brake disc is visible through the bore in the wheel-side brake pad.6299) Hydraulically operated disc brake with 2-piston floating caliper and fixed disc Sintered metal mm (in) 1.. in actuating cylinder BMW Integral ABS Type Sensor gap.0670) (active sensor) mm (in) 0.5987) mm (in) 5.2..5 (0..0059) mm (in) 32/36 (1.1023) mm (in) 13 (0.2599/1.1968) mm (in) 4. the brake lining is worn to its minimum permissible thickness) cm2 33.1.5118) Active fully integral system mm (in) 0.0059) mm (in) 26/28 (1.0393 in) (sq in) cm2 86 (13.0 (0.7 (0.

...... white 34...23)......... 18 Bleed screw to brake caliper ....................................4 ...... e • • Installation is the reverse of the removal procedure......... Integral ABS Fill and bleed front wheel circuit (a 34..16). e • Integral ABS Drain front wheel circuit (a 34....... Tightening torque: Brake caliper to fork slider...Removing and installing front brake caliper 34 11 Attention: Do not allow brake fluid to come into contact with painted parts of the motorcycle as brake fluid destroys paint......... 7 X Nm Nm Nm Nm Colour code: Brake pads/brake calipers . Carefully remove the brake caliper. 30 Brake hose to brake caliper ........ 7 Grub screw in front brake caliper ................... Attention: Replace the sealing rings (2) in the brake line. Remove the brake caliper securing screws...... Do not damage the brake pads when installing.......... 1 d Suds 2 R28340010 • • • Disconnect brake line (1)...

...... e Attention: – – Do not separate the brake caliper halves! Integral ABS Drain front wheel circuit (a 34.. • • • • • Carefully press out brake pistons (1).. 7 Nm Grub screw in front brake caliper ... score-marks and other damage..... Remove the brake caliper..... Remove the two sealing rings from each brake cylinder bore. risk Do not insert your of injury...white e Attention: fingers between the pistons. • • • • • • • • Remove and install the other two brake pistons in the same way........... Using piston resetting tool.. press the pistons fully back............3 2 1 34 1 531 34 1 532 S340220 34 11 521 Disassembling and assembling front brake caliper e Attention: pistons parallel with their bores Keep the brake when installing. Coat new sealing rings (2....23). Integral ABS Fill and bleed front wheel circuit (a 34.5 ... 7 Nm Colour code: Brake pads/brake calipers . BMW No.. Close the bleed screw. 3) with brake fluid and install. Insert a piece of cloth between the two brake pistons not secured by the resetting tool.. 34 1 520.16).... Coat brake caliper pistons (1) with brake fluid and insert.. Install brake caliper. Remove the brake pads. Secure two opposing brake pistons with spacer.... 34 1 531. X Tightening torque: Bleed screw to brake caliper ... Inspect the brake caliper piston for hairline cracks.... BMW No.......... 34.. using a compressed air gun at the brake line connection..

...........17).....2 2 1 R22340090 Removing and installing rear brake caliper 34 21 Attention: Do not allow brake fluid to come into contact with painted parts of the motorcycle as brake fluid destroys paint........... 5 Nm X Integral ABS Drain rear wheel circuit (a 34.26)........ e • • • Tightening torque: Brake caliper to rear wheel drive ......... position the brake caliper with the bleed nipple at the highest point...... Attention: Replace the sealing rings (2) in the brake line.. 40 Nm Brake hose to brake caliper .... Integral ABS Fill and bleed rear wheel circuit (a 34........6 ... Disconnect brake line (1) from brake caliper.... 18 Nm Bleed screw to brake caliper . L Note: • To bleed.. Remove the brake caliper. 34.. Do not damage the brake pads.... e • Installation is the reverse of the removal procedure.

........... Remove the brake caliper......... Coat the adapter plate locating pins with Shell Retinax A and install the adapter plate......26)........ Carefully press out brake piston (3) with a compressed air gun applied to the connecting bore...... • • • e Attention: pistons parallel with their bores Keep the brake when installing......17).. BMW No.. risk of injury... 5 Nm 34.. 5 Nm X X Tightening torque: drive ......... L Note: • • • • Remove sealing rings (4) from left and right bores. Hold a cloth over the brake caliper piston......... The installed position must be correct (arrow pointing in forward-travel direction)..... Integral ABS Fill and bleed rear wheel circuit (a 34...7 ......1 5 2 3 4 R21340010 34 21 Disassembling and assembling rear brake caliper Disassembling rear brake caliper Assembling rear brake caliper • • – – Integral ABS Drain rear wheel circuit (a 34. Close the bleed screw. Coat both brake caliper pistons with brake fluid and install them. Insert locating plate (5) into brake caliper.. • • e Attention: from gap between piston and Keep fingers away side contact face of brake pads. 40 Nm Brake caliper to rear wheel Brake hose to brake caliper . Tightening torque: Bleed screw to brake caliper .. 34 1 531. Coat the new sealing rings with brake fluid and insert them into the left and right brake caliper bores.. press the pistons fully back..... work at low air pressure. Using piston resetting tool....... 18 Nm Bleed screw to brake caliper . score-marks and other damage..... Inspect the brake caliper piston for hairline cracks..

Removing and installing front brake discs 34 11 34 21 Removing and installing rear brake disc Warning: When removing and installing the brake calipers.. Degrease the brake disc before installing..... Remove brake discs. force back the pistons carefully to ensure that the wheel-circuit reservoir does not overflow.... e • • Install ABS sensor ring (2) on left and thrust washers (3) on right beneath brake disc. 21 Nm X 34.. If fluid escapes. • • Remove the brake caliper. and note ABS sensor ring between left brake disc and front wheel. d • • Remove the brake calipers....... Remove rear wheel.. proceed in accordance with “instructions for filling reservoir” (a 34..... Attention: Note thrust washers between right brake disc and front wheel. L Note: • • • Retaining screws (1) are secured with thread-locking compound and should be heated if necessary before removal.... d Warning: When removing and installing the brake caliper. Degrease brake discs before installing. proceed in accordance with “instructions for filling reservoir” (a 34. Attention: Make sure the spacer is fitted when the rear wheel is installed. If fluid escapes. e X e Attention: Install brake discs right way round (inscriptions on brake discs facing toward the outside)...28)... 21 Nm Tightening torque: Brake disc to rear wheel drive (clean thread + Loctite 2701).... Remove front wheel.... force back the pistons carefully to ensure that the wheel-circuit reservoir does not overflow... Installation is the reverse of the removal procedure..8 . Remove brake disc.. 1 2 1 3 1 R28340150 R28340130 L Note: • Retaining screws (1) are secured with thread-locking compound and should be heated if necessary before removal.. Tightening torque: Brake disc to front wheel (clean thread + Loctite 2701)..25)......

.9 ............. Guide the sensor cable down until clear.... Tightening torque: Sensor ...... 4 Nm X 34. e Attention: cable correctly. Remove sensor (2).... Installation is the reverse of the removal procedure.... hand-tight.........3 1 2 3 R22340060 Removing and installing Integral ABS sensor Removing and installing front Integral ABS sensor 34 52 044 • • • • • Remove the cable ties securing the sensor cable... Disconnect plug (1) of sensor cable. Route the sensor Ensure that clips (3) are correctly seated...

.... Tightening torque: Sensor .... Before removing/installing.. Coat O-rings with oil before installing.... • • • • • • • • • e Attention: X Route the sensor cable correctly. hand-tight... 4 Nm 34.10 .1 2 R22340070 34 52 111 Removing and installing rear Integral ABS sensor Remove front and rear seats..... Disconnect plug (1) of sensor cable.... Remove small right side fairing panel.. if necessary... clean the sensor bore... Installation is the reverse of the removal procedure.. Remove sensor (2). Remove right case......... Remove the cable ties securing the sensor cable......

if necessary.. Check and.. 13 1 500. • • • • • • • Tightening torque: Footbrake lever to footrest plate (clean thread + apply Loctite 2701) . Remove brake master cylinder.. e Attention: Bleed the brake system carefully. Installation is the reverse of the removal procedure.....18)...5 6 7 3 2 4 1 35 21 R22460140 Removing and installing footbrake lever Release and remove stud (1)..12)... 21 Nm Integral ABS Drain rear control circuit (a 34... e Attention: fluid to come into contact with Do not allow brake painted parts of the motorcycle as brake fluid destroys paint... e Attention: X Check and.. Lubricate pivot bushing with Shell Retinax A... adjust the blow-by clearance of the piston rod and the setting of the brakelight switch (a 34. if necessary.. Tighten non-reusable hose clip (7) with pliers. 9 Nm Master brake cylinder to 34. Disconnect brake line (5) and hose (6).. Release and remove stud (1). BMW No.. 34 31 Removing and installing rear brake master cylinder • • • • • • Remove right side panel.... Installation is the reverse of the removal procedure... Integral ABS Fill and bleed rear control circuit (a 34. Remove bolt (2) of footbrake lever with nut (3)... adjust the blow-by clearance of the piston rod and the setting of the brakelight switch (a 34... X Tightening torque:footrest.21). Remove footbrake lever with torsion spring (4).12).11 ..

13.6 +/. Remove the feeler gauge....... Distance A: . 34.. Recheck play. 0.5354+/-0. • • • Press the footbrake lever.0059 in) No play perceptible Feeler gauge thickness: ...0.0137 in) • • • • • • Slacken locknut (1)..Checking and adjusting blow-by clearance of piston rod Checking blow-by clearance of piston rod Adjusting blow-by clearance at piston rod 2 1 A 3 R22340010 R22340020 • Set the adjusting screw of the footbrake lever to distance A..2 mm (0..0078 in) Play must be perceptible Feeler gauge thickness: .. 0. Slowly release the footbrake lever and check play.........) • Insert feeler gauge at right angles to direction of travel between the brake-light switch lever and the stop on the footrest plate (arrow). 0.35 mm (0.12 . Insert feeler gauge at right angles to direction of travel between the brake-light switch lever (3) and the stop on the footrest plate (arrow).5 mm (0. Feeler gauge thickness:. Apply coloured sealing lacquer to the locknut. Turn piston rod (2) clockwise toward the footbrake lever to obtain play....15 mm (0...1969 in) (Top edge of footbrake lever to top edge of adjusting screw. Carefully back off piston rod to take up play and tighten locknut.

Do not operate the brake lever until self-diagnosis has completed.......See Group 32 34.. rear 4 B 3 R22340030 R22340020 • • Depress the footbrake lever and secure it in this position..60 mm (0.. Recheck the setting. 1 + 0.........5 mm (0...13 . Removing and installing piston in brake-lever fitting a .....90 mm (0.. Slowly release the footbrake lever and check the point at which the switch trips... 1..............0354 in) Brake light switch must remain on Feeler gauge thickness: .... Hold the brake light switch and tighten the screw..0393 + 0.... R22340020 Brake light switch must switch off Feeler gauge thickness: .. • Switch on the ignition.. Insert feeler gauge at right angles to direction of travel between the brake-light switch lever (3) and the stop on the footrest plate (arrow).. L Note: on the ignition. 0......0629 in) • • • Turn the brake light switch until the switch trips at distance (B).... Distance B: ... B • • • Depress the footbrake lever (brake light comes on and pump starts up)..Checking and adjusting setting of rear brake light switch Checking setting of brake light switch.1968 in) (clearance at switching point between brake-light switch lever and footrest plate)......... always wait for the After switching BMW Integral ABS to complete its self-diagnosis. rear Adjusting brake light switch. Slacken screw (4). • Switch off the ignition......

Comply with all maintenance and repair instructions and always work through the various steps in the correct order.14 . Push protective caps (1) up.3 4 2 1 R28340060 34 00 Removing and installing Integral ABS pressure modulator Removing Integral ABS pressure modulator d Warning: All repair and maintenance work on the BMW Integral ABS must be performed by trained.16). 34. Disconnect ground lead from battery and insulate. Use only new brake fluid from freshly opened containers. qualified specialists. Remove spring clips (2). Drain the brake system (a 34. e Attention: • • • • Do not allow brake fluid to come into contact with painted parts of the motorcycle as brake fluid destroys paint.

Seat the protective caps on the connectors.. • • Switch on the ignition... X pressure modulator to battery carrier ....e Attention: • Installing Integral ABS pressure modulator Do not bend the brake lines.. Slip the protective caps up the brake lines. Without starting the engine. Fill and bleed the brake system (a 34.19). 7 Nm 34.... e Attention: • • • • • L Note: Do not permit brake fluid to enter the plugs.. Disconnect plugs (3) of the front and rear wheel circuit reservoirs. Check that spring clips are correctly positioned (arrows).4 control unit are deleted and the adaptation values are reset. fully open the throttle once or twice so that the Motronic control unit can register the throttle-valve positions. Install new spring clips. Release ABS pressure modulator and pull it carefully to the left to remove. • Installation is the reverse of the removal procedure: pay particular attention to the following.. d Warning: • • • • • • • • Always fit new spring clips each time the plugs are disconnected... This can temporarily impair the operating characteristics when the engine is restarted. Disconnect the brake lines from the ABS pressure modulator.. run a bleed test using the BMW MoDiTeC (a 34. Unlock plug (4) (arrow) and disconnect the plug. Disconnect plug from Hall sensor. Connect the battery. Remove Motronic control unit. 10 Nm Tightening torque: ABS ABS pressure modulator to holder .15 . Always replace the seals (square-section rings) between the brake lines and the pressure modulator when you replace the brake lines. L Note: Disconnecting the battery means that the entries in the fault memory of the Motronic MA2.. Clip in brake lines.29)... After all the work on the brake system has been completed. Ensure correct positioning.

Remove front brake pads. and locator. 34 1 531. Do not operate the brake lever until self-diagnosis has completed. always wait for the After switching BMW Integral ABS to complete its self-diagnosis. qualified specialists. Disconnect the brake bleeding device from the bleed screw.16 . Close the bleed screw. If other devices are used. Remove fuel tank. e Attention: • • • • Do not scrape the wheel – mask it off if necessary.34 00 Draining the Integral ABS brake system • • Draw off the old brake fluid from the wheel-circuit reservoir and reinstall the cap. Open the bleed screw. Attention: To prevent brake fluid entering plugs. Release the brake. Drain the wheel circuit with the pump. e 34. comply with their manufacturers’ instructions. Release the brake and switch off the ignition. BMW No. d 34 1 531 L Note: 34 1 532 R28000180 This description applies for the brake filling and bleeding unit with extraction of the brake fluid by partial vacuum. Comply with all maintenance and repair instructions and always work through the various steps in the correct order. BMW No. Use only new brake fluid from freshly opened containers. to force the pistons in the left and right brake calipers all the way back and hold them in this position. Disconnect the brake bleeding device from the bleed screw. Switch on the ignition. Wrap cloths around the left and right brake calipers. R28340110 • Open front wheel-circuit reservoir (1). e Attention: Integral brakes. • • • • • • • • • • 1 Gently pull the handbrake lever until the pump just starts up. The procedure for draining the right brake caliper is the same as that for the left caliper. Warning: All repair and maintenance work on the BMW Integral ABS must be performed by trained. e Use resetting tool. but do not switch on the device. do not disconnect plugs from the ABS pressure modulator. Connect the brake bleeding device to the bleed screw of the left brake caliper. Drain both wheel circuits Attention: Do not allow brake fluid to come into contact with painted parts of the motorcycle as brake fluid destroys paint. Draining front wheel circuit L Note: on the ignition. • • Remove front and rear seats. 34 1 532. Close the bleed screw. the rear brake must be ready for use.

Install resetting tool. 34. with the handle toward the outside in the rear brake caliper. press the pistons fully back and secure them in this position. instead of the outboard brake pad. always wait for the BMW Integral ABS to complete its self-diagnosis. Do not operate the brake lever until self-diagnosis has completed. 1 R28340110 • Open rear wheel-circuit reservoir (1). 34 1 536 34 1 531 R28000170 • • • • • Install adapter. Open the bleed screw. Release the brake and switch off the ignition.Draining rear wheel circuit e Attention: the rear brake must be ready for Integral brakes. L Note: • • • • • • After switching on the ignition. 34 1 536. BMW No. Gently press the footbrake lever until the pump just starts up. Draw off the old brake fluid from the wheel-circuit reservoir and reinstall the cap. Close the bleed screw. e Attention: • • To prevent brake fluid entering the plugs. do not disconnect the plugs from the ABS pressure modulator. Disconnect the brake bleeding device from the bleed screw. Wrap a cloth around the brake caliper. Connect the brake bleeding device to the bleed screw. Drain the wheel circuit with the pump. – Install front brake pads. if applicable. use.17 . but do not switch on the device. BMW No. Switch on the ignition. 34 1 531. Remove rear brake pads.

34 2 532: front metering cylinder (1). draw off the old brake fluid and clean the reservoir.Draining control circuits Draining rear control circuit e Attention: Do not allow brake fluid to come into contact with painted parts of the motorcycle as brake fluid destroys paint. using ring spanner. 34 2 532: rear metering cylinder (4). Wrap cloths around the reservoir. R28340110 • – – – Draw off the brake fluid from the circuits in the correct sequence. rear integral circuit (5) and rear control circuit (6). Remove front reservoir cap with rubber diaphragm. Draw off old brake fluid and clean the reservoir.18 . 34. using ring spanner. Draining front control circuit • Remove rear reservoir cap with rubber diaphragm. BMW No. • • • • Turn the front wheel to a position in which the brake fluid reservoir is horizontal and secure the handlebars in this position. 5 6 4 1 3 R28340110 • 2 – – – Draw off the brake fluid from the circuits in the correct sequence. BMW No. front integral circuit (2) and front control circuit (3).

or else air will be drawn into the brake system. Remove front and rear seats. qualified specialists. e Attention: – – On account of the vacuum extraction process. Remove front reservoir cap with rubber diaphragm. the system must be bled again manually in the specified sequence and in accordance with the instructions for bleeding the brakes. front integral circuit (2).19 . d During the filling and bleeding procedure. 34. front control circuit (3) and front metering cylinder (1) for the second time. Filling the front control circuit – Turn the front wheel to a position in which the brake fluid reservoir is horizontal and secure the handlebars in this position. Use only new brake fluid from freshly opened containers. Remove fuel tank. 1 3 2 L Note: This description applies for the brake filling and bleeding unit with extraction of the brake fluid by partial vacuum. Consequently. BMW No. Wrap cloths around the reservoir. R28340110 • • • • • Filling and bleeding control circuits e Attention: fluid to come into contact with Do not allow brake painted parts of the motorcycle as brake fluid destroys paint. it is not possible to tell whether there is brake fluid in the hose of the brake bleeding device when it is free of bubbles. KR340280 • Top up the brake fluid level to the “MAX” mark (arrow). 34 2 532: front metering cylinder (1). – – – Place motorcycle on its centre stand. comply with their manufacturers’ instructions. Draw off the brake fluid from the circuits in the correct sequence while topping up continuously with fresh brake fluid and using ring spanner. If other devices are used.34 00 Filling and bleeding Integral ABS system e Attention: Warning: All repair and maintenance work on the BMW Integral ABS must be performed by trained. make sure that the fluid replenishing hole is always below the level of the brake fluid. Comply with all maintenance and repair instructions and always work through the various steps in the correct order.

4. never pump quickly or vigorously.. Instructions for bleeding: 1........ Wipe the rim of the reservoir...20 .DOT 4 • • Remove reservoir cap with rubber diaphragm... 34 2 532............ 5.. – front control circuit (3) and – front metering cylinder (1) for the second time using ring spanner...... In the following sequence. Warning: When performing maintenance and repair work on BMW Integral ABS......... Switch off the brake bleeding device...... Slowly pull brake lever to full extent of its travel and close the bleed screw. run a bleed test using the BMW MoDiTeC.... Slowly pull brake lever until brake-light switch clicks (blow-by bore closed). 34.. Turn the handlebars fully to the left.... Repeatedly pull front brake lever lightly to expel air from brake master cylinder... Add brake fluid up to the “MAX” mark.... Set the handbrake lever to position 4....... BMW No.. Slowly release the brake lever. Turn the handlebars to full left lock.. • • • Fit the protective caps on the bleed screws...... MIN (top edge of the marking ring) Attention: After all the work on the brake system has been completed......... 3..... Repeat steps 1 to 4 until the bake fluid is clear and free of bubbles......... 2... • • • Recheck the brake-fluid level...... Open the bleed screw.. – front integral circuit (2).. the rubber diaphragm and the cover to remove brake fluid. Place the motorcycle on its centre stand.. R28340110 e Brake fluid .. bleed: – front metering cylinder (1).. and carefully re-assemble the components.. d 1 3 2 R22000140 Specified level not below ...Bleeding front control circuit • • • • • Seal the reservoir by installing the rubber diaphragm and the reservoir cap... in accordance with instructions for bleeding...

Bleeding the rear control circuit Switch off the brake bleeding device. – rear control circuit (3) and – rear metering cylinder (1) for the second time using ring spanner. bleed: – rear metering cylinder (1). 5. • • R22000151 • Top up the brake fluid level to the “MAX” mark. – rear integral circuit (2). d 2 3 1 R28340110 • – – – – Draw off the brake fluid from the circuits in the correct sequence while topping up continuously with fresh brake fluid and using ring spanner. BMW No. 4. never pump quickly or vigorously. as otherwise air will be drawn into the brake system. 2. Slowly release the brake lever. e Attention: bleeding the system. rear integral circuit (2). 34. BMW No. Warning: When performing maintenance and repair work on BMW Integral ABS. Slowly depress brake lever until brake-light switch clicks (blow-by bore closed). the system must be bled again manually in the specified sequence and in accordance with the instructions for bleeding the brakes. Slowly depress brake lever to full extent of its travel and close the bleed screw. 3. Instructions for bleeding: 1. rear control circuit (3) and rear metering cylinder (1) for the second time. Consequently. 34 2 532: rear metering cylinder (1).21 . it is not possible to tell whether there is brake fluid in the hose of the brake bleeding device when it is free of bubbles. 34 2 532. Open the bleed screw. do not allow While filling and the brake fluid level to drop below the “MIN” mark. Repeat steps 1 to 4 until the bake fluid is clear and free of bubbles. In the following sequence.Filling the rear control circuit • Remove rear reservoir cap with rubber diaphragm. e Attention: On account of the vacuum extraction process. in accordance with instructions for bleeding.

................... run a bleed test using the BMW MoDiTeC.. Wipe the rim of the reservoir......... the rubber diaphragm and the cover to remove brake fluid................... R22000150 Specified level not below ........ Recheck the brake-fluid level......... Top up the brake fluid at least until the level reaches the “MIN” mark...........• • • • – Fit the protective caps on the bleed screws.......... and carefully re-assemble the components.......... Place the motorcycle on its centre stand..22 ..DOT 4 e 34......... MIN Attention: After all the work on the brake system has been completed...... Brake fluid....

e Attention: – – 34 1 581 Integral brakes. Slowly fill container. with new brake fluid until it is approximately 1/2 full. R28340110 L Note: • If necessary. BMW No. always wait for the BMW Integral ABS to complete its self-diagnosis. but do not switch on the device. 34 1 581. Switch on the ignition. Wrap cloths around the left and right brake calipers. and locator. to force the pistons in the left and right brake calipers all the way back and hold them in this position. Install rear brake pads and brake caliper. Do not operate the brake lever until self-diagnosis has completed. 34 1 532. Remove front brake pads. if applicable. 34 1 581. R22000340 1 • • • Screw container. use a cable tie to secure the bleed hose to the bleed screw. BMW No. Place the motorcycle on its centre stand. L Note: After switching on the ignition.Filling and bleeding wheel circuits e Attention: fluid to come into contact with Do not allow brake painted parts of the motorcycle as brake fluid destroys paint. Connect the brake bleeding device to the bleed screw of the left brake caliper. BMW No. the rear brake must be ready for use. Use resetting tool. Filling and bleeding front wheel circuit e Attention: To prevent brake fluid entering the plugs. do not disconnect the plugs from the ABS pressure modulator. onto front wheel circuit reservoir. 34 1 531 34 1 532 R22000290 e Attention: • Do not scrape the wheel – mask it off if necessary.23 . 34. • • • Open front wheel-circuit reservoir (1). BMW No. 34 1 531.

continue pumping until the fluid in the container just disappears from view. Release the brake and switch off the ignition. Attention: After changing and/or bleeding the brakes. The procedure must be repeated if the fluid drops below the “min” level. 34. MIN R28340090 L Note: use a cable tie to secure the bleed If necessary. e Attention: • • • Gently pull the handbrake lever until the pump just starts up. Connect the brake bleeding device to the bleed screw of the right brake caliper. Open the bleed screw. which means that the level in the wheel-circuit reservoir drops all the more rapidly. The procedure for changing the brake fluid in the right brake caliper is the same as that for the left caliper. Pump out the brake fluid with virtually no pressure to begin with. Disconnect the brake bleeding device from the bleed screw. e L Note: The higher the brake pressure the faster the fluid is pumped through the system.24 . Close the bleed screw. Close the bleed screw. Disconnect the container from the wheel-circuit reservoir. but do not switch on the device. because the piston in the base of the wheel-circuit reservoir must always be covered by the fluid. then vary the brake pressure. Disconnect the brake bleeding device from the bleed screw. hose to the bleed screw. Release the brake. while topping up the container with new brake fluid if necessary.• • • • MAX • Pump off brake fluid until it emerges clear and free from air bubbles. When the brake fluid is clear and free of bubbles. • • • • • • The brake fluid must always be visible in the container. always top up the fluid in the wheel-circuit reservoir to the correct level in accordance with the instructions.

Instructions for filling front wheel circuit reservoir

e Attention:

Integral brakes, the rear brake must be ready for use. Install front brake pads, if applicable.

MAX

MIN

34 1 533 34 1 531

R28340090


34 1 532
R22000300

• •

• •

Top up fluid in front wheel-circuit reservoir to “MAX” if necessary Install adapters 22, BMW No. 34 1 533, in resetting tool, BMW No. 34 1 531/532, for both front brake calipers, and tighten the resetting tool until the adapters are secure.

• • • • •

Top up the fluid in the wheel-circuit reservoir until one of the three protrusions in the filler neck just touches the surface of the fluid (arrow). Screw container, BMW No. 34 1 581, onto front wheel circuit reservoir. Remove adapter, BMW No. 34 1 533, and force back pistons far enough to allow the brake pads to be fitted. Install front brake pads. With the ignition switched on, bed in the brake pads against the brake discs. Disconnect the container from the wheel-circuit reservoir. Hand-tighten cap of front wheel-circuit reservoir. Check operation of the brake system with the ignition switched on.

episton in the base of the wheel-circuit reservoir e Attention: Attention: The
must always be covered by the fluid, as otherwise air can be drawn into the brake system. Bleed the system again if this happens.

After all the work on the brake system has been completed, run a bleed test using the BMW MoDiTeC and check the fault code memory!

Switch on the ignition. Brake fluid ...................................................DOT 4

L Note: on the ignition, always wait for the X After switching
BMW Integral ABS to complete its self-diagnosis. Do not operate the brake lever until self-diagnosis has completed.

Tightening torque: Bleed screw in front brake caliper .................. 7 Nm

Pull handbrake lever until the pistons of the front brake calipers are in contact with resetting tool, BMW No. 34 1 531.

34.25

Filling and bleeding rear wheel circuit

Attention: Integral brakes, the front brake must be ready for use. – Place the motorcycle on its centre stand.

e

34 1 581

R22000350


1

• •
R28340110

Screw container, BMW No. 34 1 581, onto rear wheel circuit reservoir. Slowly fill container, BMW No. 34 1 581, with new brake fluid until it is approximately 1/3 full. Connect the brake bleeding device to the bleed screw, but do not switch on the device.

• •

Open rear wheel-circuit reservoir (1). Remove rear brake pads.

L Note: use a cable tie to secure the bleed If necessary,
hose to the bleed screw.

Switch on the ignition

L Note: on the ignition, always wait for the After switching
34 1 536
BMW Integral ABS to complete its self-diagnosis. Do not operate the brake lever until self-diagnosis has completed.

34 1 531

R28000170

• •

Install adapter, BMW No. 34 1 536, instead of the outboard brake pad. Install resetting tool, BMW No. 34 1 531, with the handle toward the outside in the rear brake caliper, press the pistons fully back and secure them in this position.

Attention: To prevent brake fluid entering the plugs, do not disconnect the plugs from the ABS pressure modulator.

e

34.26

• • • •
MAX

Close the bleed screw. Release the brake and switch off the ignition. Disconnect the brake bleeding device from the bleed screw. Disconnect the container from the wheel-circuit reservoir.

e Attention:and/or bleeding the brakes, always After changing
top up the fluid in the wheel-circuit reservoir to the correct level in accordance with the instructions.
R28340090

MIN

e Attention:

The brake fluid must always be visible in the container, because the piston in the base of the wheel-circuit reservoir must always be covered by the fluid. The procedure must be repeated if the fluid drops below the “min” level.

• • •

Very gently press the footbrake lever until the pump just starts up. Open the bleed screw, while topping up the container with new brake fluid if necessary. Pump out the brake fluid with virtually no pressure to begin with, then vary the brake pressure.

L Note:

The higher the brake pressure the faster the fluid is pumped through the system, which means that the level in the wheel-circuit reservoir drops all the more rapidly. When the brake fluid is clear and free of bubbles, continue pumping until the fluid in the container just disappears from view.

34.27

d 34. always wait for the After switching BMW Integral ABS to complete its self-diagnosis. the front brake must be ready for use. BMW No. 34 1 536. 34 1 531. Fully tighten resetting tool. Remove resetting tool. Do not operate the brake lever until self-diagnosis has completed. and adapter. e Attention: L Note: on the ignition.Instructions for filling rear wheel circuit reservoir • Switch on the ignition. Bleed the system again if this happens. as otherwise air can be drawn into the brake system. 34 1 536. BMW No. MIN R28340090 Attention: The piston in the base of the wheel-circuit reservoir must always be covered by the fluid. and adapter. BMW No. 34 1 531.28 . • Operate the footbrake lever until the pistons of the rear brake caliper are in contact with resetting tool. Integral brakes. BMW No. and adapter. Warning: Make sure that the wheel-circuit reservoir does not overflow when the brake pads/brake calipers are installed. BMW No. BMW No. 34 1 531. 34 1 536. e • • Top up the fluid in the wheel-circuit reservoir until one of the three protrusions in the filler neck just touches the surface of the fluid (arrow). 34 1 536 34 1 531 MAX R28000170 • • Top up fluid in rear wheel-circuit reservoir to “MAX” if necessary.

Hand-tighten cap of rear wheel-circuit reservoir...• • • • Install rear brake pads and brake caliper.. Connect the BMW MoDiTeC to the diagnosis connector... 34..... Connect the BMW MoDiTeC to the diagnosis connector.. 5 Nm Brake caliper to rear wheel drive .. Install fuel tank. never pump quickly or vigorously.... • • Perform bleed test... 34 00 Integral ABS Reading fault memory with BMW MoDiTeC e Attention: on the brake system has been After all the work completed......................... Read out the fault memory.. run a bleed test using the BMW MoDiTeC.......29 .. • • • • Remove front and rear seats.. 40 Nm X • • Remove front and rear seats... • • Perform bleed test with BMW MoDiTeC....... Clear the fault memory if applicable.... or perform all requisite repair work... d Warning: maintenance and repair work on When performing BMW Integral ABS.....DOT 4 Integral ABS Performing bleed test with BMW MoDiTeC Tightening torque: Bleed screw in rear brake caliper ....... Check operation of the brake system with the ignition switched on...... Disconnect the container from the wheel-circuit reservoir. 34 00 Brake fluid.. Perform all requisite repair work.........

Cut the bleed lines to length if necessary. and cut the ends at an angle.R22340080 Integral ABS Removing and installing bleed lines. Pay particular attention to the following: Make sure the bleed lines are free of kinks.30 . 34. wheel circuit reservoirs 34 51 • • • • Remove caps of wheel circuit reservoirs complete with bleed lines. Installation is the reverse of the removal procedure.

... Always fit new spring clips each time the plugs are disconnected... 5 Nm e Attention: Fit new sealing rings for brake line... Remove spring clips (2).. Install square-section rings with brake lines. Slip the protective caps up the brake lines... 34 2 561.... • • Carefully remove square-section rings (3) using disassembly tool. BMW No.. Install new spring clips..... Remove brake lines...16). Ensure correct positioning.. Clip in brake lines......... Check that spring clips are correctly positioned (arrows). Secure brake line to master cylinder so that it cannot become kinked or abraded when the handlebars are turned.....1 3 2 34 2 561 R28340160 Integral ABS: Removing and installing brake lines • • • • • • • • • • • • Drain the brake system (a 34.. Fill and bleed the brake system (a 34......... d Warning: X Tightening torque: Brake hose and brake line.. 7 Nm Bleed screw in rear brake caliper .. 34... Seat the protective caps on the connectors. 18 Nm Bleed screws in front brake calipers.19).. Push protective caps (1) up.... Check that square-section rings are correctly seated.. L Note: the seals (square-section rings) beAlways replace tween the brake lines and the pressure modulator when you replace the brake lines....31 . Installation is the reverse of the removal procedure: pay particular attention to the following......

32 .Installed position of front brake line R22340100 34.

Installed position of rear brake line R22340110 34.33 .

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