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)

12. 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. instruments. test drive Confirm pre-delivery check in “Service and Technical Booklet”. 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. telltale and warning lights. Final cleaning Motorcycle handed over on: Order No. BMW Pre-delivery check Order No.BMW Motorrad Pre-delivery check R 1100 S EVO / R 1150 R / R 1150 RT Customer Registration No. gear shift Handbrake and foot brake Lights and signalling equipment.2000 Printed in Germany . Check operation of optional extras If necessary. 01 71 0 029 614 UX-VS-2.

9 – 36. 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. API classes SE.15) Unit of measurement/specification litres (Imp.50 (6.75 (6.06) 11 32 30 30 23 22 5 8 20 30 40 105 unscrew/20 180 unscrew/40 8 8 25 UX-VS-2. pints) [SI 11 048 90] Engine oil grade: brand-name HD oil for four-stroke spark-ignition engines.26 – 42. pints) litres (Imp.177) 4. rear Rear wheel studs Tightening cylinder heads Nut M 10 screw Locknut. valve adjusting screw Cylinder head cover Spark plugs NGK BKR 7 EKC Order No. pints) Brand-name hypoid gear oil.5 (0.9 (36. 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 .26) rear: 2.0 (0. 0.5 (0.15 (0.30 (0. SAE class GL 5 SAE 90 Rear wheel drive Initial filling/oil change approx.41) of oil to bottom edge of filler neck litres (Imp. 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.25 (0.012) adjust at TDC 0. front Brake caliper fasteners.177) front: 2.5 – 2.039) 1.02) zero play white 1.8 (0.5 (31.6) 3. front Minimum front pad thickness Minimum rear pad thickness Minimum front disc thickness Minimum rear disc thickness Tyre pressures depending on load Inlet: 0. 11. pints) litres (Imp.039) 1. SAE class GL 5 SAE 90 Valve clearances measured cold (max. pints) Brand-name hypoid gear oil.44) of oil to bottom edge of filler neck litres (Imp.5 (0. combination . SF SG.006) Exhaust: 0.0 (0.BMW Motorrad Service data R 1150 RT Item Oil capacities Engine (with filter) (without filter) Desired value 3.100 ±50 mm (in) mm (in) mm (in) mm (in) rpm zero play approx.039) (wear mark) 4.0315) 1. 1. 0.0 (1.8 (1.2 – 2.76) approx.

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

00.2 .

2 Tighten all nuts to correct wrench angle 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.3 .1 Tighten all nuts to closing torque 1.00 Tightening torque Model Connection 11 Engine Cylinder head Tightening sequence: 1 Tighten cylinder head nuts (oiled) in diagonally opposite sequence 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 00.000 km (600 miles).3 Tighten all nuts to correct wrench angle 2 M 10 screw 3 M 6 screw After 1.

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 .

to gearbox and left footrest plate 2. frame tube to transmission 3. terminal block. 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.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 1.6 .

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. 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.7 . screw can be released and tightened a number of times) 00.Model Connection 31 Front forks Quick-release axle clamp screws Sliding tube bridge to slider tube Threaded connection.

final torque Lock nut. final torque Lock nut. 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. slacken 3. slacken 3. floating bearing stud bolt. Swinging arm to right rear axle housing Floating bearing stud bolt. 85 kg (187 lbs) onto motorcycle and tighten loose reaction link) 160 (clean thread + Loctite 2701) Fixed 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. Swinging arm to left rear axle housing Fixed bearing stud bolt. initial torque 2. Swinging arm to left rear axle housing 1. floating bearing stud bolt.8 . Swinging arm to left of transmission 1.Model Connection 33 Rear wheel drive Rear axle differential Oil filler plug Oil drain plug Threaded ring Hexagon nut. initial torque 2. Swinging arm to right of transmission Floating bearing stud bolt.

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. handlebar lever Nm Nm Nm Nm R 1150 RT 30 7 21 (clean thread + Loctite 2701) 11 (Tuflok-Blau thread-locking compound.9 .

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. 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. M 12 screw Pivot mount to engine.10 .

11 .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.

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. medium-strength Thread retainer.Table of operating fluids Item Lubricant Use Order number Quantity Staburags NBU 30 PTM Optimoly MP 3 Optimoly TA Silicone grease 300. 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 00.12 . strong Thread retainer.

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

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 . freight company) without delay. Comply with specific national market procedures. Attention: Do not knock the cross-struts out or the motorcycle may be damaged.16 . e • • Remove the end-walls. +49 89/14327-632 Fax.Sales. 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. if necessary. 00. examine the contents for consequential damage. Remove plastic covers.g. e • Dispose of the packing materials in an environmentally responsible manner as described in Circular 23/91 . Notify the supplier without delay (e.Checking the crated motorcycle for damage Unpacking the motorcycle • When the motorcycle arrives. In case of damage in importer markets • • • Note the damage on the delivery slip.g. Force off cross-struts with a suitable lever.12 80788 München Tel. +49 89/14327-632 Fax. +49 89/14327-709 • • Lever off the cover. • • • – – – – – – – – – – – In case of damage in Germany • • • Note the damage on the delivery slip. In case of doubt.12 D-80788 München Tel. Remove the side-walls. +49 89/14327-709 Notify the supplier (e. please submit enquiries to: Bavaria Wirtschaftsagentur GmbH Abteilung ZW . Attention: Remove any nails projecting from the base of the crate or lying on the base or on the floor. check the crated motorcycle immediately for damage and.

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

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

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

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

....... R22000080 • Check oil level with the motorcycle upright..... rear 2............................2 bar (31.... 105 Nm X • Checking tyre pressures Check/correct tyre pressures.26 psi) two-up ...... front 2.. Costs are to be processed by the warranty claim system (stage 4).. rear 2.................................. order them through the usual channel....9 bar (42. e Attention: Never top up the engine-oil level past the “MAX” mark.. If parts are needed........ MAX BMW recommends Castrol 00......... front 2................ Required level:.........9 bar (42................ rear 2.....Inspecting motorcycle for damage • • • • • – – – Check for defects.................. 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 ..26 psi) .5 bar (36.........90 psi) ...............26 psi) .....................06 psi) Checking that delivery is complete – – – All optional extras Toolkit Documentation Checking engine oil level when cold.....3937 in)..................... UX-VS-1 Fax: + 49 89-382-33220 Rectify the fault.06 psi) two-up + luggage ..5 bar (36...5 bar (36.. 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...21 .................. Use the “express handling service” to notify BMW Motorrad.... Tyre pressures: one-up ..

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

. The Note: Do high steam or water pressure could damage seals...flashes at 1 Hz General warning light .. • With the ignition switched on.................. never pump quickly or vigorously.. ON – Self-diagnosis is in progress d – – – – – – – – – – • • • • • • • • Clutch Check gear shift action...... Perform all requisite repair work.. Confirm pre-delivery check in Service and Technical Booklet... See “Checking motorcycle for damage” if defects are found. Lnot use a steam or high-pressure water jet...... Perform bleed test with BMW MoDiTeC: • Remove front and rear seats........ bed in the brake pads against the brake discs......23 ........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.flashes at 4 Hz General warning light ......... take the motorcycle for a test ride.. • Connect the BMW MoDiTeC to the diagnosis connector... the hydraulic system or electrical components..... • Switch on the ignition........ if necessary. ABS warning light.. only RESIDUAL BRAKING FUNCTION is available..... Perform BMW Integral ABS pull-away test: When a speed of 5 km/h (3 mph) is reached..... the ABS warning light must go out.... Final cleaning • Clean the motorcycle....... d • • • Perform bleed test..... OFF – Self-diagnosis successfully completed.. 00... 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.......... Prior to conclusion of the self-diagnosis... 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.. ABS warning light. Handbrake and foot brake Check lights and signalling equipment: Front and rear parking lights Instrument lighting Low and high headlight beams...... If necessary... Perform BMW Integral ABS self-diagnosis: • Release the brake levers...........

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.3937 in). Checking the oil level just after the engine has been run or when it is not properly warm will falsify the reading. • – – – – – – – – – – – 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. brake-fluid levels in the control circuits remain constant despite brake-pad wear.24 . After switching off the engine at operating temperature. The user must be given the following information: running-in recommendations and inspection intervals safety check features of BMW Integral ABS: fully integral brake. • – – – – – 00. wait at least 5 minutes for the oil to drain back into the sump. 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. 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. pump noises. self-diagnosis with pull-away test. residual braking function.

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

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

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

28 .00.

Integral ABS: Performing bleed test with BMW MoDiTeC (Inspections I. Connect the BMW MoDiTeC to the diagnosis connector.000 km (600 miles) BMW Service every 10.29 . II.00 Key to maintenance intervals – – – – BMW Inspection at 1.000 miles) BMW Annual Service I II III IV 00 13 624 Reading the BMW MoDiTeC fault code memory (Inspections I. Perform bleed test.000 miles) BMW Inspection every 20. never pump quickly or vigorously. Perform all requisite repair work. Connect the BMW MoDiTeC to the diagnosis connector. II. d Warning: • • When performing maintenance and repair work on BMW Integral ABS. 00. III and IV) • • • • Remove front and rear seats. Read all fault memories.000 km (12.000 km (6. III and IV) • • Remove front and rear seats. Perform all requisite repair work.

..000 km (1.... pints/3. to remove the oil filter....96 US quarts) without oil filter renewal . e X Tightening torque: Oil filter. amendment PD2 is permissible..50 l (0...30 ................ 3.........50 l (6... 11 4 650..........60 Imp.. II... combination with CD or CE specification. Refill with oil to correct level.. 11 Nm Oil drain plug.............. 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.16 Imp........ 0..... pints/3.. Reinstall the oil drain plug with a new sealing ring..... R22000080 • • Remove screw plug.00 11 209 Changing engine oil.... 32 Nm Engine oil capacities: with oil filter renewal ................. III and IV) • Insert and tighten the screw plug...75 l (6. SG. BMW No........88 Imp..... 11 4 650 C000030 • • • • Use oil filter wrench. API classifications SF.... or not later than every 3.... Attention: Never top up the engine-oil level past the “MAX” mark.. replacing oil filter element (Inspections I. 3.. BMW recommends Castrol 00... Brand-name HD oil of CCMC classification G4.. G5..........69 US quarts) Quantity of oil between MIN and MAX marks .. Remove oil drain plug and drain off oil..... SH........ Coat sealing ring on new oil filter element with oil and install filter........ • Change the oil at operating temperature... pints/0...800 miles).52 US quarts) Engine oil grade: Brand-name HD oil for spark-ignition engines.....

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

Disengage stowage compartment and lift it up to remove. • • • • Remove front and rear seats. Observe relevant safety regulations. d • Remove screw securing fuel tank.R22160010 16 12 008 Replacing fuel filter (Inspection III) In normal operating conditions every 40.32 . Disconnect quick-connect adapters of the fuel lines. Disconnect the plug of the fuel pump.000 miles) • • • • Disconnect breather and overflow hoses. Remove left and right side sections of fairing. lay a cloth between the fork bridge and the fuel tank.000 miles).000 km (12. Warning: Fuel is flammable and a hazard to health. Drain fuel tank. Remove fuel pump unit. 00. • • Pull fuel tank up and to the rear to remove. L Note: To avoid damaging the paintwork of the fuel tank.000 km (24. Use a cable tie to secure the stowage compartment to the motorcycle. if fuel quality is poor every 20.

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

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

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

..........Checking brake fluid level (Inspections II and III) • Correct the fluid level if necessary......... Check brake fluid level at sight glass............ Do not operate the brake lever until self-diagnosis has completed... L Note: on the ignition.............. R22000150 Required level not below ......... Required level not below ..................................... Switch on the ignition.. Checking brake system for correct operation and freedom from leaks... this indicates some other fault.... After this. Remove case and right trim panel... Check the brake fluid level...... always wait for the After switching BMW Integral ABS to complete its self-diagnosis...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..... Turn the handlebars fully to the left.............. Warning: When performing maintenance and repair work on BMW Integral ABS. MIN 00.... Wipe down all threaded unions on the brake lines and check them.. Brake fluid............... inspect the brake lines for leaks.. d • Correct the fluid level if necessary......... Brake fluid ................... d • R22000140 • Apply the brake hard and hold on in this position for a short time...36 ... If the level drops below the MIN mark....................DOT 4 Rear brake • • • Place the motorcycle on its centre stand.. repairing/replacing if necessary (Inspection III) • Front brake • • • • • Place the motorcycle on its centre stand.. never pump quickly or vigorously... Check all brake lines and their holders for damage and correct positioning.................. 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 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

Do not scrape • • – Use resetting tool. 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. qualified specialists. e Attention: • 1 R28340110 • Open front wheel-circuit reservoir (1). the rear brake must be ready for use. (a 00. comply with their manufacturers’ instructions. Wrap cloths around the left and right brake calipers.40 . 34 00 070 Bleeding/changing 34 1 532 R22000290 brake fluid in front wheel circuit Integral brakes. 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. Remove front brake pads (left and right). and locator. 00. only when the cap has been removed from the wheel-circuit reservoir. 34 1 532.34 00 090 Changing/bleeding brake fluid in wheel circuit • • Draw off the old brake fluid from the wheel-circuit reservoir. Remove fuel tank.43) Draw off the old brake fluid from the wheel-circuit reservoir. 34 1 531. d Attention: Install piston resetting tool. BMW No. Comply with all maintenance and repair instructions and always work through the various steps in the correct order. BMW No. If other devices are used. Use only new brake fluid from freshly opened containers. BMW No. Do not allow brake fluid to come into contact with painted parts of the motorcycle as brake fluid destroys paint. e Attention: • e Attention:the wheel – mask it off if necessary. to force the pistons in the left and right brake calipers all the way back and hold them in this position. 34 1 531. [Bleeding only] Bleed the front wheel circuit.

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

Instructions for filling front wheel circuit reservoir Attention: Integral brakes. 34 1 581. L Note: • Brake fluid .. always wait for the BMW Integral ABS to complete its self-diagnosis. BMW No. 7 Nm X 00.. Bleed the system again if this happens.DOT 4 After switching on the ignition... Remove adapter. 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).. Attention: The piston in the base of the wheel-circuit reservoir must always be covered by the fluid...... 34 1 531/532. With the ignition switched on...... in resetting tool. 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... and force back pistons far enough to allow the brake pads to be fitted. onto front wheel circuit reservoir. Hand-tighten cap of front wheel-circuit reservoir......... the rear brake must be ready for use.. BMW No... BMW No... and tighten the resetting tool until the adapters are secure... Screw container.. for both front brake calipers. 34 1 533. bed in the brake pads against the brake discs.... Disconnect the container from the wheel-circuit reservoir.... Tightening torque: Bleed screw in front brake caliper .... 34 1 533.. Check the function of the brake system..... Install front brake pads...... as otherwise air can be drawn into the brake system. BMW No........ Install fuel tank.... BMW No.. Pull handbrake lever until the pistons of the front brake calipers are in contact with resetting tool.. 34 1 531.. e • Attention: 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! e • Switch on the ignition..42 . Do not operate the brake lever until self-diagnosis has completed..

• • Fill front wheel-circuit reservoir with brake fluid up to “MAX” mark and install cap.. Release the brake and disconnect silicon hose. L Note: • If necessary.. Connect 1.5m (4. Disconnect silicon hose. • • Fill front wheel-circuit reservoir with brake fluid in accordance with instructions. 34 2 541.... 7 Nm 00. L Note: • • • • • Brake fluid . Connect end of hose to cap.. 34 1 561.... Pump the brake fluid with virtually no pressure until the hose is full of brake fluid. BMW No.. always top up the fluid in the wheel-circuit reservoir to the correct level in accordance with the instructions. e Attention: R28000220 After changing and/or bleeding the brakes. 34 1 561.Only bleeding the front wheel circuit – – Draw off the old brake fluid from the wheel-circuit reservoir... Open the bleed screw. BMW No. BMW No...... Fill front wheel-circuit reservoir with brake fluid up to “MAX” mark and install cap.. Close the bleed screw..9214 ft) silicon hose.. to the bleed screw of the right brake caliper..42) Check operation of the brake system with the ignition switched on.... Very gently pull the handbrake lever until the pump just starts up... Remove left and right brake pads.. run a bleed test using the BMW MoDiTeC. 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.DOT 4 After switching on the ignition.... to the bleed screw of the left brake caliper.. force back the brake pistons and secure the pistons in this position. d Warning: – Check that the brake fluid in the hose does not foam......... 7 Nm Grub screw in front brake caliper ..5 m (4... The procedure for bleeding the right brake caliper is the same as that for the left caliper. BMW No. use.. 34 1 561.. Pump the brake fluid with virtually no pressure to begin with... (a 00..... then vary the brake pressure..... X Tightening torque: Bleed screw in front brake caliper ..... 34 2 541...9214 ft) silicon hose.... Wrap cloths around the left and right brake calipers..40) e Attention: the rear brake must be ready for Integral brakes. e Attention: After all the work on the brake system has been completed. 34 2 541.. proceed as described in the section on bleeding and changing brake fluid in front wheel circuit. Remove cap.... • • • • 34 1 561 • • • • 34 2 541 • Pump brake fluid through the system until it is clear and free from air bubbles.. (a 00. Switch on the ignition. 34 1 561..43 . from bleed screw and drain the hose.. Connect 1.. Release the brake and switch off the ignition...... BMW No. If the fluid foams. use a cable tie to secure the bleed hose to the bleed screw.. BMW No..... BMW No. 34 2 541.

34 1 536. BMW No. Do not allow brake fluid to come into contact with painted parts of the motorcycle as brake fluid destroys paint. Draw off the old brake fluid from the wheel-circuit reservoir. BMW No. onto rear wheel circuit reservoir. press the pistons fully back and secure them in this position. e Attention: 34 1 531 R28000170 • • • – Install adapter. with new brake fluid until it is approximately 1/3 full.47) Draw off the old brake fluid from the wheel-circuit reservoir. 34 1 531. 34 1 581 Attention: Install piston resetting tool. BMW No. (a 00. 34 1 531. with the handle toward the outside in the rear brake caliper. Install resetting tool. BMW No. but do not switch on the device. [Bleeding only] Bleed the rear wheel circuit. Wrap a cloth around the brake caliper. 34 1 531 only when the cap has been removed from the wheel-circuit reservoir. Slowly fill container. 00.34 00 080 Bleeding/changing brake fluid in rear wheel circuit Attention: Integral brakes. e • 34 1 536 Remove fuel tank. If necessary. • 1 R28340110 • • • • Open rear wheel-circuit reservoir (1). BMW No. the front brake must be ready for use. BMW No.44 . use a cable tie to secure the bleed hose to the bleed screw. L Note: If necessary. Remove rear brake pads. 34 1 581. e R22000350 • • • Screw container. manually push back brake piston far enough to permit installation of resetting tool. instead of the outboard brake pad. 34 1 581. Connect the brake bleeding device to the bleed screw.

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

... 34 1 531.46 .. and adapter. L Note: Attention: After all the work on the brake system has been completed.29) Install fuel tank... Disconnect the container from the wheel-circuit reservoir... 34 1 531.Instructions for filling rear wheel circuit reservoir Attention: Integral brakes....... Perform bleed test with BMW MoDiTeC....... e • Install rear brake pads and brake caliper.... Do not operate the brake lever until self-diagnosis has completed. as otherwise air can be drawn into the brake system. BMW No.... BMW No.... Switch on the ignition.. BMW No.. Fully tighten resetting tool............... d • • • • Attention: The piston in the base of the wheel-circuit reservoir must always be covered by the fluid.. run a bleed test using the BMW MoDiTeC.. BMW No.. and adapter... 34 1 536...... BMW No. Warning: Make sure that the wheel-circuit reservoir does not overflow when the brake pads/brake calipers are installed. 34 1 531. Remove resetting tool. • • Top up fluid in rear wheel-circuit reservoir to “MAX” mark if necessary.. and adapter. 40 Nm X 00... Brake fluid .... 5 Nm Brake caliper to rear wheel drive .... the front brake must be ready for use... (a 00. BMW No.. Tightening torque: Bleed screw in rear brake caliper . 34 1 536.....DOT 4 • Operate the footbrake lever until the pistons of the rear brake caliper are in contact with resetting tool. 34 1 536... e • • After switching on the ignition.... Bleed the system again if this happens. 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). always wait for the BMW Integral ABS to complete its self-diagnosis.. Check operation of the brake system with the ignition switched on.... Hand-tighten cap of rear wheel-circuit reservoir......

. (a 00... L Note: • • • • • After switching on the ignition... Disconnect silicon hose... BMW No. 34 1 561... Close the bleed screw..44) • 34 1 561 • • • • 34 2 541 Pump brake fluid through the system until it is clear and free from air bubbles... then vary the brake pressure.. hose to the bleed screw. Very gently press the footbrake lever until the pump just starts up..... Pump the brake fluid with virtually no pressure to begin with.Only bleeding the rear wheel circuit – – – Draw off the old brake fluid from the wheel-circuit reservoir..9214 ft) silicon hose....... force back the brake pistons and secure the pistons in this position. from bleed screw and drain the hose..... e Attention:and/or bleeding the brakes. 34 2 541. X Tightening torque: Bleed screw in rear brake caliper .... Remove rear brake pads.... 34 2 541.. Brake fluid . Connect 1. R28000230 • • • • Fill rear wheel-circuit reservoir with brake fluid up to “MAX” mark and install cap... Remove cap. Connect end of hose to cap.... BMW No...46) Check operation of the brake system with the ignition switched on.. Release the brake and switch off the ignition......47 ...... If the fluid foams..... e Attention: on the brake system has been After all the work completed. to the bleed screw. Pump the brake fluid with virtually no pressure until the hose is full of brake fluid... BMW No... proceed as described in the section on bleeding and changing brake fluid in rear wheel circuit.... 34 2 541.. d Warning: Check that the brake fluid in the hose does not foam.. Fill rear wheel-circuit reservoir with brake fluid in accordance with instructions....5m (4. run a bleed test using the BMW MoDiTeC. 34 1 561..... BMW No. BMW No... Do not operate the brake lever until self-diagnosis has completed. Wrap a cloth around the rear brake caliper. Open the bleed screw..... 6 Nm Brake caliper to rear wheel drive . L Note: use a cable tie to secure the bleed If necessary.DOT 4 • Switch on the ignition...... (a 00.. always After changing top up the fluid in the wheel-circuit reservoir to the correct level in accordance with the instructions. 40 Nm 00. always wait for the BMW Integral ABS to complete its self-diagnosis.

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

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

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

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

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

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

..............8 mm (0............. 12 3 510. Slacken/retighten M10 screw..0393 in) Tightening torque: Spark plug NGK BKR7EKC ..... 0... • Tighten cylinder head nuts........2.risk of breakage! Spark plug:........ 25 Nm X R21000370 • Select a gear and turn the rear wheel. 12 3 520...... Tighten the cylinder head nuts one after the other in diagonally opposite sequence 1............ Tighten nut to initial torque..54 .. Top dead centre on ignition stroke: The TDC mark is visible and the inlet and exhaust valves in the cylinder concerned are closed. Slacken off one nut at a time 1...... • Tightening procedure after 1.............. Remove spark plugs with the spark plug wrench... Tighten nut to specified wrench angle.... 180° 2.... 20 Nm 1............... 1. e Attention: Catch escaping oil.... e Attention: Do not bend electrodes ..... or set the piston to TDC on the ignition stroke by turning the belt pulley..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.. • Remove cylinder head cover......3..0 mm (0..... NGK BKR 7 EKC Electrode gap: .. 40 Nm 00........... BMW No....000 km (600 miles) 1............. BMW No.1.0314 in) Wear limit: ..

...............0118 in) Tightening torque: Locknut ...30 mm (0. Remove the flap in the right side panel..0393 in) Make sure that all seals are correctly seated..... II and III) 13 60 110 Checking freedom of throttle cable. 1 mm (0...0393 in) Play of throttle cable: .... checking for chaffing and kinks....... 0....55 ........ • • Push back rubber cap (arrow) on throttle and choke cables... Feeler gauge must pull through between valve stem and adjusting screw with slight resistance... replacing if necessary Checking throttle-cable play Checking and adjusting idle speed and throttle-valve synchronisation (Inspections I............... Use the adjusting screws to adjust play of throttle and choke cables..0059 in) Exhaust ...approx.. Remove the left side panel.. Assembly is the reverse of the disassembly procedure........15 mm (0. Tightening torque: Cylinder head cover .. correct with adjusting screw.... if necessary.............. Valve clearances with engine cold (max...... 1 mm (0............ 8 Nm X • • R22000320 Recheck valve clearances after adjusting.. II and III) • • • Test-drive the motorcycle until the engine is warm............... 8 Nm 00.................................at least 90 °C (194 °F) R21000340 • Check valve clearance with feeler gauge and. e Attention: X Play of choke cable: ........Checking/adjusting valve clearances 11 34 004 (Inspections I......... Oil temperature: . Seals and sealing faces must be free from oil and grease. 0......... 35 °C/95 °F): Inlet ....approx..................

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

. L Note: • • • Make sure that when the throttle grip is released both throttle valves return to their fully closed positions...........06 (36... (Readings shown by Synchro tester must increase and decrease together). rear R22000330 • • • • Use the adjusting screw (arrow) to adjust play of the choke cable to zero...... Repeatedly open the throttle gradually and increase engine speed from idle to approximately n = 2..... Integral ABS • If necessary. rear two-up + luggage . II......... Move the handlebars all the way from left to right and check the settings....Final inspection with road safety and functional check (Inspections I..... Seal off the vacuum bores..26 (36.....5 2. Tyre pressures: one-up .. front ..2 2.90 (36. front .... III and IV) Road safety check • Check wheels and tyres....... Assembly is the reverse of the disassembly procedure................9 bar bar bar bar bar bar (31................... Make sure that engine speed does not vary when the handlebars are moved in this way....500 rpm to check throttle-valve synchronisation.......9 2. Tighten the locknuts and recheck carburettor balance........26 (42.....57 ...... • Check/correct tyre pressures.........5 2.... • Wait at least 10 minutes after heating the engine to operating temperature in the trial run/road test before checking/correcting engine oil level.... If necessary........ front ..5 2...................... correct by turning the adjusting screws of the throttle-valve Bowden cable.........06 psi) psi) psi) psi) psi) psi) Roadworthiness check • Lights • Telltale/warning lights • Horn • Instruments • Special equipment • Clutch • Gear shift • Steering • Footbrake and handbrake... 2. take the motorcycle for a test ride........... Push the rubber cap into position over the adjusting screw..................... 00... rear two-up .....26 (42.

58 .00.

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

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

7 (0.15 (0. Brake disc thickness Minimum thickness of brake disc Permissible lateral runout Piston dia.1772) mm (in) 0. in brake caliper Piston dia.0670) (active sensor) 34.2.33) mm (in) 320 (12.1..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.. rear mm (in) 276 (10.5987) mm (in) 5.6299) Hydraulically operated disc brake with 2-piston floating caliper and fixed disc Sintered metal mm (in) 1..7 (0..1969) mm (in) 4. the brake lining is worn to its minimum permissible thickness) cm2 33.0670) (active sensor) mm (in) 0.0236/1.8661) mm (in) 5.1968) mm (in) 4. in actuating cylinder BMW Integral ABS Type Sensor gap.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.0393 in) (sq in) cm2 86 (13.0079.0 (0.0059) mm (in) 32/36 (1.5118) Active fully integral system mm (in) 0.0 (0..0 (0.1023) mm (in) 13 (0..23) (sq in) Brake pad surface area Brake disc dia.5 (0.4173) mm (in) 16 (0.2..1772) mm (in) 0.0393) (If the brake disc is visible through the bore in the wheel-side brake pad.0. front Sensor gap.2599/1.5 (0.15 (0..3 . Brake disc thickness Minimum thickness of brake discs Permissible lateral runout Piston dia. in brake caliper Piston dia.0079.0 (0.0.8 (5.0059) mm (in) 26/28 (1.

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

.. 34 1 520........... Remove the brake pads... Coat new sealing rings (2.... 3) with brake fluid and install.16).... • • • • • Carefully press out brake pistons (1).... Using piston resetting tool. score-marks and other damage..... 34. Install brake caliper. Remove the brake caliper. using a compressed air gun at the brake line connection..... Secure two opposing brake pistons with spacer.white e Attention: fingers between the pistons. e Attention: – – Do not separate the brake caliper halves! Integral ABS Drain front wheel circuit (a 34...... 7 Nm Grub screw in front brake caliper .. BMW No. Close the bleed screw........ Integral ABS Fill and bleed front wheel circuit (a 34... Insert a piece of cloth between the two brake pistons not secured by the resetting tool. 34 1 531. BMW No..... press the pistons fully back.. • • • • • • • • Remove and install the other two brake pistons in the same way.. Coat brake caliper pistons (1) with brake fluid and insert... Remove the two sealing rings from each brake cylinder bore.... Inspect the brake caliper piston for hairline cracks.... X Tightening torque: Bleed screw to brake caliper .23)......5 ......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. risk Do not insert your of injury. 7 Nm Colour code: Brake pads/brake calipers ...

. 40 Nm Brake hose to brake caliper ... Attention: Replace the sealing rings (2) in the brake line..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. e • Installation is the reverse of the removal procedure...26)...... Integral ABS Fill and bleed rear wheel circuit (a 34.6 ........... Disconnect brake line (1) from brake caliper......... Do not damage the brake pads...... 18 Nm Bleed screw to brake caliper . 34.. Remove the brake caliper........ 5 Nm X Integral ABS Drain rear wheel circuit (a 34......... position the brake caliper with the bleed nipple at the highest point.. L Note: • To bleed... e • • • Tightening torque: Brake caliper to rear wheel drive .....

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

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

....... Route the sensor Ensure that clips (3) are correctly seated........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.. Installation is the reverse of the removal procedure..... 4 Nm X 34.... Tightening torque: Sensor ...9 ... e Attention: cable correctly.... hand-tight.. Disconnect plug (1) of sensor cable...... Guide the sensor cable down until clear..... Remove sensor (2).

... Disconnect plug (1) of sensor cable........ • • • • • • • • • e Attention: X Route the sensor cable correctly. Remove right case...10 . hand-tight.... Remove the cable ties securing the sensor cable.....1 2 R22340070 34 52 111 Removing and installing rear Integral ABS sensor Remove front and rear seats.... Before removing/installing....... 4 Nm 34. Remove sensor (2)...... Installation is the reverse of the removal procedure.. Remove small right side fairing panel. Coat O-rings with oil before installing.. if necessary. Tightening torque: Sensor ... clean the sensor bore...

. 21 Nm Integral ABS Drain rear control circuit (a 34. e Attention: X Check and. Remove footbrake lever with torsion spring (4).....12). e Attention: Bleed the brake system carefully.. adjust the blow-by clearance of the piston rod and the setting of the brakelight switch (a 34. Release and remove stud (1). BMW No.. 13 1 500.. Installation is the reverse of the removal procedure.11 .. if necessary.... Remove brake master cylinder..... X Tightening torque:footrest. if necessary. Disconnect brake line (5) and hose (6). Integral ABS Fill and bleed 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. Check and... 9 Nm Master brake cylinder to 34. Remove bolt (2) of footbrake lever with nut (3)...21).... Lubricate pivot bushing with Shell Retinax A. Installation is the reverse of the removal procedure.12)....18)... • • • • • • • Tightening torque: Footbrake lever to footrest plate (clean thread + apply Loctite 2701) . adjust the blow-by clearance of the piston rod and the setting of the brakelight switch (a 34. 34 31 Removing and installing rear brake master cylinder • • • • • • Remove right side panel... Tighten non-reusable hose clip (7) with pliers.5 6 7 3 2 4 1 35 21 R22460140 Removing and installing footbrake lever Release and remove stud (1)...

. Slowly release the footbrake lever and check play.2 mm (0.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.. 13.. 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)..... 34.. 0... Remove the feeler gauge..... Apply coloured sealing lacquer to the locknut.. Turn piston rod (2) clockwise toward the footbrake lever to obtain play. 0...0.0078 in) Play must be perceptible Feeler gauge thickness: .15 mm (0...12 ...0059 in) No play perceptible Feeler gauge thickness: .... Distance A: .) • Insert feeler gauge at right angles to direction of travel between the brake-light switch lever and the stop on the footrest plate (arrow).35 mm (0..5 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. Feeler gauge thickness:. 0.. • • • Press the footbrake lever.0137 in) • • • • • • Slacken locknut (1).5354+/-0. Recheck play.6 +/.

. R22340020 Brake light switch must switch off Feeler gauge thickness: ...90 mm (0...Checking and adjusting setting of rear brake light switch Checking setting of brake light switch......... • Switch on the ignition... 0....0354 in) Brake light switch must remain on Feeler gauge thickness: . 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). Do not operate the brake lever until self-diagnosis has completed.1968 in) (clearance at switching point between brake-light switch lever and footrest plate).13 . Distance B: . rear Adjusting brake light switch......... Removing and installing piston in brake-lever fitting a ...............See Group 32 34.... Slowly release the footbrake lever and check the point at which the switch trips.60 mm (0........ L Note: on the ignition. rear 4 B 3 R22340030 R22340020 • • Depress the footbrake lever and secure it in this position.... Slacken screw (4).. Recheck the setting.. 1 + 0.0629 in) • • • Turn the brake light switch until the switch trips at distance (B)..5 mm (0...0393 + 0... • Switch off the ignition. 1...... Hold the brake light switch and tighten the screw... B • • • Depress the footbrake lever (brake light comes on and pump starts up)....... always wait for the After switching BMW Integral ABS to complete its self-diagnosis.

qualified specialists.14 . 34. e Attention: • • • • Do not allow brake fluid to come into contact with painted parts of the motorcycle as brake fluid destroys paint. Use only new brake fluid from freshly opened containers.16). Disconnect ground lead from battery and insulate. Drain the brake system (a 34. Push protective caps (1) up. Comply with all maintenance and repair instructions and always work through the various steps in the correct order.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. Remove spring clips (2).

Always replace the seals (square-section rings) between the brake lines and the pressure modulator when you replace the brake lines. Disconnect the brake lines from the ABS pressure modulator. Without starting the engine. Fill and bleed the brake system (a 34..29).. Ensure correct positioning. e Attention: • • • • • L Note: Do not permit brake fluid to enter the plugs.. fully open the throttle once or twice so that the Motronic control unit can register the throttle-valve positions. 7 Nm 34. Disconnect plug from Hall sensor.. run a bleed test using the BMW MoDiTeC (a 34... Remove Motronic control unit. Unlock plug (4) (arrow) and disconnect the plug. Connect the battery.. 10 Nm Tightening torque: ABS ABS pressure modulator to holder .. • • Switch on the ignition. Disconnect plugs (3) of the front and rear wheel circuit reservoirs. L Note: Disconnecting the battery means that the entries in the fault memory of the Motronic MA2.4 control unit are deleted and the adaptation values are reset...19).. After all the work on the brake system has been completed. Clip in brake lines. Release ABS pressure modulator and pull it carefully to the left to remove. X pressure modulator to battery carrier ...e Attention: • Installing Integral ABS pressure modulator Do not bend the brake lines. • Installation is the reverse of the removal procedure: pay particular attention to the following... Seat the protective caps on the connectors..15 .. This can temporarily impair the operating characteristics when the engine is restarted. Slip the protective caps up the brake lines. Check that spring clips are correctly positioned (arrows).. Install new spring clips. d Warning: • • • • • • • • Always fit new spring clips each time the plugs are disconnected.

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

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

draw off the old brake fluid and clean the reservoir. BMW No. 34 2 532: rear metering cylinder (4). 34. rear integral circuit (5) and rear control circuit (6).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. • • • • Turn the front wheel to a position in which the brake fluid reservoir is horizontal and secure the handlebars in this position. Draw off old brake fluid and clean the reservoir. using ring spanner. 5 6 4 1 3 R28340110 • 2 – – – Draw off the brake fluid from the circuits in the correct sequence. R28340110 • – – – Draw off the brake fluid from the circuits in the correct sequence. using ring spanner.18 . 34 2 532: front metering cylinder (1). Draining front control circuit • Remove rear reservoir cap with rubber diaphragm. BMW No. front integral circuit (2) and front control circuit (3). Wrap cloths around the reservoir. Remove front reservoir cap with rubber diaphragm.

e Attention: – – On account of the vacuum extraction process. 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. comply with their manufacturers’ instructions. Remove front reservoir cap with rubber diaphragm.19 . make sure that the fluid replenishing hole is always below the level of the brake fluid. or else air will be drawn into the brake system. 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. front control circuit (3) and front metering cylinder (1) for the second time. Comply with all maintenance and repair instructions and always work through the various steps in the correct order. Draw off the brake fluid from the circuits in the correct sequence while topping up continuously with fresh brake fluid and using ring spanner. KR340280 • Top up the brake fluid level to the “MAX” mark (arrow). d During the filling and bleeding procedure. 34 2 532: front metering cylinder (1).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. the system must be bled again manually in the specified sequence and in accordance with the instructions for bleeding the brakes. BMW No. 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. Wrap cloths around the reservoir. front integral circuit (2). qualified specialists. – – – Place motorcycle on its centre stand. 1 3 2 L Note: This description applies for the brake filling and bleeding unit with extraction of the brake fluid by partial vacuum. If other devices are used. Use only new brake fluid from freshly opened containers. Remove front and rear seats. Consequently. 34. Remove fuel tank.

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

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

....... the rubber diaphragm and the cover to remove brake fluid............... Place the motorcycle on its centre stand...... Wipe the rim of the reservoir.. Recheck the brake-fluid level.. MIN Attention: After all the work on the brake system has been completed..... 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.. R22000150 Specified level not below ..... Brake fluid.............................DOT 4 e 34...22 . run a bleed test using the BMW MoDiTeC..............

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

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

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

Instructions for filling rear wheel circuit reservoir • Switch on the ignition. Remove resetting tool. BMW No. always wait for the After switching BMW Integral ABS to complete its self-diagnosis. 34 1 531. Do not operate the brake lever until self-diagnosis has completed. Fully tighten resetting tool. 34 1 531. Bleed the system again if this happens.28 . BMW No. Warning: Make sure that the wheel-circuit reservoir does not overflow when the brake pads/brake calipers are installed. e Attention: L Note: on the ignition. 34 1 531. 34 1 536 34 1 531 MAX R28000170 • • Top up fluid in rear wheel-circuit reservoir to “MAX” if necessary. 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). as otherwise air can be drawn into the brake system. 34 1 536. MIN R28340090 Attention: The piston in the base of the wheel-circuit reservoir must always be covered by the fluid. 34 1 536. BMW No. Integral brakes. • Operate the footbrake lever until the pistons of the rear brake caliper are in contact with resetting tool. BMW No. BMW No. d 34. the front brake must be ready for use. and adapter. BMW No. and adapter. and adapter.

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

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

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

32 .Installed position of front brake line R22340100 34.

33 .Installed position of rear brake line R22340110 34.

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