BMW-S1000 RR K67 Service Manual

BMW
MOTORRAD
BMW S1000 RR
K67
(0E21/0E23/0E24/0E20/0E43)
Repair Guide
BMW Motorrad
General Information
Repair Guide
BMW Motorrad
BMW-Motorrad - S 1000 RR
Technical data - S 1000 RR

11 - Engine
Designation Precondition Value Valid

CO2 emission following world-wide 149 g/km
harmonised motorcycle
test cycle (WMTC)
Torque at engine 113 Nm
speed 11000 min-1
Press loss Engine at operating max 30 %
through valves or cylinder temperature
Running-in speed Odometer <7000 min-1

reading 0...300 km
Odometer <9000 min-1
reading 300...1000 km
Odometer no full load
reading 0...1000 km
Maximum engine speed max 14600 min-1
Displacement 999 cm3
Piston stroke 49.7 mm
Compression test pressure Good min 13 bar
Normal 10...13 bar
Poor max 10 bar
Idle speed Engine at regular 1270+50 min-1
operating temperature −50
Engine design Oil-/water-cooled four-stroke inline

four, with four valves per cylinder
Engine number location Crankcase, bottom right
Engine type A10A10A
Nominal capacity at engine 152 kW
speed 13500 min-1
Compression ratio 13,3:1
Cylinder bore 80 mm
Engine oil, capacity with filter change approx. 4.0 l
Fluids and lubricants
Viscosity class
Specification (SAE 5W-40, API SJ / JASO MA2, Additives (e.g. molybdenum-based) are
not permissible because they can attack coated components of the engine,
BMW Motorrad recommends BMW Motorrad ADVANTEC Ultimate oil.)
Engine oil, specified level Engine at operating between MIN and MAX mark
temperature, vehicle is
in vertical position
Engine oil, quantity for topping up Difference between MIN max 1.3 l
and MAX
11 12 - Cylinder head with cover
Wear limit, tilt clearance, valve to at valve lift 10+0.1 mm max 0.40 mm
valve guide −0.1
1.02 mm
052021 BMW Motorrad, UX-VA-4 1/4

Correlation of cylinder-head gasket for piston
(mark: 1 hole) protrusion <2.62 mm
Correlation of cylinder-head gasket for piston 1.12 mm
(mark: 2 holes) protrusion ≥2.62 mm
11 21 - Crankshaft with bearings
Bore diameter for crankshaft main 38.000...38.015 mm
bearing
Colour codes of crankshaft bearing Crankcase yellow / Bearing shells, yellow
shells crankshaft yellow
Crankcase Bearing shells, green
yellow/crankshaft violet
Crankcase yellow / Bearing shells, blue
crankshaft green
Crankcase green / Bearing shells, green
crankshaft green
Crankcase green / Bearing shells, blue
crankshaft yellow
Crankcase green / Bearing shells, black
crankshaft violet
Crankcase violet / Bearing shells violet
crankshaft violet
Crankcase Bearing shells, green
violet/crankshaft yellow
Crankcase violet / Bearing shells, black
crankshaft green
Labelling on crankcase Labelling on engine (G) green / (Y) yellow / (V) violet
Classification of crankshaft bearing housing top section (in
shells (main bearing) direction of travel, rear)
Identification of main bearing and BMW part number / 1234567 12

crankshaft journal on crank web revision index
Date / Time YYMMD HHMM
sequential ID number 123456
Main bearing GGYYV (example)
classification 1-5
Pin bearing classification RBRB (example)
1-4
Marks on crankcase Colour dots above the yellow/green/violet
Classification of crankshaft bearing crankcase sealing face
shells (main bearing) (at rear as viewed in
forward direction of
travel)
Mark for classification of the Labelling on crank web (G) green / (Y) yellow / (V) violet
crankshaft bearings
for identifying the bearing shells

Mark for classification of the Coloured dots on the yellow/green/violet

crankshaft bearings crankshaft
for identifying the bearing shells
11 24 - Conrod with bearings

Conrod bearing, bore diameter Identification/colour A/red or B/blue
coding on the
connecting rod foot
Conrod bearing, bore diameter Identification/colour A/red or B/blue

coding on the
connecting rod foot
Colour codes, conrod bearings Rod bore red (A) / Bearing shell red
Assignment, conrod/conrod cap crankshaft journal red
Rod bore blue (B) / Bearing shell blue
crankshaft journal blue
Rod bore blue (B) / Bearing shell violet
crankshaft journal red
Rod bore red (A) / Bearing shell violet
crankshaft journal blue
Mark for classification of the conrod Coloured dots on the red/blue
bearings crankshaft
Overview of conrod marks A Correlation, conrod bearing cap to

conrod
B Weight class
C Hole diameter
D Production date
11 25 - Piston with rings and bolts

Piston, installed direction Arrow in direction of travel
11 34 - Valves with springs

Exhaust valve clearance Engine cold 0.20...0.26 mm
Inlet valve clearance Engine cold 0.14...0.20 mm
11 40 - Oil supply
Oil pressure idle 1.5 bar
Engine oil is at regular operating at engine rpm 6000 min 3.5 bar
temperature -1


12 - Engine electrical system

Type of Ignition system BMS-O
12 12 - Ignition lead, spark plugs
Electrode gap of spark plug 1.0+0.1 mm
−0.1
Spark plugs, manufacturer and NGK LMAR9FI-10G

designation
Spark plug thread M10 x 1
12 31 - Alternator with drive and fasteners
Alternator type Permanent magnet generator
Alternator power 450 W


13 - Fuel preparation and control

Alternative fuel grade Super unleaded (power- and
consumption-related restrictions.)
maximum 10 % ethanol, E10
95 ROZ/RON
90 AKI
Recommended fuel grade Super Plus, unleaded maximum 5%
ethanol, E5
98 ROZ/RON
93 AKI


16 - Fuel supply

Usable fuel capacity approx. 16.5 l
Fuel reserve approx. 4 l
16 14 - Delivery, preparation and measurement, control unit, fuel pump
Operating pressure of fuel pump 5 bar
Delivery rate of fuel pump 60 l/h


17 - Cooling

Cut-in temperature for coolant 118 °C
temperature warning
Cooling system test pressure Test pressure must 2 bar
remain
unchanged: min 5 min
Coolant, specified level cold engine between MIN and MAX mark on the
expansion tank
Coolant, total capacity 2.95 l

General consumable (Antifreeze and corrosion inhibitor)
Coolant's ability to resist freezing min −25 °C
temperatures
Coolant-full quantity Difference between MIN 0.15 l
- and MAX-mark
Coolant system, total 2.95 l
17 40 - Fan
Cut-in temperature for radiator fan Coolant temperature 101 °C
sensor
17 65 - Thermostat with housing
Opening temperature for coolant 85 °C
circuit thermostat


21 - Clutch

Clutch type Multi-plate oil-bath (anti-hopping) with
self-reinforcement
21 21 - Clutch with driver plate
Height of entire plate stack 48.7 mm


23 - Gearbox

Type of transmission Claw-shift 6-speed gearbox,
integrated into engine block
23 22 - Gears
Gearbox transmission ratios Primary transmission 1.652 (76:46 teeth)
ratio
1st gear 2.647 (45:17 teeth)
2nd gear 2.091 (46:22 teeth)
3rd gear 1.727 (38:22 teeth)
4th gear 1.500 (33:22 teeth)
5th gear 1.360 (34:25 teeth)
6th gear 1.261 (29:23 teeth)
23 41 - External gearshift components
Selector-rod-end setting free length of thread on 6+2 mm
lower ball joint −2


31 - Front axle, front-wheel steering

Type of front suspension Upside-down telescopic fork
Spring travel, front at front wheel 120 mm
Type of front suspension Upside-down telescopic fork
Fork oil, capacity of left fork leg approx. 350 ml
Telescopic fork oil (Telescopic fork oil, type 2)
Fork oil, capacity of right fork leg approx. 350 ml
Level of fork oil in left fork leg (air Forks fully compressed 135+2 mm
chamber) and damper unit bled, −2
compression spring and
spacer bush removed
Level of fork oil in right fork leg (air Forks fully compressed 135+2 mm
spacer bush removed
31 42 - Telescopic forks
Load-dependent adjustment of spring including rider 85 kg 40+2 mm
preload −2
Negative spring displacement of front

wheel
Projection of fork tube in fork bridge, measured without fork 6 mm
top cover
Fixed fork tube outside diameter 45 mm
Fixed fork tube runout max 0.2 mm
Compression stage, basic setting, Road use with Position 5
front rider 85 kg
Racing use with Position 7
rider 85 kg
Rebound stage, basic setting, front Road use with Position 5
rider 85 kg
Racing use with Position 5
rider 85 kg


32 - Steering and wheel alignment

32 73 - Bowden cables
Distance between adjusting screw 3+1.5 mm
and handlebar fitting (clutch-cable −1.5
setting)
Clutch-lever play measured on outer 3...5 mm
clutch lever, handlebars
in straight-ahead
position, with cold
engine
in straight-ahead
position, with cold
engine
32 76 - Steering damper
Steering damper basic setting Public roads Turn adjusting screw until the limit
position in the direction (A), then turn
in direction (B) for 8 clicks.
Racing Turn adjusting screw until the limit
position in the direction (A), then turn


33 - Rear axle, rear-wheel drive and rear-wheel guidance

Spring travel, rear at rear wheel 117 mm
Type of final drive Chain drive
Type of rear suspension Two-arm aluminium swinging arm
33 35 - Rear wheel swinging arm with pivot mount, link
Traction strut gap dimension to Basic setting 9.5 mm
compensate the swinging arm pivot Adjustment range 8.0...13.0 mm
point setting
Swinging arm pivot point 12.5 mm
Position 2
Swinging arm pivot point 13.0 mm
Position 3
33 54 - Spring strut, mounting parts
Load-dependent adjustment of spring Road use with 35+2 mm
preload rider 85 kg −2
Suspension compression at rear Racing use with 30+2 mm

wheel rider 85 kg −2
Compression stage, basic setting, Road use with Turn adjusting screw (1) until the limit
rear rider 85 kg position in the direction (+), then turn
in direction (–) for 5 clicks.
Racing use with Turn adjusting screw (1) until the limit
rider 85 kg position in the direction (+), then turn
in direction (–) for 3 clicks.
Rebound stage, basic setting, rear Road use with Turn adjuster knob until the limit
rider 85 kg position in the direction (A), then turn
Racing use with Turn adjuster knob until the limit
rider 85 kg position in the direction (A), then turn
33 82 - Traction drive, chain pinion, belt pinion
Number of teeth, rear-wheel drive 17:45
Pinion / sprocket
Secondary transmission ratio 2,647
33 83 - Traction drive, chain, belt
Chain deflection Motorcycle with no 45...50 mm
weight applied,
supported on its side
stand
Permissible chain length measured from the max 144 mm
centre of 10 rivets,
chain pulled taut


34 - Brakes

Brake fluid level, front Brake-fluid reservoir The brake fluid level may not drop
horizontal below the MIN mark.
Hydraulic fluid (Brake fluid, DOT4)
Brake fluid level, rear Brake-fluid reservoir The brake fluid level may not drop
horizontal below the MIN mark
34 11 - Front wheel brakes

Type of front brake Twin disc brake, diameter 320 mm, 4-
piston fixed caliper
Brake-pad material, front Sintered metal
Brake-pad wear limit, front Friction pad only, min 1 mm
without backing plate

without backing plate.
The wear indicators
(grooves) must be
clearly visible
Brake disc diameter, front 320 mm
Brake disc lateral runout, front removed, at outer max 0.1 mm
diameter, components
cooled down
installed, at outer max 0.15 mm
cooled
Brake disc thickness, front When new 4.5 mm
Wear limit min 4.0 mm
Play of brake controls on the piston 0.6...1.4 mm
Front brake
Thickness of brake-pad carrier plate min 4.5 mm
34 21 - Rear wheel brakes

Brake-pad wear limit, rear Friction pad only, min 0.9 mm

Brake-pad material, rear Organic material
Type of rear brake Hydraulically actuated disc brake with
1-piston floating caliper and fixed disc
Brake disc diameter, rear 220 mm
Brake disc lateral runout, rear removed, at outer max 0.1 mm
cooled down
installed, at outer max 0.15 mm
cooled
Brake disc thickness, rear When new 5 mm


35 - Foot operation

35 21 - Footbrake lever, connecting linkage
Blow-by clearance of the footbrake between the footbrake 2 mm
lever lever and footrest plate
Blow-by clearance of the footbrake between the footbrake 2...3 mm
lever lever and footrest plate


36 - Wheels and tyres

36 23 - Electronic components
Wheel-speed sensor, rear 0.8+0.8 mm
−0.7
Distance from sensor ring
Wheel-speed sensor, front 0.8+0.8 mm
−0.7
Distance from sensor ring
36 30 - Motorcycle wheels
Balance weight for rear wheel max 80 g
Weights have to be affixed with one
half on the left and one half on the
right, in other words centred on the
rim
Balance weight for front wheel max 80 g
rim
Permissible rear-wheel imbalance max 5 g
Permissible front-wheel imbalance max 5 g
36 31 - Wheels with bearings
Rear-wheel type Aluminium cast wheel
Rear wheel rim size 6.0" x 17"
Front-wheel type Aluminium cast wheel
Front-wheel rim size 3.50" x 17"
36 32 - Tyres
Speed category, front/rear tyres required at W
least 270 km/h
Wheel valve test pressure 4 bar
Tyre designation, rear 190/55 ZR 17
Tyre designation, front 120/70 ZR 17
Tyre pressure, rear with cold tyre; one-up 2.9 bar
and two-up
Tyre pressure, front with cold tyre; one-up 2.5 bar
and two-up
Tyre tread depth, front and rear for Germany min 1.6 mm
Load index, rear tyre min 75 g/cm3
Load index, front tyre min 58 g/cm3
Recommended tyre combinations An overview of currently approved
tyres is available from your authorised
BMW Motorrad Retailer or on the
Internet at bmw-motorrad.com.


46 - Frame and mounted components

46 51 - Motorcycle frame
Position of the vehicle identification Frame, front right on steering head
number
Frame type Aluminium composite bridge frame,
engine also load bearing
Type plate location Frame, front right on steering head


61 - General vehicle electrics

61 13 - Plug, terminal
Fuse 1 DWA, OBD, ignition 15 A
switch, instrument
cluster
Fuse 2 Multifunction switch left, 7.5 A
RDC control unit, sensor
box
Main fuse Alternator regulator, 40 A
isolating relay, BCL,
BMS-O, ABS, SAF
Electrical rating of on-board sockets Total for all sockets max 5 A
61 21 - Battery with holder
Battery type AGM (Absorbent Glass Mat)
Battery rated capacity 8 Ah
Battery rated voltage 12 V


63 - Lights

63 10 - Front lights, position lights and side lights
Bulb for parking light LED
63 12 - Headlight
Distance from light/dark limit to upper Chassis and suspension 5 cm
edge of low-beam headlight light- in the basic setting and
emitting surface vehicle subject to a load
of 85 kg
Distance between headlight and 5m
vertical surface
For headlight adjustment
Bulbs for the low-beam headlight LED
Bulb for high-beam headlight LED
63 13 - Flashing turn indicators, front
Bulbs for turn indicators LED
63 21 - Rear light cluster
Bulb for tail light/brake light LED
63 23 - Flashing turn indicators, rear
Bulbs for flashing turn indicators, rear LED
63 26 - Number-plate light
Light source for the number plate light LED


65 - Audio, navigation, information systems

65 75 - Anti-theft alarm
Activation time on arming approx. 30 s
Alarm duration approx. 26 s


77 - Optional accessories, motorcycle

77 41 - Case, liner
Maximum permissible speed for max 180 km/h
riding with aluminium cases fitted to
the motorcycle
Payload per aluminium case max 10 kg
77 43 - Topcase, liner
Maximum permissible speed for max 180 km/h
riding with aluminium topcase fitted to
the motorcycle
Payload of aluminium topcase max 5 kg
77 45 - Tank rucksack
Maximum permissible speed for ≤130 km/h
riding with the tank bag fitted to the
motorcycle
Tank rucksack volume without capacity approx. 7 l
expansion
Capacity expansion approx. 3 l
Payload of tank rucksack ≤5 kg

Tightening torques - S 1000 RR

11 - Engine Value Valid
11 11 - Engine block
Main bearing screw connection
M9 x 95 Closing torque, 20 Nm
1st additional angle of rotation, 90°
2nd additional angle of rotation, 90°
M9 x 95 1st additional angle of rotation, 90°
Crankcase screw connection
M6 x 40 9 Nm
Crankcase screw connection
Additional angle of rotation, 90°
Starter cover on crankcase
M6 x 25 5 Nm
Screw plug on engine
M10 x 1 x 6 10 Nm
Cylinder head cover to cylinder head
M6 x 20 10 Nm
Camshaft bearing cap to cylinder head
M6 x 35 Tightening sequence: See repair
manual
1st tightening torque, 5 Nm
2nd tightening torque, 13 Nm
Cover for secondary air system to cylinder head cover
M6 x 20 5 Nm
Threaded plug (cam-follower shaft) to cylinder head
M10 x 1 10 Nm
Cylinder head to crankcase
M8 1st tightening torque, 20 Nm
1st additional angle of rotation, 90°
3. Additional angle of rotation, 45°
Cylinder head to frame
Cylinder head, left, to frame, M10 x 50 60 Nm
Cylinder head, right, to frame, M10×50, Renew screw Tightening sequence: with taper
elements (expander element
outside)
Cylinder head/crankcase on right to frame

M10×50, Renew screw Tightening sequence: with taper
outside)
11 13 - Oil sump
Oil drain plug to oil pan
M16 x 1.5 28 Nm
Oil pan to crankcase
M6 x 35, Renew screw Tightening torque, 3 Nm
11 14 - Housing cover
Clutch cover to crankcase
Engine cover, left, to crankcase
Insulating mat with retaining plate to engine housing cover on right
M5 x 10 - 10.9, Renew screw 5 Nm
Thread-locking compound (micro-encapsulated)
Screw plug for crankshaft
M40 12 Nm
Sprocket wheel timing chain drive to crankshaft
M12 x 1.5 x 40 120 Nm
11 24 - Conrod with bearings
Threaded fasteners for conrods
MJ8 x 1 x 35 Closing torque, 5 Nm
Pre-tensioning torque, 25 Nm
Additional angle of rotation, 105+5°

11 31 - Camshaft
Axle for timing chain drive reduction gear to cylinder head
M10 x 40 60 Nm
Tensioning/slide rail for timing chain to crankcase
M16 x 1.5 30 Nm
Timing-chain tensioner to cylinder head
M20 x 1.5 42 Nm
11 36 - Camshaft adjustment
Switching cam adjuster to camshaft bearing cap
M6 x 30 - 10.9 13 Nm
11 41 - Oil pump with strainer and drive
Oil-coolant pump chain guide to crankcase
M6 x 20 9 Nm
Pinion on shaft for oil/coolant pump
M6, Renew nut 10 Nm
Oil-coolant pump to crankcase
M6 x 35 9 Nm
Screw plug for oil pressure control valve to crankcase
M14 x 1.5 x 10 25 Nm
11 42 - Oil filter and lines
Oil filter to engine
Lubricate seal with engine oil 11 Nm
Oil filter adapter to crankcase
M20 x 1.5 35 Nm
Oil line to crankcase
M6 x 16 9 Nm
Screw connection oil spray bar to crankcase
M5 x 12 5 Nm
11 51 - Coolant pump with drive
Oil/Coolant pump to crankcase
M6 x 35 9 Nm
11 53 - Thermostat and on-engine coolant lines
Connecting branch for coolant pump to crankcase
M40 x 2 12 Nm
11 61 - Intake system
Air intake to cylinder head
M6 x 16, Renew screw 8 Nm
11 72 - Secondary air system
Secondary air system changeover valve to intake air silencer
PT40 x 15 3 Nm
11 78 - CO adjustment, oxygen sensor
Monitoring oxygen sensor to exhaust manifold
M12 x 1.25 25 Nm
Thinly lubricate thread, Lubricant (Optimoly TA)
Front oxygen sensor to exhaust manifold
M14 x 1.25 45 Nm
Thinly lubricate thread, Lubricant (Optimoly TA)


12 - Engine electrical system Value Valid
Spark plug in cylinder head
M10 x 1 12 Nm
12 31 - Alternator with drive and fasteners
Stator to engine housing cover, left
Holder for alternator cable to engine cover
M5 x 16 4.5 Nm
Thread-locking compound (Loctite 243, Medium strength)
Magnet wheel to crankshaft
M12 x 1.5 x35 - 10.9 120 Nm
Thread lightly oiled
12 32 - Regulator
Voltage regulator to holder
M6, Renew nut 8 Nm
Thread-locking compound (mechanical)
12 41 - Starter with fastener
Starter motor to crankcase
M6 x 35 8 Nm
Wiring harness (positive wire) to starter motor
M5 x 10 3 Nm
12 52 - Plug, clips, loose parts
Engine wiring harness (earth) to cylinder head
M5 x 10 5 Nm
Wiring harness (earth) to crankcase
M6 x 12 8 Nm
12 62 - Coolant temperature
Coolant temperature sensor to thermostat housing
M12 x 1.5 15 Nm
12 72 - Transmitter for control unit
Knock sensor to crankcase
M8 x 30 20 Nm
Crankshaft sensor on engine housing cover
Camshaft sensor to cylinder head
M6 x 16 10 Nm
Switching cam sensor on cylinder head cover
M6 x 16 5 Nm


13 - Fuel preparation and control Value Valid
13 54 - Throttle valve and actuation
Fuel injection pipe to intake silencer
TS5 x 14 3 Nm
Injection strip on throttle valve assembly
Screw clamp for throttle valve connection 1.5 Nm
13 63 - Electromechanical switchgear
Servomotor for unfiltered-air flap to air intake duct
Screw for plastic, 6 x 22 2 Nm
13 71 - Intake air silencer
Intake silencer to throttle-valve assembly
M6 x 12 6 Nm
Intake silencer to frame
M6 x 30 8 Nm
Rear air guide to frame
M6 x 12 8 Nm
Servomotor to intake silencer


16 - Fuel supply Value Valid
16 11 - Fuel tank with filler neck
Fuel tank to retaining bridge, rear
M6 x 115 5 Nm
Fuel tank to frame
M8 19 Nm
Fuel filler cap to fuel tank
M5 x 20 2.5 Nm
16 13 - Breather, emissions monitoring
Holder, activated charcoal filter to frame
M6 x 16 5 Nm
Tank ventilation distributor to throttle valve
M5 x 16 5 Nm
16 14 - Delivery, preparation and measurement, control unit, fuel pump
Electric fuel pump to fuel tank
M5 x 20 5 Nm


17 - Cooling Value Valid
Coolant line to bracket
M5 x 16 5 Nm
17 11 - Radiator with fasteners
Radiator holder to crankcase
M8 x 24 8 Nm
Radiator to frame
M6 x 25 8 Nm
17 13 - Expansion tank
Coolant expansion tank to frame
M6 x 20 8 Nm
17 21 - Oil cooler
Oil cooler to radiator
17 22 - Oil cooler lines
Return line for oil cooler to engine
Oil lines for oil cooler to crankcase
M6 x 20 8 Nm
17 40 - Fan
Fan to radiator
17 65 - Thermostat with housing
Thermostat cover to crankcase
M6 x 25 9 Nm


18 - Exhaust system Value Valid
18 51 - Exhaust system parts with mountings
Cover to exhaust flap
M5 x 12 5 Nm
Bracket for exhaust manifold to frame
Lubricate shank, Lubricant (Optimoly TA)
Servomotor holder for exhaust flap to frame
M5 x 10 2 Nm
Servomotor holder for exhaust flap to engine
Aluminium screw, M6 x 25 5 Nm
Exhaust manifold to holder
Bracket to silencer
Exhaust manifold to cylinder head
M7 14 Nm
Clamping collar for rear silencer
M8 14 Nm
M8 24 Nm
Silencer to footrest system
M8 x 40 19 Nm
Servomotor for exhaust flap to Bowden-cable counter support
Screw for plastic, TS5 x 15 2 Nm


21 - Clutch Value Valid
21 21 - Clutch with driver plate
Pressure plate to driver
M6 x 25 10 Nm
Screws oiled
Clutch hub to drive shaft
M20 x 1.5, Renew nut Tightening sequence: 1st
Thread-locking compound (micro-encapsulated) tightening torque
190 Nm
Loosen screw connection
Tightening sequence: 2nd
tightening torque
190 Nm
Caulk nut to transmission shaft


23 - Gearbox Value Valid
23 00 - Gearbox
Pinion to transmission output shaft
M24 x 1.5 125 Nm
secure with profile washer, Thread-locking compound
(mechanical)
23 12 - Bearing in housing, sealing rings
Bearing retaining plate with bearing carrier to crankcase
M5 x 18 5 Nm
23 14 - Electrical components
Gearbox potentiometer to selector-drum carrier
M5 x 14 - 10.9 5 Nm
23 31 - Internal gearshift components
Locking lever to crankcase
M6 x 30 9 Nm
Locking plate of gearshift rail to crankcase
M5 x 12 5 Nm
Selector star to selector drum
Bearing carrier, selector drum, to crankcase
M6 x 25 9 Nm
Gearshift shaft (retaining plate) to crankcase
M6 x 16 9 Nm
Gearshift lever to side-stand pivot mount
M8 x 65 19 Nm
Gear selector lever to gearshift shaft
M6 x 25 8 Nm
Gearshift rod to gearshift lever
Gearshift rod to gear selector lever
Selector rod to gearshift lever
M6 x 20, Replace screw 8 Nm


31 - Front axle, front-wheel steering Value Valid
Damper unit to forkleg
M8 x 25 25 Nm
Cover to fixed fork tube 20 Nm
Adjustment specification, steering-head bearing

top slotted nut, M35 x 1 Tightening torque, 1 Nm
Secure with circlip turn further until circlip can be
installed
bottom slotted nut, M35 x 1 Tightening torque, 40 Nm
Swing fork 3x to the left/right
slacken (forks turned fully to the left),
80°
Tightening torque (forks turned fully to
right), 15 Nm
Fork bridge, top, to fork fixed tube
M8 x 25 19 Nm
Fork bridge, bottom, to fork fixed tube
M8 x 35 Tightening sequence: Tighten

screws six times in alternate
sequence
19 Nm
Clamping screws in axle holder

sequence
19 Nm
Lock nut (on damper rod) to fork-leg cap 15 Nm
Adjusting steering-head bearing (for maintenance)
Bottom slotted nut, M30 x 1 (forks turned fully to right), 15 Nm
Rubber ring
Top slotted nut, M30 x 1 Tightening torque, 1 Nm
installed
Quick-release axle in threaded bush

M24 x 1.5 50 Nm
Top fork bridge to steering tube
M28 x 1 100 Nm


32 - Steering and wheel alignment Value Valid
32 71 - Motorcycle handlebars
Bracket for reservoir to fork bridge
Expansion tank to bracket
M5 x 18 5 Nm
Handlebar weight to handlebar half
M8 x 35 19 Nm
Handlebar half to fork leg
Threaded pin, M6 x 10 8 Nm
Clamping bolt, M8 x 25 19 Nm
32 72 - Handlebar lever
Adapter to clamp
M3 x 14 1 Nm
Bleed screw to handlebar fitting
M7 x 12 5 Nm
Throttle twistgrip to handlebar
M3.5 x 30 2 Nm
Handbrake fitting to handlebars
M6 x 20 Tightening sequence: tighten top
until fully closed
8 Nm
Clutch lever fitting to handlebar
M6 x 20 Tightening sequence: tighten top
until fully closed
8 Nm
Hand lever to clutch lever fitting
M6, Renew nut Tightening sequence: Tighten the
Thread-locking compound (mechanical) nut, counter-holding the bolt
6 Nm
Hand lever to handbrake fitting
M6, Screw 1 Nm
M6, Renew nut Tightening sequence: Tighten the
Thread-locking compound (mechanical) nut, counter-holding the bolt
6 Nm
32 73 - Bowden cables
Guide clip for clutch cable to upper fork bridge
M5 x 16 2 Nm
Clutch cable counter support to engine
M6 x 16 10 Nm
Steering damper to fork bridge

Steering damper to frame


33 - Rear axle, rear-wheel drive and rear-wheel guidance Value Valid
Rear wheel swinging arm to frame
M27 x 1.25 Tightening torque, 15 Nm
Loosen, 120°
Tightening torque, 5 Nm
M18 x 1.5, Renew nut 100 Nm
Nut on swinging arm axle
M18 x 1.5, Replace nut 100 Nm
Swinging arm axle to frame
M27 x 1.25 Tightening torque, 15 Nm
Loosen, 120°
Tightening torque, 5 Nm
Locknut of the final-drive chain tensioning screw
M8 19 Nm
33 54 - Spring strut, mounting parts
Spring strut to swinging arm
Spring strut at deflection lever
M12 x 75 - 10.9 100 Nm
Clamping bolt at adjusting strut
M6 x 25 8 Nm
Screw in adjusting ring
M5 x 16 6 Nm
Relay lever to frame
Pivot strut to rear wheel swinging arm
Link strut to relay lever
33 84 - Traction drive, chainwheel, belt wheel
Chain sprocket to chain-sprocket carrier
M12 x 1.5 - 10, Renew nut Tightening sequence: tighten in
Thread-locking compound (mechanical) diagonally opposite sequence
110 Nm
33 85 - Mounted parts, traction drivetrain
Chain drop guard to engine
M6 x 45 5 Nm
Chain guard to swinging arm
Pinion cover to chain failure protection
M5 x 20 2 Nm


34 - Brakes Value Valid
Radial brake caliper on wheel axle clamp
M10 x 65 38 Nm
Brake disc to front wheel
M8 x 27 - 10.9, Renew screw Tightening sequence: tighten in
Thread-locking compound (micro-encapsulated) diagonally opposite sequence
19 Nm
Bleed screw on handbrake lever fitting
M7 5 Nm
Bleed screw, front, in banjo bolt
M6 6 Nm
Locking pin for front brake pads
Steel locking pin 8 Nm
Expansion tank to rear frame
Brake disc to rear wheel
M6 x 18, Renew screw Tightening sequence: tighten in
8 Nm
Rear brake calliper bleeder screw
M10 14 Nm
34 31 - Footbrake cylinder, tandem brake master cylinder
Brake fluid reservoir to rear frame
Renew screw 5 Nm
Footbrake cylinder with heel deflector, right, to footrest plate
Pushrod, footbrake cylinder

M6, Locknut 6 Nm
34 32 - Brake lines
Brake hose with banjo bolt to components
M10 x 1 24 Nm
Holder, brake line/brake hose
M5 x 14, 3 mm collar 5 Nm
Brake-hose distributor to fork bridge
M6 x 16 8 Nm
34 51 - Mechanical, hydraulic components
ABS pressure modulator to rear carrier


35 - Foot operation Value Valid
35 21 - Footbrake lever, connecting linkage
Footbrake lever to front footrest holder



36 - Wheels and tyres Value Valid
Wheel-speed sensor to brake calliper mount, rear
Wheel-speed sensor, front to forkleg
Bracket for wheel-speed sensor cable to fork
M5 x 10 5 Nm
Wheel speed sensor cable clip to brake calliper mount
Sensor ring to rear wheel
M5 x 10 5 Nm
Sensor ring to front wheel
M5 x 10 5 Nm
Rear quick-release axle in swinging arm
M24 x 1.5 125 Nm
Tyre pressure monitoring (RDC) sensor to wheel rim

M8, Renew nut 6 Nm


46 - Frame and mounted components Value Valid
46 51 - Motorcycle frame
Rear frame to frame
M10 x 35 38 Nm
Engine to frame
Engine, left, to frame, M10 x 50 60 Nm
Engine, right, to frame
M10×50, Renew screw Tightening sequence: with taper
outside)
Nut for service data package bush to frame
M36 x 0.75 50 Nm
Thread-locking compound (Loctite 270, High strength)
Nut for service data package bush to frame
M36 x 0.75, Renew nut 70 Nm
Thread-locking compound (Loctite 270, High strength)
Positioning of the swinging arm pivot point bush in the main frame, left
M6 x 12 8 Nm
Positioning of the swinging arm pivot point bush in the main frame, right
M6 x 26,7 5 Nm
Stud bolt for tank fastening to frame
M8 19 Nm
Absorber weight to steering head
M8 x 50 19 Nm
46 53 - Side stand
Pivot mount for side stand to frame
Side stand to pivot mount
M10 x 1 35 Nm
Side-stand switch to pivot-bearing screw
46 61 - Front-wheel cover
Front-wheel cover to slider tube
M5 x 14, 3 mm collar, renew screw 2 Nm
46 62 - Rear-wheel cover, number-plate carrier
Adapter to number plate carrier
Rear carrier to rear frame
M5 x 20 2 Nm

Number-plate carrier to rear frame
M5 x 25, without collar 2 Nm
46 63 - Motorcycle fairing, windscreen
Front panel carrier to main frame
Fork partition to bottom fork bridge
Bracket for rear left engine spoiler to engine
M10 x 12 - 10.9 19 Nm
Engine spoiler bracket front left or right to engine
Bracket for engine spoiler right rear to engine
M8 x 16 19 Nm
Trim panels
M5 2 Nm
Windscreen to trim panel and air inlet
M5 x 16 1 Nm
Windscreen to air intake 1 Nm
46 71 - Engine fasteners, footrests
Front footrest holder to main frame
M8 x 25 19 Nm
Heel deflector, left, to footrest plate
M6 x 20 8 Nm
Footrest pin to footrest



51 - Trim panels Value Valid
51 16 - Mirrors, covers, ashtrays, stowage compartments
Mirror to front panel carrier
M6, Replace nut 8 Nm
51 25 - Other fasteners
Ignition/steering lock to fork bridge
M8 x 18, Renew screw Tighten bolt until tool handle shears
Thread-locking compound (micro-encapsulated) off.


52 - Seats and seat bench Value Valid
52 53 - Seat
Bearing support for tail-hump cover/passenger seat to rear frame
Front seat to rear frame


61 - General vehicle electrics Value Valid
61 11 - Wiring harness
Cable duct to intake silencer
TS5 x 15, Screw for plastic 3 Nm
Cable duct to frame
M5 x 25 2 Nm
61 13 - Plug, terminal
On-board diagnosis connector to rear carrier
61 21 - Battery with holder
Wiring harness to battery
M6 x 13,5 5 Nm
Battery tray to rear frame
M5 x 16 5 Nm
61 31 - Switch, sensor
Switch for intelligent emergency call to adapter

M5 x 22 3 Nm
Right multifunction switch to throttle grip

Screw for plastic, PT2.5 x 15 0.5 Nm
Cover to right multifunction switch
Handlebar grip, left, to handlebar

M3.5 x 30 2 Nm
Multi-controller to grip
Screw for plastic, TSRS 2.5 x 23 0.5 Nm
Microswitch to clutch lever fitting
M2 x 22 0.3 Nm
61 33 - Emergency power siren, horn
Horn to headlight
61 35 - Control units, module
Control unit holder for chassis and suspension adjustment to engine
M6 x 30 8 Nm
RDC control unit to bracket
M5 x 14 2 Nm
Rotational speed sensor to frame
M6 x 20 8 Nm
Engine control unit bracket to frame
M5 x 25 5 Nm
61 36 - Relay

Relay cover to relay carrier
Relay carrier to engine
M6 x 16 8 Nm


63 - Lights Value Valid
63 12 - Headlight
Headlight to front panel carrier
M6 x 30 8 Nm
63 21 - Rear light cluster
Rear light/turn indicator bulb to number plate carrier
M6 x 20 3 Nm
Nut, M6
63 23 - Flashing turn indicators, rear
Turn indicator/rear light cluster to number-plate carrier
M6 x 20 3 Nm


65 - Audio, navigation, information systems Value Valid
65 75 - Anti-theft alarm
Anti-theft alarm bracket to rear carrier
M5 x 12 2 Nm


77 - Optional accessories, motorcycle Value Valid
77 02 - Maintenance and Technology
Swinging-arm adapter to rear wheel swinging arm
M8 x 30 20 Nm
77 14 - Engine guard, crash bars
Guard, left, to crankcase cover
M6 x 40 Tightening sequence: see
installation instructions
7 Nm
Guard, right, to timing-gear cover
M6 x 45 9 Nm
77 21 - Wheels
Front brake disc to forged wheel or Carbon wheel
Cylinder-head screw, M8 x 25 Tightening sequence: tighten in
diagonally opposite sequence
24 Nm
Rear brake disc to forged wheel or Carbon wheel
8 Nm
End stoppers in rear axle
M8 x 50 20 Nm
End stoppers in front axle
M8 x 50 20 Nm
77 22 - Handlebars scope
Switch tongue to clutch lever
M2, Renew screw 0.3 Nm
Brake/clutch lever protector on handlebars
M8 x 40 20 Nm
Remove adjuster to clamp
M6 x 40 12 Nm
77 25 - Frame, footrests, mounted parts
Foot brake lever to footrest plate
M8 x 35 20 Nm
Footbrake cylinder to footrest plate
M6 x 20 10 Nm
77 31 - Trim panels
Cover for mounting of mirror
M6 x 25 3 Nm
77 44 - Mounted parts, topcase, luggage carrier
Spacer for saddlebags to rear frame
M8 x 30 19 Nm
77 45 - Tank rucksack
Rear attachment to holder
M5 x 14 2 Nm
Front attachment to rubber grommet
M5 x 25 2 Nm
77 52 - Audio, navigation, information system
USB charging socket to holder
M18 x 1 3 Nm

Service data - S 1000 RR

11 - Engine
Running-in speed Odometer <7000 min-1
reading 0...300 km
Odometer <9000 min-1
reading 300...1000 km
Odometer no full load
reading 0...1000 km
Fluids and lubricants
Viscosity class
Engine oil, specified level Engine at operating between MIN and MAX mark
temperature, vehicle is
in vertical position
Engine oil, quantity for topping up Difference between MIN max 1.3 l
and MAX
1134 - Valves with springs
Exhaust valve clearance Engine cold 0.20...0.26 mm
1212 - Ignition lead, spark plugs
Spark plugs, manufacturer and NGK LMAR9FI-10G
designation
13 - Fuel preparation and control
Recommended fuel grade Super Plus, unleaded maximum 5%
ethanol, E5
98 ROZ/RON
93 AKI
16 - Fuel supply
17 - Cooling
Cooling system test pressure Test pressure must 2 bar
remain
Coolant, specified level cold engine between MIN and MAX mark on the
expansion tank
31 - Front axle, front-wheel steering

Fork oil, capacity of left fork leg approx. 350 ml
Fork oil, capacity of right fork leg approx. 350 ml
Level of fork oil in left fork leg (air Forks fully compressed 135+2 mm

spacer bush removed
Level of fork oil in right fork leg (air Forks fully compressed 135+2 mm
spacer bush removed
3142 - Telescopic forks
Projection of fork tube in fork bridge, measured without fork 6 mm
top cover
3273 - Bowden cables
Distance between adjusting screw 3+1.5 mm
and handlebar fitting (clutch-cable −1.5
setting)
in straight-ahead
position, with cold
engine
3383 - Traction drive, chain, belt
Chain deflection Motorcycle with no 45...50 mm
weight applied,
supported on its side
stand
Permissible chain length measured from the max 144 mm
centre of 10 rivets,
chain pulled taut
34 - Brakes
Brake fluid level, front Brake-fluid reservoir The brake fluid level may not drop
horizontal below the MIN mark.
Brake fluid level, rear Brake-fluid reservoir The brake fluid level may not drop
horizontal below the MIN mark
3411 - Front wheel brakes

The wear indicators
(grooves) must be
clearly visible
Brake disc thickness, front When new 4.5 mm
3421 - Rear wheel brakes
Brake-pad wear limit, rear Friction pad only, min 0.9 mm
Brake disc thickness, rear When new 5 mm

3630 - Motorcycle wheels

Balance weight for rear wheel max 80 g
rim
Permissible rear-wheel imbalance max 5 g
Permissible front-wheel imbalance max 5 g
Balance weight for front wheel max 80 g
rim
3632 - Tyres
Wheel valve test pressure 4 bar
Tyre pressure, rear with cold tyre; one-up 2.9 bar
and two-up
Tyre pressure, front with cold tyre; one-up 2.5 bar
and two-up
Tyre tread depth, front and rear for Germany min 1.6 mm
6121 - Battery with holder
Battery type AGM (Absorbent Glass Mat)
6312 - Headlight
Distance from light/dark limit to upper Chassis and suspension 5 cm
edge of low-beam headlight light- in the basic setting and
emitting surface vehicle subject to a load
of 85 kg
Distance between headlight and 5m
vertical surface
For headlight adjustment
M6 x 20 10 Nm
M6 x 35 Tightening sequence: See repair
manual
2nd tightening torque, 13 Nm
11 13 - Oil sump
Oil drain plug to oil pan
M16 x 1.5 28 Nm
11 14 - Housing cover
M40 12 Nm
M12 x 1.5 x 40 120 Nm
11 36 - Camshaft adjustment
M6 x 30 - 10.9 13 Nm
11 42 - Oil filter and lines
Oil filter to engine

Lubricate seal with engine oil 11 Nm
M10 x 1 12 Nm
12 72 - Transmitter for control unit
M6 x 16 5 Nm
13 54 - Throttle valve and actuation
Fuel injection pipe to intake silencer
TS5 x 14 3 Nm
13 71 - Intake air silencer
Intake silencer to throttle-valve assembly
M6 x 12 6 Nm
Intake silencer to frame
M6 x 30 8 Nm
Rear air guide to frame
M6 x 12 8 Nm
16 11 - Fuel tank with filler neck
M6 x 115 5 Nm
Fuel tank to frame
M8 19 Nm
17 11 - Radiator with fasteners
Radiator to frame
M6 x 25 8 Nm
23 00 - Gearbox
Pinion to transmission output shaft
M24 x 1.5 125 Nm
secure with profile washer, Thread-locking compound
(mechanical)
M8 x 65 19 Nm
M8 x 25 25 Nm
Cover to fixed fork tube 20 Nm

top slotted nut, M35 x 1 Tightening torque, 1 Nm
installed

bottom slotted nut, M35 x 1 Tightening torque, 40 Nm
Swing fork 3x to the left/right
slacken (forks turned fully to the left),
80°
Tightening torque (forks turned fully to
right), 15 Nm
M8 x 25 19 Nm

sequence
19 Nm

sequence
19 Nm
Lock nut (on damper rod) to fork-leg cap 15 Nm
Bottom slotted nut, M30 x 1 (forks turned fully to right), 15 Nm
Rubber ring
Top slotted nut, M30 x 1 Tightening torque, 1 Nm
installed
M24 x 1.5 50 Nm
Top fork bridge to steering tube
M28 x 1 100 Nm
32 71 - Motorcycle handlebars

M8 19 Nm
33 84 - Traction drive, chainwheel, belt wheel
M12 x 1.5 - 10, Renew nut Tightening sequence: tighten in
Thread-locking compound (mechanical) diagonally opposite sequence
110 Nm
33 85 - Mounted parts, traction drivetrain
Pinion cover to chain failure protection
M5 x 20 2 Nm
M10 x 65 38 Nm
M8 x 27 - 10.9, Renew screw Tightening sequence: tighten in
19 Nm
M7 5 Nm
M6 6 Nm
8 Nm
M10 14 Nm
34 32 - Brake lines
M6 x 16 8 Nm
M5 x 10 5 Nm
M5 x 10 5 Nm
M24 x 1.5 125 Nm

M8, Renew nut 6 Nm
46 61 - Front-wheel cover
46 63 - Motorcycle fairing, windscreen
Fork partition to bottom fork bridge
Bracket for engine spoiler right rear to engine
M8 x 16 19 Nm
Bracket for rear left engine spoiler to engine
M10 x 12 - 10.9 19 Nm
61 35 - Control units, module
Engine control unit bracket to frame
M5 x 25 5 Nm

Engine
Repair Guide
BMW Motorrad
11 00 040 Testing compression with BMW Motorrad diagnostic system

+ 11 00 567
Preparatory work
=> Removing and installing the rear-wheel stand special tool
(motorcycles without centre stand) (Description in item: 46
52 510, Billed as a separate item)
Removing tail-hump cover
Removing rider’s seat
Removing complete fuel-tank cover
Removing fuel tank
Loosen engine control unit with wiring harness
Remove the intake air silencer
Disconnecting connector for bottom fuel injectors
Removing the rear air intake duct
Removing secondary air system line
Remove the direct ignition coils
Removing spark plugs
Core activity
(-) Testing compression
Check
Install diagnosis adapter (No. 11 7 846) with hose (No. 11 7 842).

Connect the measuring device and follow the instructions issued by the
diagnostic system.
Test the compression with the measuring device.
Technical data
Compression test Good min 13 bar
pressure Normal 10...13 bar
Poor max 10 bar
Result:
Compression lower than normal value
Measure:
Carry out repairs as specified.
Follow-up work
Installing spark plugs
Installing direct ignition coils
Installing secondary air system line
Installing rear air intake duct
Connecting connectors for bottom fuel injectors
Install the intake air silencer
Attaching engine control unit with wiring harness
Installing fuel tank
Installing complete cover of fuel tank
Connecting BMW Motorrad diagnostic system to vehicle
Performing vehicle test with BMW Motorrad diagnostic system
Disconnecting BMW Motorrad diagnostic system from vehicle
Installing rider’s seat
Installing tail-hump cover
Final check of work performed

11 00 050 Removing/installing engine

+ 11 00 541
ATTENTION
Use of hard or sharp-edged objects in proximity to component
Component damage
Take care not to scratch components; cover or mask as necessary.
NOTICE
The running-in rpm limit has to be set if engine, running gear, crankcase,
piston(s), crankshaft, conrod or crankshaft bearings have been replaced.
Preparatory work
Disconnect battery from vehicle
Removing fuel tank
Removing fairing side panel with engine spoiler left and right
Removing air deflector for radiator
Removing trim for right frame
Draining engine oil from engine
Draining coolant
Removing gearshift lever with Gear Shift Assistant
Removing pinion cover
Removing the trim of the relay
Remove left front oxygen sensor
Disengaging clutch cable
Removing radiator with oil cooler
Removing chain drop guard
Removing silencer
Removing cover of exhaust-flow control valve
Disengaging Bowden cables from exhaust-flow control valve
Disengaging servomotor for exhaust-flow control valve
Disconnecting oxygen sensors
Removing exhaust manifold
Releasing pinion
Relieving chain tension
Removing pinion
Releasing engine wiring harness
11 00 103 Disassembling and assembling engine (engine removed)

+ 11 00 648
NOTICE
Preparatory work
Securing engine to assembly stand
Removing the left and right switching cam adjusters
Remove sensors
Removing coolant venting hose
Removing fairing bracket
Removing holder for clutch cable
Removing right crankshaft cover
Removing holder for servomotor for exhaust flap
Removing thermostat
Core activity
(-) Removing cylinder head cover
Remove bolts (1) with seals .

Remove cylinder head cover (2) with seals (3) and (4).
(-) Removing left crankcase cover
ATTENTION
Component damage
Remove screws (1).

Loosen housing cover (2), observe dowel pins (3) in this process.
Remove the housing cover (2).

(-) Removing right crankcase cover
Remove screws (1).

Turn lever(2) to the back.
Release mechanism does not function any longer.
Remove engine housing cover (3), checking dowel pins (4).
Remove seal (5).
(-) Removing starter
Remove screws (1).

Remove spacer (2).
Remove starter motor (3), paying attention to the O-ring (4) while doing so.
(-) Checking valve clearance
Check
Determine valve clearance with feeler gauge (1) by measuring between
cams and rocker arms.
Technical data
Exhaust valve Engine cold 0.20...0.26 mm
clearance
Check cylinder 1.
Check all other cylinders by turning the engine clockwise by half a
crankshaft turn each time:

Check
Attach holding fixture (No. 11 0 991) with side A CHECK on camshafts (2)
and (3).
Chain guard (No. 11 0 991) must rest flat on edge of housing and test
springs must slide to limit position in grooves (arrows) without great force.
Result:
Chain guard cannot be pushed on.
Measure:
Repeat the adjustment process.
Result:
Chain guard can be pushed on.
Measure:
Remove holding fixture (No. 11 0 772) from camshafts (2) and (3).
Slide sliding piece (1) to the outside.
(-) Removing locating pin
Remove locating pin (No. 11 0 971).
(-) Turning engine through several revolutions and making sure

that all components move freely
Turn the engine through several revolutions and make sure that all
components move freely.

(-) Recheck the valve clearance
After assembly, recheck valve clearances for all cylinders.
Technical data
clearance
(-) Installing starter
Check the O-ring (1) for damage, replace if necessary.

Clean the contact face (arrow) and lubricate.
Lubricant
Molykote D paste
Position and install starter motor (2).

Install spacer (3).
Install screws (4).
Tightening torques
M6 x 35 8 Nm
(-) Installing right crankcase cover
Align thrust piece (1) so that the recess (arrow) faces the rear.
Clean the sealing surfaces.

Make sure that dowel pins (4) are installed.
Place the gasket (5) in position.
Install engine housing cover (3) while turning the lever (2) toward the rear.
Make sure that the engine housing cover (3) rests completely against the
sealing surface of the engine housing.
Install new screws (1) and tighten until hand-tight.
Tighten the screws with torque wrench (No. 00 2 703) in accordance with
the specified tightening sequence.

Tightening torques
M6 x 35, Renew screw Tightening torque,
3 Nm
Additional angle of
rotation, 90°
(-) Installing left crankcase cover
CAUTION
Crimping danger
Strong magnetic attraction force between magnet wheel and stator of the
alternator.
When assembling the components, do not reach at or in the sealing surface
edges.
Do not jam any lines or cables.
Clean the sealing faces.

Apply a thin coat of surface sealing compound to the sealing surface of the
engine housing.
Sealant
Dow Corning 07 58 0 397 777

Install housing cover (2).
Install new bolts (1), do not tighten.
Tightening torques
3 Nm
Additional angle of
rotation, 90°
(-) Installing cylinder head cover
Check seals (1) for SLS system and replace as needed.

Make sure that seals (1) are installed.

Make sure that seals (1) and (2) are installed in cylinder head cover (3).
Install cylinder head cover (2) with seals (3) and (4).
Before installing the bolts (1), check if seals (3) and (4) are resting correctly
on the sealing surfaces.
Install screws (1) with seals.
Tightening torques
M6 x 20 10 Nm
Follow-up work
Installing thermostat
Installing holder for exhaust flap servomotor
Installing right crankshaft cover
Installing holder for clutch cable
Installing fairing bracket
Installing coolant vent hose
Installing sensors
Installing left and right switching cam adjuster
Removing engine from assembly stand

11 00 209 Oil change, engine, with filter

+ 11 00 611
Preparatory work
Removing right engine spoiler
Core activity
(-) Engine-oil change, with filter
NOTICE
Change the oil at operating temperature:
Make sure the temperature is as specified in the repair instructions.
Or, alternatively, check whether the oil/coolant radiator is hot (risk of burning!).

Place a suitable tray underneath the engine to catch escaping oil.
CAUTION
Hot exhaust system
Risk of burn injury
Do not touch a hot exhaust system.
Remove oil drain plug (1) and drain engine oil.

Remove old sealing ring (2) from oil drain plug (1).
Removing oil filter

Information about different oil filters
There are different oil filters:
Oil filter(1)
Oil filter(2)
The oil filter (1) is replaced with oil filter (2) in the frame of the running-in
check.
Choose the corresponding repair path.
Version 1: Removing oil filter in the framework of running-in check

Place a suitable container underneath the oil filter.
Remove oil filter (1), using oil filter wrench (No. 11 4 661).
Dispose of the oil filter in an environmentally friendly manner.
Clean oil drips off the exhaust manifold.

11 00 551 Replacing power train (engine removed)
NOTICE
NOTICE
Transfer the engine number (with leading "E") to the new part.
Preparatory work
Removing knock sensors
Removing coolant hose to radiator
Removing cylinder head cover
Checking valve clearance
Adjust engine to firing TDC
Removing the camshaft bearing support
Remove the camshafts
Removing valve shims
Removing timing-chain tensioner
Removing chain sprocket reduction gear for camshafts
Removing cylinder head
Removing propulsion unit from assembly stand
Core activity
(-) Removing knock sensors
Remove screws (1).

Removing knock sensors (2).
(-) Secure the propulsion unit to assembly stand

Before installing the bolts (1), check if seals (3) and (4) are resting correctly
on the sealing surfaces.
Tightening torques
M6 x 20 10 Nm
Follow-up work
Installing left and right switching cam adjuster
Installing coolant hose to radiator
Installing holder for clutch cable
Installing fairing bracket
Installing knock sensors

11 00 609 Oil change in engine with filter (for maintenance)
Preparatory work
Core activity
(-) Engine-oil change, with filter
NOTICE
Change the oil at operating temperature:
Make sure the temperature is as specified in the repair instructions.
Or, alternatively, check whether the oil/coolant radiator is hot (risk of burning!).

Place a suitable tray underneath the engine to catch escaping oil.
CAUTION
Hot exhaust system
Risk of burn injury
Remove oil drain plug (1) and drain engine oil.

Remove old sealing ring (2) from oil drain plug (1).
Removing oil filter

Information about different oil filters
There are different oil filters:
Oil filter(1)
Oil filter(2)
The oil filter (1) is replaced with oil filter (2) in the frame of the running-in
check.
Choose the corresponding repair path.
Version 1: Removing oil filter in the framework of running-in check

Place a suitable container underneath the oil filter.
Remove oil filter (1), using oil filter wrench (No. 11 4 661).
Dispose of the oil filter in an environmentally friendly manner.
Clean oil drips off the exhaust manifold.

11 00 646 Checking pressure loss with BMW diagnostic system (spark plug removed)
Preparatory work
Core activity
(-) Checking pressure loss
Check
Install diagnosis adapter (No. 11 7 843) with hose (No. 11 7 842) and
adapter for pressure loss (No. 11 7 841).
Connect the measuring device and follow the instructions issued by the
diagnostic system.
Check pressure loss with the measuring device.
Technical data
Press loss Engine at max 30 %
through valves or operating
cylinder temperature
Result:
Pressure loss greater than maximum permissible value.
Measure:
Pinpoint the cause of the fault.
Possible causes:
inlet valves
exhaust valves
piston and cylinder
Follow-up work
Performing vehicle test with BMW Motorrad diagnostic system

11 11 514 Replace engine block (engine removed)
NOTICE
NOTICE
Transfer the engine number (with leading "E") to the new part.
Preparatory work
Remove sensors
Removing holder for servomotor for exhaust flap
Removing thermostat
Core activity

ATTENTION
Component damage
Remove screws (1).


11 12 116 Removing/installing cylinder head or replacing cylinder-head gasket

+ 11 12 814
ATTENTION
Risk of oil contamination or mixing of oil and coolant
Component damage
Change engine oil and oil filter.
Change contaminated coolant.
Preparatory work
Removing fuel tank
Draining coolant
Removing throttle-valve assembly
Removing the left switching cam adjuster
Removing the right switching cam adjuster
Removing the exhaust duct
Releasing gearshift lever
Release chain failure protection
Removing silencer
Releasing oil cooler
Removing bracket for radiator
Removing radiator

Releasing engine wiring harness
Checking valve clearance
Removing timing chain tensioning rail and timing chain guide rail
Core activity
(-) Removing cylinder head
Release clamp (1) with pliers (No. 17 5 571).

Pull off coolant venting hose (2) and thread through frame to the inside.
Remove the screw (1) with expander element (2) and taper element (3).
Remove screws (1).
Slacken the screws in reverse sequence from (10) to (1).

Remove screws (1) with washers (2).
Remove (1) cylinder head.
Removing cylinder head gasket (1).
(-) Installing cylinder head

Install cylinder head gasket (1) and align fitting sleeves (arrows).
NOTICE

If the power train, engine housing, piston, crankshaft or connecting rod will be
replaced, measure the piston protrusion to determine the correct cylinder head
gasket.
NOTICE
The new cylinder-head gasket must be the same thickness as the cylinder-
head gasket it replaces.
Install cylinder head (1), noting the passing sleeves (arrows).
Degrease bolts (1) with washers (2).

Insert screws (1) with washers (2), but do not tighten them.
Tighten bolts in specified sequence (1) to (10).
Tightening torques
Cylinder head to crankcase
M8 1st tightening torque,
20 Nm
1st additional angle of
rotation, 90°
2nd additional angle
of rotation, 90°
3. Additional angle of
rotation, 45°
Install screws (1).
Tightening torques
Engine to frame
Engine, left, to frame, M10 x 50 60 Nm

Insert taper elements (3) with the taper to the outside.

Insert expander element (2) with tapered side facing taper element (3).
Install bolt (1).
Tightening torques
Cylinder head/crankcase on right to frame
M10×50, Renew screw Tightening
sequence: with
taper elements
(expander element
outside)
1st tightening torque,
30 Nm
2nd additional angle
of rotation, 90°
Work out coolant venting hose (1) through the frame.

Slide on coolant venting hose (1) and align recess on lug (arrow).
Secure clamp (2) with pliers (No. 17 5 571).
Follow-up work
Installing timing chain tensioning rail and timing chain guide rail
Installing chain sprocket reduction gear for camshafts
Installing timing chain tensioner
Adjusting valve clearance
Installing valve shim
Installing camshafts
Installing camshaft bearing bridges
Recheck the valve clearance
Checking timing
Installing cylinder head cover

Secure engine wiring harness on cylinder head
Installing exhaust manifold
Installing radiator
Installing bracket for radiator
Secure the oil cooler
Installing air deflector for radiator
Secure the clutch cable
Connecting oxygen sensors
Securing servomotor for exhaust-flow control valve
Securing Bowden cables to exhaust-flow control valve
Installing cover of exhaust-flow control valve
Installing silencer
Filling cooling system
Secure chain failure protection
Installing the trim for the relay
Installing pinion cover
Securing gearshift lever
Installing the exhaust duct
Installing the right switching cam adjuster
Installing the left switching cam adjuster
Installing throttle-valve assembly
Engine-oil change, with filter
Installing trim for right frame
Install fairing side panel with engine spoiler right and left
Checking coolant level
Checking engine oil level

11 12 256 Removing/installing and sealing or replacing cylinder-head cover

+ 11 12 821
Preparatory work
Removing fuel tank
Loosening tank ventilation distributor
Core activity
Remove bolt (1).

Loosen switching cam sensor (2) with O-ring (3) and hang it on one side.
Remove expanding rivet (1) and release the cable duct (2).


Remove seals (1) and (2) from cylinder head cover (3).
(-) Replacing cylinder-head cover
Remove screws (1).

Remove cover for the secondary air system (2) and inserts for the
secondary air system (3) and install them on a new cylinder head cover.
Install screws (1).
Tightening torques
Cover for secondary air system to cylinder head cover
M6 x 20 5 Nm
(-) Installing cylinder head cover
Check seals (1) for SLS system, replace if necessary.

Ensure that the seals (1) are installed.
Install new seals (1) and (2) in cylinder head cover (3).

Before installation of screws (1), check whether the seals (3) and (4) rest
correctly on the sealing surfaces.
Tightening torques
M6 x 20 10 Nm
Position cable duct (2) and install expanding rivet (1).
Check O-ring (3) and replace if required.

Lubricate O-ring (3).
Installation tool
Silicone spray 83 19 2 208 609
Secure switching cam adjuster with (2) O-ring (3).

Install bolt (1).
Tightening torques
M6 x 16 5 Nm
Follow-up work

Securing tank ventilation distributor

11 12 641 Replacing cylinder head (cylinder head removed)
Preparatory work
Removing air intake stub
Remove bypass distributor
Removing camshaft sensor
Core activity
(-) Removing cam followers
Remove screw plugs (1) with sealing rings (2).
Remove screw plug (1) with sealing ring (2).
Remove rocker arm shafts (1).

Remove rocker arms (2).
Remove needle rollers (1).


(-) Removing valves

Removing inlet valves
Secure mount (No. 11 0 853) to valve spring compressor (No. 11 0 851).

Adjust the compression fixture (No. 11 0 852) on spring cup (1).
Secure thrust cage (No. 11 0 852) to valve spring compressor (No. 11 0
851).
Position the valve spring compressor (No. 11 0 851) and press down spring
cup (1).
Use a suitable tool to remove valve shims (1).
Back off the special tool.

Remove spring cup (2).
Remove outer valve spring (3) and inner valve spring (4).
Remove intake valve (5).
Repeat this procedure with the other valves.
Removing exhaust valves

Adjust the compression fixture (No. 11 0 852) on spring cup (1).
Secure thrust cage (No. 11 0 852) to valve spring compressor (No. 11 0
851).
Position the valve spring compressor (No. 11 0 851) and press down spring
cup (1).
Use a suitable tool to remove valve shims (1).

Remove valve spring (3).
Remove exhaust valve (4).
Removing valve stem seals and spring retainers

Remove valve stem seal (1) with puller (No. 11 1 756).
Repeat this procedure for all valve stem seals and spring retainers.
(-) Installing valves

Installing valve stem seals and spring retainers
Install spring cup (2).
Carefully install new valve stem seal (1) with drift (No. 11 5 602) on block.
Repeat this procedure for all valve stem seals and spring retainers.
Installing exhaust valves

Install exhaust valve (4).
Install valve spring (3) with the tight winding pointing down (arrow).

Adjust the compression fixture (No. 11 0 852) on spring cup (1) and secure it
on the valve spring compressor (No. 11 0 851).
Position the valve spring compressor (No. 11 0 851) on spring cup (1), press
down spring cup (1).
Lubricate valve shims (1) lightly to keep them from sliding down.
Lubricant
Molykote D paste
Use a suitable tool to install valve shims (1). Also ensure that they are
attached in the groove on the valve (arrow).


Installing intake valves
Install intake valve (5).
Install inner valve spring (4) and outer valve spring (3).
Coloured marks face up.
Close-spaced spring coils face down.

Adjust the compression fixture (No. 11 0 852) on spring cup (1) and secure it
on the valve spring compressor (No. 11 0 851).
Position the valve spring compressor (No. 11 0 851) on spring cup (1), press
down spring cup (1).
Lubricate valve shims (1) lightly to keep them from sliding down.
Lubricant
Molykote D paste
Use a suitable tool to install valve shims (1). Also ensure that they are
attached in the groove on the valve (arrow).
(-) Installing cam followers
Install rocker arms (1).

Lubricate rocker arm shafts (2) with engine oil and install, threading in rocker
arm (1) at the same time.
Install needle rollers (3).
Needle rollers (3) seated in grooves (arrows) of the rocker arm shafts (2).

Renew sealing ring (2).

Install screw plug (1) with sealing ring (2).
Tightening torques
M10 x 1 10 Nm
Renew sealing rings (2).

Install screw plugs (1) with sealing rings (2).
Tightening torques
M10 x 1 10 Nm
Follow-up work
Installing camshaft sensor
Installing bypass distributor
Install intake manifold

11 12 651 Check tilt clearance valve for valve guide (valves removed)
Core activity
(-) Checking tilt clearance valve to valve guide
Slide O-ring (1) 4x1.5 SNR: 07 11 9 906 969 onto valve stem (2).
Adjust gap for a valve lift of 10 mm +/-1 mm.
If necessary, secure O-ring with adhesive tape between O-ring and valve
head (arrow) to prevent shifting.
Insert valve with O-ring in cylinder head.
Use measuring shoe (No. 34 2 510) as gauge tip.

Align dial gauge (No. 00 2 510) with measuring axis at height of valve head
in measuring direction X (perpendicular to the direction of travel).
Make sure that if possible, dial gauge is working/preloaded in the upper
measuring range (5-9 mm).
Set dial gauge to 0. Valve is thereby in tilt limit position (due to dial gauge
preload).
Move valve against the dial gauge in X-direction to the other limit position.
CAUTION: pressing beyond point of resistance will lead to falsified
measuring results.
Technical data
Wear limit max 0.4 mm
New condition intake 0.05...0.15 mm
New condition 0.08...0.18 mm
exhaust
Perform measurement in the same way in measuring direction Y (in direction

of travel).

11 13 000 Removing/installing or sealing oil pan

+ 11 13 531
Preparatory work
Removing fuel tank
Removing silencer
Disengaging radiator
Core activity
(-) Removing oil pan
Remove screws (1).

Remove oil sump (2).
(-) Installing oil pan
Check O-ring (1) of drainage pipe (2) and renew if necessary.

Lubricate the O-ring (1) with engine oil.


Apply sealing compound evenly on the sealing surface of the oil sump (1).
Sealant
Dow Corning 07 58 0 397 777
Position oil sump (1) and work in drainage pipe (2).

Install bolts (3), do not tighten.
Tighten bolts (1) to (14) in the sequence given.
Tightening torques
Oil pan to crankcase
3 Nm
Additional angle of
rotation, 90°
Follow-up work
Securing radiator

Installing silencer
Pouring in engine oil

11 14 075 Replacing engine-block cover, left

+ 11 14 858
Preparatory work
Removing left engine spoiler
Loosening cable for alternator
Removing crankshaft sensor
Core activity
(-) Releasing the left engine housing cover
ATTENTION
Component damage
Remove screws (1).

Hang housing cover (2) to the side.
Remove bolt (1) and holder (2).

Release rubber grommet (3).
Remove screws (4) and stator (5).
(-) Replacing left crankcase cover
Remove s eal plug(1) and O-ring (2).

Install seal plug (1) and O-ring (2) in the new engine housing cover (3).

Clean thread.
Insert stator (1) in new engine housing cover (3) and position.
Install screws (2).
Tightening torques
Thread-locking compound (micro-
encapsulated)
Clean thread.
Clean rubber grommet (1).
Apply sealing compound to sealing surface (Arrow) of rubber grommet (1)
and insert rubber grommet .
Sealant
Dow Corning 07 58 0 397 777
Position holder (2) and install bolt (3).
Tightening torques
M5 x 16 4.5 Nm
Thread-locking compound (Loctite
243, Medium strength)
(-) Securing left engine housing cover
CAUTION
Crimping danger
alternator.
edges.

engine housing.
Sealant
Dow Corning 07 58 0 397 777

Tightening torques
3 Nm
Additional angle of
rotation, 90°
Follow-up work
Securing crankshaft sensor
Securing cable for alternator
Installing left engine spoiler

11 14 085 Replacing right engine-block cover

+ 11 14 859
Preparatory work
Core activity
Remove screws (1).

Turn lever(2) to the back.
Release mechanism does not function any longer.
Remove engine housing cover (3), checking dowel pins (4).
Remove seal (5).
Remove oil filler plug (1) with O-ring (2).

Remove screws (3).
Remove retaining plate (4) and insulating mat (5).
Remove retaining clip (1).

Loosen release lever (2), detach spring (3) and remove.
Remove release lever (2).
Change engine housing cover (4).
Insert release lever (2), feed in spring (3) and attach (arrow).
Install release lever (2) up to the limit position.
Install retaining clip (1).
Clean the threads.

Install insulating mat (5) and retaining plate (4).

Install screws (3).
Tightening torques
Insulating mat with retaining plate to engine housing cover on right
encapsulated)
Install oil filler plug (1) with O-ring (2).
(-) Installing right crankcase cover
Align thrust piece (1) so that the recess (arrow) faces the rear.

Place the gasket (5) in position.
Install engine housing cover (3) while turning the lever (2) toward the rear.
Make sure that the engine housing cover (3) rests completely against the
sealing surface of the engine housing.
Install new screws (1) and tighten until hand-tight.
Tightening torques
3 Nm
Additional angle of
rotation, 90°
Follow-up work
Adjusting clutch play
Installing right engine spoiler

11 26 002 Replacing freewheel for starter motor

+ 11 26 609
ATTENTION
Disassembly of or changes to the throttle-valve assembly
Component damage or malfunctions with impairment of vehicle safety
Do not disassemble the throttle-valve assembly.
Do not attempt changes to the throttle-valve assembly.
Preparatory work
Removing fuel tank
Core activity
(-) Removing starter freewheel
Remove screws (1).

Loosen lid (2) for starter motor freewheel using light impact blows.
Remove lid (2) for starter motor freewheel, checking dowel pins (arrows).
Remove breather port (1) with O-ring (2).
Remove starter motor freewheel (1) with bearings (2).

Remove starter reduction gear (1) with O-Ring (2).
(-) Replacing the starter motor freewheel
Install open grooved ball bearing (1) on right side in direction of travel of
starter motor freewheel (2).
Install half opened grooved ball bearing (3) on left side in direction of travel
of starter motor freewheel (2) making sure the closed side (arrow) faces
outward.
(-) Install the starter freewheel
Check O-ring (2) and renew if required.

Install starter reduction gear (1).
Install starter motor freewheel (1) with bearings (2), align gears (arrows)
where required.


Install ventilation connection (1) with O-ring (2).

Apply sealing compound evenly on sealing surface of cover (1) for starter
motor freewheel.
Sealant
Dow Corning 07 58 0 397 777
Install cover (2) for starter motor freewheel, checking dowel pins (arrows).
Remove bolts (1), do not tighten.
Tighten bolts in specified sequence (1) to (6).
Tightening torques
Starter cover on crankcase
M6 x 25 5 Nm

Follow-up work
Perform the vehicle test with BMW Motorrad diagnostic system, read
out fault memory and reset adaptation values

11 30 501 Adjusting ignition timing (cylinder-head cover removed)
Core activity
(-) Adjusting ignition timing
Remove holding fixture (No. 11 0 991).
Slacken bolt (1) for timing chain sprocket.
Position hook wrench (No. 11 0 992) on gear of intake camshaft (1).

Twist camshafts (1) and (2) until holding fixture (No. 11 0 991) can be
pushed on with side B ADJUST.
Turn hook wrench (No. 11 0 992) counter-clockwise to create clearance.

Tighten bolt (1) for timing chain sprocket holding hook wrench (No. 11 0
992) without play.
Tightening torques
M12 x 1.5 x 40 120 Nm

If necessary, turn hook wrench (No. 11 0 992) to relieve holding fixture (No.
11 0 991) and remover holding fixture (No. 11 0 991).
Remove hook wrench (No. 11 0 992).
Remove bolt (1).

Turn crankshaft 6 rotations until camshafts (1) and (2) are in firing TDC
position of cylinder 1 and recesses (arrows) are flush with edges of housing.
Check if TDC mark (arrow) is visible through opening in left engine cover (1).
Insert alignment pin (No. 11 0 993) until it noticeably engages to limit

position and, if necessary, turn crankshaft on bolt (1) in counter-clockwise
direction.
NOTICE
Crankshaft must always be turned in direction of rotation.
If the alignment pin does not engage, turn crankshaft two rotations in
counterclockwise direction until the firing TDC for Cylinder 1 is reached.

Install bolt (2).
Check
and (3).
Result:
Measure:
Repeat the adjustment process.
Result:
Measure:
Removing locating pin
Remove bolt (1).

Securing crankshaft sensor(2).
Install bolt (3).

Tightening torques
Installing left crankshaft cover

Install crankshaft cover (1) with O-ring (2).
Tightening torques
M40 12 Nm

Tightening torques
M40 12 Nm

11 30 502 Checking valve timing (cylinder head cover removed)
Core activity
(-) Checking timing
Remove crankshaft cover (1) with O-ring (2).
Removing left crankshaft cover

Remove crankshaft cover (1) with O-ring (2).

Turn crankshaft on screw connection of alternator in counter-clockwise
direction until intake cam (1) and exhaust cam (2) for cylinder 1 are in the
position shown and recesses (arrows) are flush with edges of housing.
Check if marks on camshaft sprockets (1) and (2) are flush with marks on
camshaft bearing bridge (arrows).
Firing TDC of cylinder 1 is set.


Remove bolt (1).
Release crankshaft sensor (2) and place aside.
Lock the crankshaft in TDC position
Check if TDC mark (arrow) is visible through opening in left engine cover (1).
Insert alignment pin (No. 11 0 993) until it noticeably engages to limit

position and, if necessary, turn crankshaft on bolt (1) in counter-clockwise
direction.
NOTICE
Crankshaft must always be turned in direction of rotation.
If the alignment pin does not engage, turn crankshaft two rotations in
counterclockwise direction until the firing TDC for Cylinder 1 is reached.
Install bolt (2).
Slide sliding piece (1) to the inside.

Check
and (3).
Result:
Measure:
=> 11 30 501, Adjusting ignition timing (cylinder-head cover removed) (Billed
as a separate item)
Result:
Measure:
Remove bolt (1).

Securing crankshaft sensor(2).
Install bolt (3).
Tightening torques

Tightening torques
M40 12 Nm

Tightening torques
M40 12 Nm

11 31 080 Removing/installing or replacing timing-chain tensioner

+ 11 31 780
Preparatory work
Core activity
(-) Removing timing-chain tensioner
Remove timing chain tensioner (1) with sealing ring (2).
(-) Installing timing chain tensioner

Install timing chain tensioner (1) with sealing ring (2).
Tightening torques
Timing-chain tensioner to cylinder head
M20 x 1.5 42 Nm
Follow-up work

11 31 539 Replacing all camshafts (cylinder-head cover removed)
Core activity
(-) Removing the camshaft bearing support
Slacken the bolts evenly in sequence from (20) to (1).
Remove screws (1).

Remove camshaft bearing brackets (2) and (3), thereby observing fitting
sleeves (4) and dowel pins (arrows).
Remove O-rings (1) and (2).
(-) Remove the camshafts
Remove exhaust camshaft (1) and intake camshaft (2).

(-) Replace the camshafts
Lubricate new camshafts on bearing positions(arrows) and cam (1), (2) with
engine-oil.
Sliding pieces (1) of intake camshaft (2) must be in position for lower engine
speed range (in right-hand direction of travel), correct, if required.
NOTICE
Slide the sliding piece back and forth between the two locking points only. If
the sliding piece is moved too far, the locking mechanism can drop out.
(-) Installing camshafts
Lubricate camshafts at bearing positions with engine oil.

Install exhaust camshaft (1) and align to firing TDC of cylinder 1.
Recess on camshaft (arrows) edge of housing of cylinder head flush, cams
(2) point up.
Install intake camshaft (3) and align to firing TDC of cylinder 1.
(4) point up.
(-) Installing camshaft bearing bridges

Make sure that fitting sleeves (1) are installed in the cylinder head.
Install new O-rings (2) and (3).
Make sure that dowel pins (arrows) are installed in cylinder head.
ATTENTION
Incorrectly positioned camshaft axial guide
Component damage
Before tightening down the fasteners of the bearing cap, make sure that the
camshaft axial guide is correctly positioned.
Position and align camshaft bearing bridges (3) and (2), while observing
fitting sleeves (4) and dowel pins (arrows).
Fit bolts (1), do not tighten.
Check if marks on camshaft sprockets and camshaft bearing bridge (arrows)

are flush; remove camshaft bearing bridges and correct the position of the
camshafts where required.
Tighten bolts in sequence (1) to (20).
Tightening torques
M6 x 35 Tightening
sequence: See
repair manual
5 Nm
2nd tightening torque,
13 Nm


Follow-up work
Turning engine through several revolutions and making sure that all
components move freely

11 31 555 Replacing timing chain(cylinder head cover removed)
Preparatory work
Removing left crankshaft cover
Removing timing-chain tensioning rail
Core activity
(-) Removing timing chain
Remove bolt (1).

Loosen chain sprocket (2), pulling up timing chain (3).
Remove timing chain (1) with chain sprocket (2).
(-) Installing timing chain
Thread in timing chain (1) with chain sprocket (2) and position.

Fit chain sprocket (2) with timing chain (3).

Install screw (1), but do not tighten.
Follow-up work
Installing timing-chain tensioner rail
Installing chain sprocket reduction gear for camshafts
Installing timing chain tensioner
Adjusting ignition timing

11 33 552 Replacing all cam followers (cylinder head removed)
Core activity
(-) Removing cam followers
Remove screw plugs (1) with sealing rings (2).

Remove needle rollers (1).


(-) Installing cam followers

Install needle rollers (3).
Needle rollers (3) seated in grooves (arrows) of the rocker arm shafts (2).


Install screw plug (1) with sealing ring (2).
Tightening torques
M10 x 1 10 Nm
Renew sealing rings (2).

Install screw plugs (1) with sealing rings (2).
Tightening torques
M10 x 1 10 Nm

11 34 001 Checking valve clearance

+ 11 34 501
Preparatory work
Removing fuel tank
Core activity
(-) Adjust engine to firing TDC
Turn crankshaft on screw connection of the timing chain pinion in clockwise

direction until marks on camshaft sprockets (1) and (2) are flush with marks
on camshaft bearing bridge (arrows).
Intake cam (1) and exhaust cam (2) for cylinder 1 are in position as shown
and recesses (arrows) are flush with edge of housing.

Check
Using a feeler gauge, check the valve clearance (1) by measuring between
cam and rocker arms.
Technical data
clearance
Check cylinder 1.
cylinder 3
cylinder 4
cylinder 2
Noting measured results
Note down the measured results on a record sheet.
Result:
Valve clearance is outside specified range.

Measure:
=> 11 34 504, Adjusting valve clearance (cylinder-head cover removed) (Billed
as a separate item)
Follow-up work

Securing radiator

11 34 502 Checking valve clearance (for maintenance)
Preparatory work
Removing fuel tank
Core activity
(-) Adjust engine to firing TDC
Turn crankshaft on screw connection of the timing chain pinion in clockwise

direction until marks on camshaft sprockets (1) and (2) are flush with marks
on camshaft bearing bridge (arrows).
Intake cam (1) and exhaust cam (2) for cylinder 1 are in position as shown
and recesses (arrows) are flush with edge of housing.

Check
Using a feeler gauge, check the valve clearance (1) by measuring between
cam and rocker arms.
Technical data
clearance
Check cylinder 1.
cylinder 3
cylinder 4
cylinder 2
Noting measured results
Note down the measured results on a record sheet.
Result:
Valve clearance is outside specified range.
Measure:
=> 11 34 504, Adjusting valve clearance (cylinder-head cover removed) (Billed
as a separate item)
Follow-up work
Securing radiator

11 34 504 Adjusting valve clearance (cylinder-head cover removed)
Core activity
(-) Adjusting valve clearance
Slacken the bolts evenly in sequence from (20) to (1).
Remove screws (1).

Remove camshaft bearing brackets (2) and (3), thereby observing fitting
sleeves (4) and dowel pins (arrows).
Remove O-rings (1) and (2).

Remove exhaust camshaft (1) and intake camshaft (2).


Swing rocker arm (1) up.
Remove adjustment plate (2) from the valve and place it in the correct
position in rack (No. 11 1 844).
Check the thickness of the adjustment plates with a caliper gauge.
Determine the thickness of the new adjustment plate in accordance with the
valve clearance measurement.
Place lightly oiled adjustment plate (2) on the valve.
Swing rocker arm (1) down.
Lubricate camshafts at bearing positions with engine oil.
Install exhaust camshaft (1) and align to firing TDC of cylinder 1.

(2) point up.
Install intake camshaft (3) and align to firing TDC of cylinder 1.
(4) point up.


Make sure that fitting sleeves (1) are installed in the cylinder head.
Install new O-rings (2) and (3).
Make sure that dowel pins (arrows) are installed in cylinder head.
ATTENTION
Incorrectly positioned camshaft axial guide
Component damage
Before tightening down the fasteners of the bearing cap, make sure that the
camshaft axial guide is correctly positioned.
Position and align camshaft bearing bridges (3) and (2), while observing
fitting sleeves (4) and dowel pins (arrows).
Fit bolts (1), do not tighten.

Tighten bolts in sequence (1) to (20).
Tightening torques

M6 x 35 Tightening
sequence: See
repair manual
5 Nm
2nd tightening torque,
13 Nm

Follow-up work

11 36 001 Replacing switching cams adjuster, left

+ 11 36 501
Preparatory work
Removing fuel tank
Core activity
(-) Removing the left switching cam adjuster
Information on disconnecting vibration-resistant plug
ATTENTION
Disconnection of the connector not in compliance with correct
procedure
Damage to locking tab
Push the connector away from the locking tab, do not lift or bend the locking
tab.
Unlock locking tab (1) in direction of arrow (arrow 1).

Press down locking tab (1) in direction of arrow (arrow 2) and disconnect
connector (2).
Disconnect connector (1).

Remove screws (2).
Release switching cam-adjuster (1) by rotating and remove using O-ring

(arrow).

(-) Checking tracks of sliding pieces
Check tracks (1) of left and ride sliding pieces while turning the crankshaft
until the track has been inspected in its entirety.
Check
Check edges (arrow) of tracks for damage while turning the crankshaft to
inspect the track in its entirety.
Result:
Edges (arrow) are damaged.

Measure:
=> 11 31 539, Replacing all camshafts (cylinder-head cover removed) (Billed
as a separate item)
(-) Installing the left switching cam adjuster
Check O-ring (arrow), replace if necessary.

Lubricate the O-ring (arrow) with engine oil.
Install switching cam adjuster (1).

Information for connecting vibration-resistant connectors

Check if the contact carrier (1) protrudes significantly from the connector
housing (2).
If necessary, hold down the connector housing (2) and slide contact carrier
from the rear at the cable inlet (3) toward the front until the contact carrier (1)
is visible
Ensure that the release tab (1) is unlocked.

Slide connector (2) in direction of arrow (arrow 1).
The connector (2) engages audibly.
Slide connector (2) in direction of arrow (arrow 2) further.
Slide locking tab (1) in direction of arrow (arrow 3).
The locking tab (1) engages audibly.
Install screws (2).
Tightening torques
M6 x 30 - 10.9 13 Nm
Connect the connector (1) with white mark on cable.
Follow-up work

Reading fault memory with BMW Motorrad diagnostic system and
resetting adaptation values

11 36 002 Replacing switching cams adjuster, right

+ 11 36 502
Preparatory work
Removing fuel tank
Core activity
(-) Removing the right switching cam adjuster
ATTENTION
procedure
tab.

connector (2).

Remove screws (2).
Release switching cam-adjuster (1) by rotating and remove using O-ring

(arrow).

(-) Checking tracks of sliding pieces
Check tracks (1) of left and ride sliding pieces while turning the crankshaft
until the track has been inspected in its entirety.
Check
Check edges (arrow) of tracks for damage while turning the crankshaft to
inspect the track in its entirety.
Result:
Edges (arrow) are damaged.

Measure:
=> 11 31 539, Replacing all camshafts (cylinder-head cover removed) (Billed
as a separate item)
(-) Installing the right switching cam adjuster
Check O-ring (arrow), replace if necessary.

Lubricate the O-ring (arrow) with engine oil.
Install switching cam adjuster (1).


housing (2).
is visible

Install screws (2).
Tightening torques
M6 x 30 - 10.9 13 Nm
Connect the connector (1) with white mark on cable.
Follow-up work


11 41 000 Removing/installing or replacing oil pump

+ 11 41 651
NOTICE
Oil pump and coolant pump are combined in a single component.
Core activity
=> Removing/installing coolant pump (without draining/refilling coolant
system) (Description in item: 11 51 563, Billed as a separate item)

11 41 004 Measuring engine oil pressure

+ 11 41 817
Preparatory work
Release plug connection for right front oxygen sensor
Core activity
(-) Removing threaded plug for oil system
(-) Measuring oil pressure
Requirement
Make sure that engine and engine oil are at operating temperature.
CAUTION
Working with hot components
Risk of burn injury
Wear protective gloves.
Install adapter (No. 11 4 604) with sealing ring (1) in the engine block.
Install pressure gauge (No. 11 4 601) with hose (No. 11 4 602).
Check
Start the engine.
Check oil pressure across the entire engine rpm range.
Technical data
Oil pressure idle 1.5 bar
Engine oil is at at engine 3.5 bar
regular operating rpm 6000 min
temperature -1
Result:
Oil pressure is lower than specified.

Measure:
Identify and rectify the cause of the fault.
Remove oil pressure measuring device (No. 11 4 600).

Remove the adapter (No. 11 4 604) with sealing ring (1).
(-) Installing threaded plug for oil system
ATTENTION
Deformed sealing ring
Oil leakage due to deformed sealing ring
When tightening the oil filler plug, make sure that the sealing ring is crushed
evenly and not pressed out from under the oil filler plug.
Install screw plug (1) with new sealing ring (2).
Tightening torques
Screw plug on engine
M10 x 1 x 6 10 Nm
Wipe away any engine oil that has leaked.
Follow-up work
Secure plug connection for right front oxygen sensor
Checking engine oil level

11 43 010 Replacing oil level indicator

+ 11 43 510
Preparatory work
Core activity
(-) Removing circlip
Remove the circlip (1).
(-) Function, milling cutter
Milling cutter (No. 11 0 952):

Guide(1)
Milling head (2)
Chamfer (3)
(-) Milling out rubber seal
Centre milling cutter (No. 11 0 952) by means of the guide (arrow) on oil-
level check (1).

Press milling cutter (No. 11 0 952) on firmly.
Uniformly mill rubber seal (1).
The metal housing becomes visible all round.
(-) Function, scraper
Scraper (No. 11 0 951) is for right-hand use.

Hook (1) for removing the remains of the rubber seal
Cutter (2) for trimming off projecting remains of the rubber seal
(-) Removing remains of rubber seal
CAUTION
Splintering oil sight glass
Danger of injury
Wear safety goggles.
Use scraper (No. 11 0 951) but without levering because this can cause
the sight glass (1) to splinter.
Remove remains of rubber seal (1) between sight glass (2) and metal
housing (3) all round completely. To do so, work scraper (No. 11 0 951)
with a turning action clockwise.
(-) Removing engine-oil level indicator
ATTENTION

Excessive load on puller tool
Damage to puller tool
Remove all rubber sealing residues before using the puller tool.
Screw sleeve (No. 11 0 954) on to puller (No. 11 0 953) and centre it on oil-
level indicator(1).
Continue tightening sleeve to expand the puller under metal housing (2).
Metal housing (2) bulges out (arrow).
Tighten the sleeve with pliers.
Install thrust piece (No. 11 0 955) in such a way that the projection (arrow) is
seated in the recess of the expanded puller (No. 11 0 953).
Install nut (1) with washer (2) and tighten.
Metal housing (3) is held firmly by the puller and the thrust piece.
The puller is supported by the projections (arrow).
Slip sleeve (No. 11 0 956) into position and turn it until it is seated correctly
on the engine block.
Install thrust nut (1).
Remove the oil-level display by tightening thrust nut (1).
(-) Installing engine-oil level indicator
Clean oil-level display (1) and sealing surface (2) in the engine housing. Use
only very fine emery paper and work very carefully to remove heavy
deposits and corrosion residues.
Position oil-level indicator (1) on drift (No. 11 0 958) and handle (No. 00 5
500).
ATTENTION
Use of lubricants
Oil sight glass detaches
Use only brake cleaner for the installation process.
Spray sealing surfaces (1) and (2) generously with brake cleaner.
Cleaner
Brake cleaner 83 19 2 154 780
ATTENTION
Use of drift not in compliance with correct procedure

Damage to oil sight glass
Do not tilt the drift in the process of installation.
Position oil-level indicator (1) square to the bore and rapidly and without
allowing it to tilt, install it with drift (No. 11 0 958) until seated.
(-) Install circlip
Install the circlip (1).

NOTICE
On completion of all work start the engine, allow it to heat up to operating
temperature, and check the oil-level indicator for leaks.
Follow-up work

11 51 002 Removing/installing coolant pump (without draining/refilling coolant system)

+ 11 51 563
Preparatory work
=> Draining coolant, refilling/bleeding system (Description in

item: 17 00 504, Billed as a separate item)
Removing silencer
Removing fuel tank
Removing coolant hose, return
Removing oil pan
Core activity
(-) Removing coolant pump
Removing oil intake port (1) with O-rings (2) and (3).
Remove screws (1).

Remove oil line (2) with O-rings (3) and (4).

Remove the nut (1).

Loosen pinion (2) with chain (3) from shaft (4) .
Loosen pinion (2) from chain (3) and remove.
Remove connecting branch (1) with O-rings (2) and (3) with hexagon head
(No. 36 3 692).
Remove screws (1).
Remove coolant pump (1) with coolant pipe (2).

If necessary, remove fitting sleeves (3) and O-ring (4).

(-) Installing coolant pump
Check O-rings (1) of coolant pipe (2) and replace as needed.

Lubricate O-rings (1) with engine oil.
Renew O-ring (4).

Make sure that fitting sleeves (3) are installed.
Install coolant pipe (2) in coolant pump (1) while noting O-ring.
Install coolant pump (1) while feeding in the coolant pipe (2) and noting the
O-ring.
Install screws (1).
Tightening torques
Oil/Coolant pump to crankcase
M6 x 35 9 Nm
Renew O-rings (2) and (3).

Lubricate O-rings (2) and (3) with engine oil.
Install O-rings (2) and (3) on connecting branch (1).

Install connecting branch (1) with O-rings (2) and (3) with hexagon head
(No. 36 3 692).
Tightening torques
Connecting branch for coolant pump to crankcase
M40 x 2 12 Nm
Observe the following when installing pinion (1):

Labelling (Arrow) points to nut (2).
Renew nut (2).
Insert pinion (1) in chain (2).

Labelling on pinion points to the nut.
Push pinion (1) with chain (2) onto shaft (3) and let it engage in mounting
flats (arrows).
Install new nut (4).
Tightening torques
Pinion on shaft for oil/coolant pump
M6, Renew nut 10 Nm

Install O-ring (4) on oil line (1).
Install oil line (2) with O-rings (3) and (4).
Install screws (1).
Tightening torques
Oil line to crankcase
M6 x 16 9 Nm

Install O-rings (2) and (3) on oil intake port (1).
Install oil intake port (1) with O-rings (2) and (3).

Follow-up work
Installing oil pan
Securing radiator
Install the coolant hose, return
Installing silencer

11 72 101 Removing and installing or replacing the line for the secondary air system
+ 11 72 660
Preparatory work
Removing fuel tank
Core activity
(-) Removing secondary air system line
Remove the cable straps (arrows).

Unlock and pull off the hose connection (1), thread out and remove the
secondary air system-line (2).
(-) Installing secondary air system line
Feed in and fit secondary air system line (2).

Slide on hose connections (1) for secondary air system until the locks
engage with an audible click.
Close the cable strap (arrows).
Follow-up work


11 72 210 Removing/installing or replacing changeover valve for secondary air system

+ 11 72 670
Preparatory work
Removing fuel tank
Core activity
(-) Removing changeover valve for secondary air system
Disconnect connector (1) for relay valve.

Squeeze ends of clamp of hose connection together (arrows) and
disconnect secondary air system hose (2).
Remove screws (3).
Remove relay valve (4) with O-ring (5).
(-) Installing changeover valve for secondary air system
Check O-ring (5) for damage; replace if necessary.

Care products
Rubber care product 83 12 0 397 018
Install relay valve (4) with O-ring (5).

Install screws (3).
Tightening torques
PT40 x 15 3 Nm
Push secondary air system hose (2) on until the clamp of the hose
connection (arrows) engages with an audible click.
Connect connector for relay valve (1).
Follow-up work


11 78 002 Replacing the oxygen control sensor, right

+ 11 78 502
CAUTION
Hot exhaust system
Risk of burn injury
Preparatory work
Core activity
(-) Remove right front oxygen sensor
ATTENTION
procedure
tab.

connector (2).
Release plug connection (1) for front oxygen sensor from holder (2).
Remove cable strap (arrow).
Disconnect plug connection (1) for front oxygen sensor.
Release and thread cable (3) out of holders (4).
ATTENTION
Engine oil makes its way into exhaust manifold
Component damage, catalytic converter will suffer damage
Using suitable auxiliary materials, seal/cover the threaded holes for the
oxygen sensors.

Remove front oxygen sensor (1) from bottom.
(-) Installing right front oxygen sensor
Lubricate the thread of the front oxygen sensor (1) lightly.
Lubricant
Optimoly TA 18 21 9 062 599
Install front oxygen sensor (1) from bottom.
Tightening torques
M14 x 1.25 45 Nm
Thinly lubricate thread, Lubricant
(Optimoly TA)
housing (2).
is visible

Lay cable (3) and secure in holders (4).

Connect plug connection (1) for front oxygen sensor.
Secure plug connection (1) for front oxygen sensor in holder (2).
Form excess cable lengths (3) into loops and secure cable strap (arrow).
Follow-up work

11 78 003 Replacing the oxygen control sensor, left

+ 11 78 503
CAUTION
Hot exhaust system
Risk of burn injury
Preparatory work
Core activity
(-) Remove left front oxygen sensor
ATTENTION
procedure
tab.

connector (2).
Release plug connection (1) for front oxygen sensor from holder (2).
Disconnect plug connection (1) for front oxygen sensor.
ATTENTION
Engine oil makes its way into exhaust manifold
Component damage, catalytic converter will suffer damage
Using suitable auxiliary materials, seal/cover the threaded holes for the
oxygen sensors.

Remove front oxygen sensor (1) from bottom.
(-) Installing the left front oxygen sensor
Lightly lubricate the threads of front oxygen sensor (1).
Lubricant
Optimoly TA 18 21 9 062 599
Install front oxygen sensor (1) from the bottom.
Tightening torques
M14 x 1.25 45 Nm
(Optimoly TA)
housing (2).
is visible

Route cable (3) and secure in holders (4).

Connect plug connection (1) for front oxygen sensor.
Route excess length of cable (3) in loops and secure with cable straps
(arrow).
Secure plug connection (1) for front oxygen sensor in holder (2).
Follow-up work

11 78 005 Replacing right oxygen sensor monitoring sensor

+ 11 78 505
CAUTION
Hot exhaust system
Risk of burn injury
Preparatory work
Removing fuel tank
Disengaging right engine spoiler
Core activity
(-) Remove right monitoring oxygen sensor
ATTENTION
procedure
tab.

connector (2).

Release and disconnect plug connection (1).
Release cable (1) for monitoring oxygen sensor from holder (arrow).

Release cable (1) from holder (arrow) and thread under holder (2) for
exhaust damper servo motor towards left side of vehicle.
Thread through the connector (1) with cable for monitoring oxygen sensor
near the drive chain (2) between rear wheel swinging arm (3) and engine
downwards.
Thread out the cable (1).

Remove monitoring oxygen sensor (2) with cable (1).
(-) Installing the right monitoring oxygen sensor
Lightly lubricate the threads of monitoring oxygen sensor (2).
Lubricant
Optimoly TA 18 21 9 062 599
Install monitoring oxygen sensor (2) with cable (1).
Tightening torques
M12 x 1.25 25 Nm
(Optimoly TA)
Feed in cable (1) and slide it under the rear wheel swinging arm to the left
side of vehicle.
Feed connector (1) with cable for the monitoring oxygen sensor through
near the drive chain (2) between rear wheel swinging arm (3) and engine to
the top.
Feed connector (1) with cable through to the right side of vehicle.
Feed cable (1) under holder (2) for the exhaust gas servo motor to the front
and secure into holder (arrow).
Secure cable (1) for monitoring oxygen sensor in holder (arrow).

housing (2).
is visible


Connect and secure the plug connection (1).

Secure the cable strap (arrow).
Follow-up work
Securing right engine spoiler

11 78 006 Replacing the oxygen monitoring sensor, left

+ 11 78 506
CAUTION
Hot exhaust system
Risk of burn injury
Preparatory work
Core activity
(-) Remove the left monitoring oxygen sensor
Release cable (1) for monitoring oxygen sensor from holder (arrows).
Release plug connection (2) and thread out from relay holder (3) outwards.
ATTENTION
procedure
tab.

connector (2).
Disconnect plug connection (1).

Release monitoring oxygen sensor (2), thread out and remove.
(-) Installing left monitoring oxygen sensor

housing (2).
is visible

Lubricate the thread of the monitoring oxygen sensor (2) lightly.
Lubricant
Optimoly TA 18 21 9 062 599
Insert monitoring oxygen sensor (2), position and install.
Tightening torques
M12 x 1.25 25 Nm
(Optimoly TA)
Connect plug connection (1).

Insert plug connection (2) behind relay holder (3) and secure.
Secure cable (1) for monitoring oxygen sensor in holders (arrows).
Follow-up work

11 84 009 Replace engine protector on the left

+ 11 84 509
Equipment trim-level variant:
079E - Billet packOE
Preparatory work
Core activity
(-) Removing left engine guard
Remove screws (2).

Remove engine guard (1).
(-) Installing left engine guard
Fit engine guard (1).

Install bolts (2), do not tighten yet.
Tighten bolts (1) to (3) in specified sequence.
Tightening torques
M6 x 40 7 Nm
Follow-up work
11 84 010 Replace engine protector on the right

+ 11 84 510
Preparatory work
Core activity
(-) Removing right engine guard
Thread out clutch cable (1).

Remove screws (3).
Remove engine guard (2).
(-) Installing right engine guard

Install screws (3).
Tightening torques
M6 x 45 9 Nm
Work clutch cable (1) into position.
Follow-up work

12 00 014 Performing vehicle test with BMW Motorrad diagnostic system

+ 12 00 516
Preparatory work
Core activity
(-) Connecting BMW Motorrad diagnostic system to vehicle
Connect the BMW Motorrad battery charger.
NOTICE
When carrying out diagnosis and programming, use a battery charger with 30
A approved by BMW Motorrad that ensures an on-board system voltage of
13 V.
Release diagnostic connector (1).

Connect connecting cable (2) of the BMW Motorrad diagnosis system to the
diagnostic connector (1).
NOTICE
See the information about the BMW Motorrad diagnostic system for all further
instructions.
(-) Performing vehicle test with BMW Motorrad diagnostic system
Perform the vehicle test with the BMW Motorrad diagnostic system and
read out the fault memory.
NOTICE
When working with the BMW Motorrad diagnostic system, always follow the
instructions it issues.
Follow instructions or use the diagnosis options, as applicable.
(-) Disconnecting BMW Motorrad diagnostic system from vehicle
Close all diagnostic programs and switch off the ignition.

Disconnect connecting cable (2) of the BMW Motorrad diagnosis system
from diagnostic connector (1).
Secure diagnostic connector (1).
Disconnect the BMW Motorrad battery charger from the vehicle.
Follow-up work


12 12 011 Renewing all spark plugs

+ 12 12 513
Preparatory work
Removing fuel tank
Core activity
(-) Removing spark plugs
Clean the spark plug shaft with compressed air.

Remove spark plugs (1) with spark plug wrench (No. 12 1 220).
(-) Replacing spark plugs
Install new spark plugs.
Technical data
Spark plugs, NGK LMAR9FI-10G
manufacturer and
designation
(-) Installing spark plugs
Install spark plugs (1) with spark-plug wrench (No. 12 1 220).
Tightening torques
M10 x 1 12 Nm

Follow-up work

12 12 509 Replace all spark plugs (for maintenance)
Core activity
(-) Removing spark plugs
Clean the spark plug shaft with compressed air.

Remove spark plugs (1) with spark plug wrench (No. 12 1 220).
(-) Replacing spark plugs
Install new spark plugs.
Technical data
Spark plugs, NGK LMAR9FI-10G
manufacturer and
designation
(-) Installing spark plugs
Install spark plugs (1) with spark-plug wrench (No. 12 1 220).
Tightening torques
M10 x 1 12 Nm

12 13 155 Replacing direct ignition coil

+ 12 13 655
Preparatory work
Removing fuel tank
Core activity
(-) Remove the direct ignition coils
ATTENTION
procedure
tab.

connector (2).
Clean the cylinder head cover with compressed air before the removal of
direct ignition coil.
Disconnect connector (1) for direct ignition coils.
Remove direct ignition coils (2) using puller (No. 12 3 621).
(-) Installing direct ignition coils

housing (2).

is visible

Install direct ignition coils (2).

Direct ignition coils must engage.
All connectors point exactly in direction of travel.
Connect connector (1) for direct ignition coils.
Follow-up work

12 31 022 Replace generator

+ 12 31 673
Preparatory work
Removing fuel tank
Releasing front carrier
Releasing voltage regulator
Core activity
ATTENTION
Component damage
Thread the cable (1) for the alternator to the front and release from holders
(arrows).
Press locks (1) and pull off relay carrier (2) and (3) from the holder to the top
and hang to the side.
Remove cable strap (arrow)
Release cable (3) for alternator.
Remove screws (1).


(-) Removing stator
Remove bolt (1) and holder (2).

Release rubber grommet (3).
Remove screws (4) and stator (5).
(-) Removing rotor
Turn crankshaft on hexagon head (1) counter-clockwise until bore holes

(arrows) are flush.
Insert alignment pin (No. 11 0 971) to the limit position.
Rotor and crankshaft are retained on the crankcase.
Remove bolt (1).

Remove rotor (1) with extractor (No. 12 5 522).

(-) Installing rotor
Fit rotor (1) on crankshaft stump.

Fix rotor (1) with alignment pin (No. 11 0 971).
Install bolt (2).
Tightening torques
Magnet wheel to crankshaft
M12 x 1.5 x35 - 10.9 120 Nm
Thread lightly oiled
(-) Installing stator
Clean thread.
Insert stator (1) and position.
Install screws (2).
Tightening torques
encapsulated)
Clean thread.
Clean rubber grommet (1) and sealing surface on engine cover.
Apply sealing compound to sealing surface (Arrow) of rubber grommet (1)
and insert rubber grommet .
Sealant
Dow Corning 07 58 0 397 777
Tightening torques
M5 x 16 4.5 Nm

Thread-locking compound (Loctite
243, Medium strength)
CAUTION
Crimping danger
alternator.
edges.

engine housing.
Sealant
Dow Corning 07 58 0 397 777

Tightening torques
3 Nm
Additional angle of
rotation, 90°
Route cable (4) for alternator and secure with cable straps (arrow).
Slide relay carrier (3) and (2) onto holder from the top until locks (1) engage
with an audible click.
Lay cable (1) for alternator to the rear and secure in holders (arrows).

Follow-up work
Securing voltage regulator
Securing front carrier

12 32 000 Removing/installing voltage regulator

+ 12 32 500
ATTENTION
Component damage
Preparatory work
Core activity
(-) Removing voltage regulator
Unlock connectors (1) and (2) and release from voltage regulator (3).
Remove nuts (1) and release voltage regulator (2).

Disconnect connectors (3) and (4) from the voltage regulator (2).
Remove voltage regulator (2).
(-) Installing voltage regulator
Position voltage regulator (2).

Connect plug (3) and (4) with voltage regulator(2) .
Hold voltage regulator (2) in position and install nuts (1).
Tightening torques
M6, Renew nut 8 Nm
Thread-locking compound
(mechanical)

Follow-up work

12 41 025 Replacing starter

+ 12 41 528
Preparatory work
Removing fuel tank
Disengaging left engine spoiler
Releasing relay holder
Core activity
(-) Removing starter
Remove bolt (1).

Remove retaining bracket (2) and holder (3).
Remove bolt (1) and release positive wire for starter motor (2).
Remove screws (3).
Pull relay holder (4) away from starter motor (5).
Remove starter motor (5), paying attention to the O-ring (6) while doing so.
(-) Installing starter
Check the O-ring (6) for damage, replace if necessary.

Clean the contact face (arrow) and lubricate.
Lubricant
Molykote D paste
Position and install starter motor (5).

Align relay holder (4) and install screws (3).
Tightening torques
M6 x 35 8 Nm
Fit the positive wire for the starter motor (2) and install the bolt (1).
Tightening torques
Wiring harness (positive wire) to starter motor
M5 x 10 3 Nm
Install holders (3) and retaining brackets (2).

Install bolt (1).
Follow-up work
Securing the relay holder
Securing left engine spoiler
Connect battery with vehicle
Checking, if necessary correcting date

12 62 010 Replacing coolant-temperature sensor

+ 12 62 510
Preparatory work
Core activity
(-) Removing coolant-temperature sensor
CAUTION
Working on hot cooling system
Risk of burn injury
Always allow the cooling system to cool down before starting work.

Disconnect connector (1) for coolant temperature sensor.
Remove coolant temperature sensor (2) with sealing ring (3) and keep the
opening closed or seal it with a suitable means to prevent coolant from
escaping.
(-) Installing coolant-temperature sensor
Install coolant temperature sensor (2) with new sealing ring (3).
Tightening torques
Coolant temperature sensor to thermostat housing
M12 x 1.5 15 Nm
Connect connector (1) for coolant temperature sensor.

Follow-up work
Checking coolant level


12 72 001 Replacing crankshaft sensor

+ 12 72 501
Preparatory work
Core activity
(-) Removing crankshaft sensor

Disconnect plug (1) for crankshaft sensor.
Remove bolt (2).
Remove crankshaft sensor (3).
(-) Installing crankshaft sensor

Install crankshaft sensor (2).
Install bolt (3).
Tightening torques
Connect plug (4) for crankshaft sensor.

Follow-up work

12 72 002 Replacing the cam trigger sensor

+ 12 72 502
Preparatory work
Removing fuel tank
Core activity
(-) Remove switching cam sensor
Remove bolt (1).

Release switching cam sensor (2) with O-ring (3).
Disconnect the connector (4) and remove switching cam adjuster (2).
(-) Installing switching cam sensor
Check O-ring (3) and renew where required.

Installation tool
Connect connector (4).

Install switching cam sensor (2) with O-ring (3).
Install bolt (1).
Tightening torques
M6 x 16 5 Nm
Follow-up work


12 72 020 Replacing camshaft sensor

+ 12 72 520
CAUTION
Hot exhaust system
Risk of burn injury
Preparatory work
Removing side panel, right, complete with engine spoiler
Core activity
(-) Removing camshaft sensor

Disconnect connector (1) for camshaft sensor.
Remove bolt (2).
Remove camshaft sensor (3) with O-ring (4).
If necessary, collect any escaping engine oil.
(-) Installing camshaft sensor

Install camshaft sensor (3) with O-ring (4).
Install bolt (2).
Tightening torques
Camshaft sensor to cylinder head
M6 x 16 10 Nm
Connect connector (1) for camshaft sensor

If required, remove engine oil that has dripped from the exhaust manifold.
Follow-up work
Securing radiator
Install the side panel, right, complete with engine spoiler


12 72 033 Replace knock sensors

+ 12 72 533
CAUTION
Hot exhaust system
Risk of burn injury
Preparatory work
Remove the left and right engine spoilers
Core activity
(-) Removing knock sensors

Disconnect the connector (1) for knock sensor .
Remove bolt (2).
Remove knock sensor (3).

Remove bolt (1).
Remove knock sensor (3).
(-) Installing knock sensors
Position knock sensor (3).

Install bolt (1).
Tightening torques
M8 x 30 20 Nm
Connect connector (2) for knock sensor .

Position knock sensor (3).

Install bolt (2).
Tightening torques
M8 x 30 20 Nm

Follow-up work
Installing right and left engine spoilers

13 51 001 Replacing fuel pressure sensor

+ 13 51 501
Preparatory work
Removing fuel tank
Core activity
(-) Remove fuel pressure sensor with fuel injection pipe

Disconnect the connector (1) from the fuel pressure sensor (2).
Disconnect connector (3) for fuel injectors.
Release wiring harness (4).
Disconnect fuel hose (1) from holder (arrow).

Remove screws (2).
Remove fuel distributor (3) with fuel pressure sensor (4) together with fuel
injection pipes (5) and (6) and fuel hose (1).
(-) Replacing fuel-pressure sensor
Lubricate O-rings (1) on new fuel distributor with pressure sensor (2).
Installation tool
Remove the spring clips (3).

Transfer upper fuel injection pipe on left (4) and right (5) to new fuel
distributor with pressure sensor (2).

Install spring clips (3).
Lubricate O-rings (1) on new fuel distributor with pressure sensor (2).
Installation tool
Remove the spring clips (3).

Transfer lower fuel injection pipe on left (4) and right (5) to new fuel
distributor with pressure sensor (2).
Install spring clips (3).
(-) Install fuel pressure sensor with fuel injection pipe
Check O-rings (1) on fuel injectors (2) and renew, if required.

Lubricate O-rings (1).
Installation tool
Clean the threads.

Fit fuel distributor (3) with fuel pressure sensor (4) together with fuel injection
pipes (5) and (6) and fuel hose (1).
Install screws (2).
Tightening torques
encapsulated)
Secure fuel hose (1) in holder (arrow).

Route the wiring harness (4).
Connect connector (3) for fuel injectors.
Connect connector (1) with fuel pressure sensor (2).

Follow-up work

13 51 002 Measuring fuel pressure

+ 13 51 502
WARNING
Fuel is highly flammable and hazardous to health
Risk of fire, risk of damage to health
Comply with the safety regulations.
Preparatory work
Removing fuel tank
Core activity
(-) Measuring fuel pressure
ATTENTION
Escape of fuel when pressurised fuel lines are opened
Damage to surfaces
Employ suitable means to catch escaping fuel.
Cut suitable fuel hose (1) to length (A) and connect to tester for fuel
pressure (No. 16 1 500).
Technical data
Dimension (A) Length approx. 15 cm
of fuel hose for tester
Connect screw clamps (2) to hoses (1) and (3).

Install coupling receptacle (part number 7 659 120) (4) and connector (part
number 7 700 800) (5).
Tighten screw clamps (2).
Secure fuel tank (1) flipped up with bolt (2) and support with suitable support
(arrow) to prevent damaging fuel line (3) or wiring harness (4).
ATTENTION
Application of force to close locked quick-action couplings
Leak due to damaged O-rings

Close the quick-action coupling of the fuel line only with the latch
open/pressed.
Connect tester (No. 16 1 500) by pressing the lock (arrow) to fuel hose (1)
and female coupling (2) of the fuel tank.
Connect connector (3) for electric fuel pump and connector (4) for fuel-level
sensor.
Start the engine and read the pressure from test instrument (No. 16 1 500).
Technical data
Operating pressure of 5 bar
fuel pump
Stop the engine and switch off the ignition.

Disconnect connector (3) for fuel pump and connector (4) for fuel-level
sensor and remove tester (No. 16 1 500).
Lift fuel tank (1) and remove rest (arrow), while doing so do not place the
fuel tank (1) on the fuel line (3) or wiring harness (4).
Remove bolt (2).
Remove fuel tank (1).
Follow-up work

13 54 017 Replacing complete throttle-valve assembly

+ 13 54 521
ATTENTION
Disassembly of or changes to the throttle-valve assembly
Component damage or malfunctions with impairment of vehicle safety
Do not disassemble the throttle-valve assembly.
Do not attempt changes to the throttle-valve assembly.
Preparatory work
Removing fuel tank
Core activity
(-) Removing throttle-valve assembly
NOTICE
Loosen the throttle-valve assembly first, then disconnect connectors;
otherwise, there is a risk of damaging the connectors.
Pull hose (1) off distributor ignition (2).

Remove screws (3).
Release the entire fuel injection pipe with injector nozzles (4) and place to
rear.
While loosening screw clamps (1) of the throttle valve assembly, the bolt (2)
must not be unscrewed too far or removed.
The spacer (3) must not fall out.

Loosen screw clamps (1).
Release throttle valve assembly (2) taking care of connections (arrows) for
bypass lines.
ATTENTION
procedure
tab.

connector (2).
Lift throttle valve assembly (1) and disconnect connectors (2) and (3).
Remove throttle-valve assembly (1).
Seal the intake ducts at the engine.
(-) Installing throttle-valve assembly
NOTICE
Connect the connector of the throttle-valve assembly first, then install throttle-
valve assembly; otherwise, there is a risk of damaging the connectors.

housing (2).
is visible


Remove cap from intake ducts.

Position throttle valve assembly (1) and connect connectors (3) and (2).
Lubricate supports of throttle valve assembly (2) and connections (arrows)

for bypass lines.
Installation tool
Install throttle valve assembly (2) while noting the connections (arrows) for
the bypass lines.
Tighten screw clamp (1).
Check O-rings (arrow); replace if necessary.

Lubricate O-rings (arrow).
Installation tool

Route fuel injection pipe with injector nozzles (1) to the front.
Install screws (2).
Tightening torques
encapsulated)
Connect hose (3) to distributor ignition (4).
Follow-up work

13 61 030 Clean the contacts

+ 13 61 530
Core activity
(-) Clean contacts on removed control unit
Requirement
Control unit is removed.
Coat cleaning surface inside on cleaning contact (1) with brake cleaner.
Cleaner
Position cleaning contact on pin contacts vertically.

Do not bend or spread pin contacts apart.
Make sure that the opening of the cleaning contact can slide onto the pin
contact and is not open on the side.
Damage to pin contacts is prevented.
Slide cleaning contact (1) onto pin contacts to stop and pull off again.
Repeat process two more times.
Clean all pin contacts.
NOTICE
In case of visible contamination of the cleaning contact, change cleaning
contact.

13 61 510 Replacing engine management control unit (not including checking/programming

software)
NOTICE
Before removal, test the control unit with the BMW Motorrad diagnostic
system and make a backup copy of the data.
Preparatory work
Loosen engine control unit with holder
Core activity
(-) Removing engine control unit with holder and control unit
basic module

Disconnect plug (1) for main wiring harness and plug (2) for engine wiring
harness.
Disconnect plug (3) for control unit basic module and wiring harness (4) from
holder (5).
Remove engine control unit(6) with holder (5).
Removing control unit basic module

Press the lock (arrow) and pull basic module control unit (1) out of holder
(2).
(-) Replacing engine control unit
Unlock retaining lug (arrows) on front and left side of the holder (1) and open
the holder (1).

Loosen and remove the upper section of holder (1) from the lock (arrows).
Unclip and remove the engine control unit (2) from the lower section of the
bracket (3).
Insert the cable strap (arrows) in the upper section of the holder (1), Do not
close.
Clip in new engine control unit (2) in lower section of the bracket (3).
Insert upper section of holder (1) in lock(arrows).
Close holder (1) and lock retaining lug (arrows) on front and left side of the
holder(1).

(-) Install the engine control unit with holder and control unit basic
module
Installing control unit basic module
Slide control unit for basic module (1) into holder (2) while allowing the lock
(arrow) to engage.
Position the engine control unit (6) with holder (5).

Reposition the wiring harness (4) in holder (5) and connect the connector (3)
for control unit basic module.
Connect the connector (2) for engine wiring harness and connector (1) for
main wiring harness.
Follow-up work
Attaching engine control unit with holder
=> Testing software (Description in item: 61 00 502, Billed as

a separate item)
=> Programming control units of vehicle (along with testing

software) (Description in item: 61 00 510, Billed as a
separate item)

13 62 010 Replacing intake-air temperature sensor

+ 13 62 501
Preparatory work
Core activity
(-) Removing intake-air temperature sensor
Disconnect connector (1) for the intake-air temperature sensor.

Remove intake air temperature sensor (2) with O-ring (3) out of intake
silencer (4).
(-) Installing intake-air temperature sensor

Care products
Install intake air temperature sensor (2) with O-ring (3) in intake silencer (4)
while observing lug (arrow).
Connect connector (1) for the intake air temperature sensor.
Follow-up work


13 63 001 Replacing servomotor for differentiated intake system (DISA)

+ 13 63 524
Preparatory work
Removing fuel tank
Removing air filter element
Core activity
(-) Remove DISA servomotor
Remove screws (1).

Lift DISA servomotor (2) with O-ring (3) and remove from shaft (4).
(-) Installing DISA servomotor
Turn adjustment lever (1) fully to the stop in clockwise direction and hold.
Suction heads (2) are in the top position.

Care products
Install DISA servomotor (2) with O-ring (3) in shaft (4) observing flattened
area (arrows) on gearing of shaft (4) and DISA servomotor (2).

Install screws (1).
Tightening torques
Follow-up work
Installing air filter element

13 63 003 Replacing the servomotor for the unfiltered-air flap

+ 13 63 503
Preparatory work
Removing fuel tank
Core activity
(-) Removing servomotor for unfiltered-air flap
Remove screws (1).

Remove servomotor (2).
(-) Installing servomotor for unfiltered-air flap
Fit servomotor (1) observing flattened areas (arrows) on gears.

Install screws (2).
Tightening torques
Servomotor for unfiltered-air flap to air intake duct
Follow-up work


13 71 010 Replace intake-air silencer

+ 13 71 510
Preparatory work
Removing fuel tank
Core activity
(-) Removing air filter element
Push locks (arrows) and remove cover (1) for air filter insert.
Remove carrier frame (1) with air filter insert (2).
(-) Removing intake-air temperature sensor
Remove intake air temperature sensor (1) with O-ring (2) out of intake
silencer (3).

(-) Removing secondary air system changeover valve
Remove screws (1).

Remove relay valve (2) with O-ring (3).
(-) Remove DISA servomotor
Remove screws (1).

Lift DISA servomotor (2) with O-ring (3) and remove from shaft (4).
(-) Replacing intake air silencer
Loosen clamp (1) with pliers (No. 17 5 500) and pull off hose .
Remove seals (3) and transfer to new intake silencer (4), replace with new
seals as needed.
Slide hose (2) with clamp (1) onto intake silencer (4) and position.
Align clamp (1) with mark and secure with pliers (No. 17 5 500).

Transfer reusable small parts to the new part (1) or replace the small parts
as necessary.
2 x shouldered bushing
2 x rubber grommet
(-) Installing DISA servomotor
Turn adjustment lever (1) fully to the stop in clockwise direction and hold.
Suction heads (2) are in the top position.

Care products
Install DISA servomotor (2) with O-ring (3) in shaft (4) observing flattened
area (arrows) on gearing of shaft (4) and DISA servomotor (2).
Install screws (1).
Tightening torques
(-) Installing secondary air system changeover valve

Care products
Install relay valve (2) with O-ring (3).

Install screws (1).
Tightening torques
PT40 x 15 3 Nm
(-) Installing intake-air temperature sensor

Care products
Install intake air temperature sensor (1) with O-ring (2) in intake silencer (3)
while observing lug (arrow).
(-) Installing air filter element
Install carrier frame (1) with air filter insert (2) and make sure that the tabs
(arrows) point up.
Install cover (1) for air filter insert while making sure that the locks (arrows)
engage.
Follow-up work

13 72 001 Renewing air cleaner insert

+ 13 72 532
Preparatory work
Core activity
Install locking template (1) behind air filter insert (2).

Contamination of the clean air space during the removal of the air filter insert
due to foreign bodies is prevented.

(-) Replacing air-filter element
Remove old air filter insert (1), replace it with new air filter insert (1) and
install in carrier frame (2).
Clean the inside of the intake port (1).

(arrows) point up.
Remove locking template (1).

engage.
Follow-up work

13 72 505 Replace air filter cartridge (for maintenance)
Preparatory work
Core activity
Install locking template (1) behind air filter insert (2).

Contamination of the clean air space during the removal of the air filter insert
due to foreign bodies is prevented.
(-) Replacing air-filter element
Remove old air filter insert (1), replace it with new air filter insert (1) and
install in carrier frame (2).

Clean the inside of the intake port (1).

(arrows) point up.
Remove locking template (1).
engage.
Follow-up work

16 11 030 Removing/installing fuel tank

+ 16 11 533
Preparatory work
Core activity
(-) Removing fuel tank
Pull off hoses (1) and (2).
Remove nuts (1) with washers (2).

Remove bolt (3) with washer (4).
Lift the fuel tank (1).

Disconnect plug connection (3) for electric fuel pump and plug connection
(2) for fuel-level sensor.
Press open the lock of the fuel delivery line (arrow) and disconnect fuel
delivery line (4).
Remove fuel tank (1).
(-) Installing fuel tank
Check O-ring of fuel delivery line (1) for damage; replace if necessary.

While installing the fuel tank, ensure that the rubber retainer fits (1) in to the
guide (arrows) of fuel tank.
Position fuel tank (1).

ATTENTION
Application of force to close locked quick-action couplings
Leak due to damaged O-rings
Close the quick-action coupling of the fuel line only with the latch
open/pressed.
Push open the lock for fuel delivery line (arrow) and push fuel delivery line
(4) into the bush with slight effort. Release the latch and check that the
delivery line is correctly seated.
Connect plug connection (2) for fuel level sensor and plug connection (3) for
electric fuel pump.
Position fuel tank (1).
Connect hoses (1) and (2).
Install bolt (3) with washer (4).
Tightening torques

M6 x 115 5 Nm
Install nuts (1) using washers (2).
Tightening torques
Fuel tank to frame
M8 19 Nm
Follow-up work

16 11 213 Renewing fuel tank cover flap

+ 16 11 543
WARNING
Preparatory work
Core activity
(-) Removing lock barrel for fuel filler cap
Open fuel filler cap (1).

Cover the fuel filler neck.
ATTENTION
Component damage
Push the latching tab (arrow) down using a suitable tool until holes (2) are
aligned.
Secure the latching tab (arrow) using drill (3) into fuel filler cap (1).
Technical data
Drill-bit diameter 2 mm
Turn key (4) to the "Open" position and remove lock barrel (5).
(-) Removing fuel-tank cap
Remove screws (1).

Remove outer ring with fuel filler cap (2) and cover ring (3).
(-) Installing fuel-tank cap
Fit cover ring (1) with the large opening (arrow) to the rear and outer ring
with fuel filler cap (2).
Install screws (3).

Tightening torques
M5 x 20 2.5 Nm
(-) Installing lock barrel for fuel filler cap
Lubricate the lock barrel (5).
Lubricant
MI-Setral-43 N 83 23 2 152 082
Install lock barrel (5) in fuel filler cap (1) in the "Open" position.
The lock barrel (5) sits flush in fuel filler cap (1).
Turn key (4) to the "Closed" position and remove drill (3) from fuel filler cap
(1).
Remove the cover from fuel filler neck and close fuel filler cap (1).
Follow-up work

16 11 531 Replacing fuel tank (fuel tank removed)
Core activity
(-) Draining fuel tank
WARNING
Drain the fuel tank, using the commercially available special tool.
(-) Remove the fuel filler cap with fuel filler neck
Remove screws (1).

Remove outer ring with fuel filler cap (2) and cover ring (3).
Remove screws (1).

Remove fuel filler neck (2) with seal (3).
(-) Removing fuel-pump unit
Remove screws (1) and remove pressure plate (2).

Release fuel-pump unit (3) on lug (arrow) from fuel tank (4).

Loosen fuel-pump unit (1) with seal (2) from fuel tank (3) making sure that
the suction strainer (4) in the fuel tank (3) does not catch and suffer
damage.
Feed out the fuel-pump unit (1) from fuel tank (3) and ensure that the lever
(5) is not bent while doing so.
(-) Replacing fuel tank
Transfer small parts to new fuel tank (1); replace as needed.

2 x Velcro strips
2 x rubber grommet
1 x flat nut, M6
2 x flat nut narrow, M5
2 x flat nut, M5
Install new thermal protection (2).
(-) Installing fuel-pump unit
Check seal (2) for damage; replace if necessary.

Push seal (2) on fuel-pump unit (1) and lubricate.
Installation tool
Feed fuel-pump unit (1) with seal (2) in the fuel tank (3) and while doing so,
ensure that the lever (5) is not bent.
Feed in the suction strainer (4) and install the fuel-pump unit (1).
Align fuel-pump unit (3) as shown (arrow) and press into fuel tank (4).
Fit pressure plate (2) making sure that the recesses (arrows) are aligned.
Install screws (1).
Tightening torques
M5 x 20 5 Nm
(-) Installing fuel filler cap with fuel filler neck
Check the seal (3) for damage; replace if necessary.

Install fuel filler neck (2) with seal (3).
Install screws (1).
Tightening torques
M5 x 20 2.5 Nm
Fit cover ring (3) with the large opening (arrow) to the rear and outer ring
with fuel filler cap (2).
Install screws (1).
Tightening torques
M5 x 20 2.5 Nm
(-) Filling fuel tank
WARNING
Fill the fuel tank with fuel.
Technical data
Recommended fuel Super Plus, unleaded
grade maximum 5%
ethanol, E5
98 ROZ/RON
93 AKI

16 12 002 Replacing quick-action coupling of the fuel flow line

+ 16 12 520
WARNING
Preparatory work
Removing fuel tank
Core activity
(-) Removing fuel supply quick-action coupling, feed line
Remove clamp (1).

Pull off hose (2) from quick-release coupling (3).
(-) Installing fuel supply quick-action coupling, feed line
Slide hose (2) onto quick-release coupling (3).

ATTENTION
Refitting hoses with non-reusable clamps at the same place
leaks
Always replace clamps fitted with non-reusable clamps.
Secure new clamp (1) with pliers (No. 13 1 500), making sure that
dimensions A and B are correct.
Technical data
Distance b (specified 4 mm
closed size for single-
eye clamp on quick-
action coupling)
Distance A (distance 3 mm
from end of hose to
hose clamp)
Follow-up work

16 13 001 Replacing carbon canister

+ 16 13 500
Preparatory work
Removing left side panel
Core activity
(-) Removing carbon canister
Pull hoses (1), (2) and (3) off the carbon canister (4).
Loosen grab strap (5) and remove carbon canister (4) from holder (6).
(-) Installing carbon canister
Connect hoses (1), (2) and (3) on carbon canister (4).

Position carbon canister (4) in holder (5) while observing locators (arrows).
Close retaining belt (6).
Follow-up work
Installing left side panel

16 13 002 Replacing fuel-evaporation control valve, activated charcoal filter

+ 16 13 510
Preparatory work
Removing the centre cover of fuel tank
Removing left cover of fuel tank
Core activity
(-) Removing tank vent valve
Disconnect connector (1) from tank vent valve (2).

Pull off hoses (3) and (4) from tank vent valve (2).
Remove tank vent valve (2) from holder (5).
(-) Installing tank vent valve
Secure tank vent valve (2) to holder (5).

Push hoses (4) and (3) on.
Connect connector (1) to tank vent valve (2).
Follow-up work
Installing left cover of fuel tank
Installing centre cover of fuel tank


16 14 009 Removing/installing fuel-pump unit

+ 16 14 502
Preparatory work
Removing fuel tank
Draining fuel tank
Core activity
(-) Removing fuel-pump unit
Remove screws (1) and remove pressure plate (2).

Release fuel-pump unit (3) on lug (arrow) from fuel tank (4).
Loosen fuel-pump unit (1) with seal (2) from fuel tank (3) making sure that
the suction strainer (4) in the fuel tank (3) does not catch and suffer
damage.
Feed out the fuel-pump unit (1) from fuel tank (3) and ensure that the lever
(5) is not bent while doing so.
(-) Installing fuel-pump unit
Check seal (2) for damage; replace if necessary.

Push seal (2) on fuel-pump unit (1) and lubricate.
Installation tool
Feed fuel-pump unit (1) with seal (2) in the fuel tank (3) and while doing so,
ensure that the lever (5) is not bent.
Feed in the suction strainer (4) and install the fuel-pump unit (1).

Align fuel-pump unit (3) as shown (arrow) and press into fuel tank (4).
Fit pressure plate (2) making sure that the recesses (arrows) are aligned.
Install screws (1).
Tightening torques
M5 x 20 5 Nm
Follow-up work
Filling fuel tank

16 14 513 Replacing fuel-level sensor (fuel-pump unit removed)
Core activity
(-) Removing fuel-level sensor
Disconnect connectors (1) and thread lines (2) out of the holders (arrows).
Lift lug (3), pull off fuel level sensor (4) and remove.
(-) Installing fuel-level sensor
Fit fuel-level sensor (1) and slide on until lug (2) engages with an audible
click.
Secure lines (3) in holder (arrows).

17 00 010 Checking cooling system for leaks (with cooling system tester)
+ 17 00 502
CAUTION
Risk of burn injury
Preparatory work
Removing right side panel
Core activity
(-) Checking cooling system for leaks
Requirement
Engine is cold.
Removing radiator cap

Seal off overflow hose (1) with hose clip (No. 13 3 010).
Remove radiator cap (2).
Secure radiator connection (No. 17 5 554) on coolant filler neck (1), connect
pump (No. 17 0 511).
Check
Pressure-test the cooling system; the pressure must remain unchanged for
at least 5 minutes.
Technical data
Cooling system Test pressure must 2 bar
test pressure remain
Result:
Pressure loss
Measure:
Check for leaks and rectify.

Install the radiator cap
Install the radiator cap (2).
Remove hose clip (No. 13 3 010) from overflow hose (1).
Allow the engine to warm up until the fan cuts in.

Allow the engine to cool down.
Check the coolant level; top up if necessary.
Technical data
Coolant, specified level cold engine between MIN and
MAX mark on the
expansion tank
Follow-up work
Installing right side panel

17 00 035 Draining coolant, refilling/bleeding system

+ 17 00 504
CAUTION
Risk of burn injury
Preparatory work
Core activity
(-) Draining coolant
Place a suitable container in position.

Remove bolt (1).
Pull off coolant hose (3), push down and catch emerging coolant.
Removing radiator cap

Seal off overflow hose (1) with hose clip (No. 13 3 010).
Remove radiator cap (2).
Drain the coolant from the radiator and the lines.
(-) Draining expansion tank
Remove bolt (1).

Loosen expansion tank (2) from lug (arrow), open cover (3) and empty the
coolant from the expansion tank (2) in the collecting vessel.
Secure expansion tank (2) on lug(arrow).

(-) Filling cooling system
Push on coolant hose (1).

Lug (2) engages in recess of coolant hose (1).
Secure clamp (3) using pliers (No. 17 5 571) and align to mark (arrow).
Install bolt (4).
Tightening torques
Coolant line to bracket
M5 x 16 5 Nm
Preparing and priming radiator filler for cooling system
Fill canister (No. 17 5 553) with an adequate quantity of coolant.
Technical data
Coolant, total 2.95 l
capacity General consumable (Antifreeze and corrosion
inhibitor)
Connect canister (No. 17 5 553), venturi nozzle (No. 17 5 552) and

distributor unit (No. 17 5 551).
Put the end of the drain hose of venturi nozzle (No. 17 5 552) into a suitable
container.
ATTENTION
Connecting compressor to distributor unit of filler adapter with
compressed-air valve open
Damage to pressure meter due to pressure peaks
Make sure the valves are closed when you connect the compressor to the
distributor unit.
Connect the compressor to the venturi nozzle (No. 17 5 552).
Technical data
Minimum Print min 8 bar
requirement,
compressor Delivery rate min 125 l/min
Begin by fully opening coolant cock (1) and then fully opening negative-
pressure cock (2) of distributor unit (No. 17 5 551).

Coolant is drawn in by vacuum from the tank.
Draw in coolant until the hose to distributor unit (No. 17 5 551) is full of
bubble-free coolant.
Close coolant cock (1) and negative-pressure cock (2).
Disconnect the compressor from venturi nozzle (No. 17 5 552).
Connecting radiator filler to cooling system
Requirement
The coolant canister must be higher than the motorcycle's radiator.
Position coolant canister (No. 17 5 553) on a higher level.

Secure the preassembled radiator filler in position at the motorcycle.
Connect radiator port (No. 17 5 554) to distributor unit (No. 17 5 551) and
radiator filler neck.
Put the end of the drain hose of venturi nozzle (No. 17 5 552) into a suitable
container.
Prepare the compressor.
Technical data
Minimum Print min 8 bar
requirement,
compressor Delivery rate min 125 l/min
Evacuating cooling system
ATTENTION
Connecting compressor to distributor unit of filler adapter with
compressed-air valve open
Damage to pressure meter due to pressure peaks
Make sure the valves are closed when you connect the compressor to the
distributor unit.
Connect the compressor to the venturi nozzle (No. 17 5 552).

Open negative-pressure cock (2) of distributor unit (No. 17 5 551).
A vacuum builds up in the system.
Evacuate the cooling system until the requisite negative pressure is
established and the needle of the pressure gauge is steady.
Technical data
Requisite vacuum for min −0.8 bar
filling the cooling
system
Close negative-pressure cock (2).

Disconnect the compressor from venturi nozzle (No. 17 5 552).

Observe the needle of the pressure gauge of distributor unit (No. 17 5 551)
for a time and check that the partial vacuum in the cooling system does not
rise to ambient pressure.
Technical data
Requisite vacuum for min −0.8 bar
filling the cooling
system
Slowly open coolant cock (1) until it is fully open.

Coolant flows into the cooling system.
When the level of fluid in the canister (No. 17 5 553) ceases to drop and
the vacuum corresponds to ambient pressure, shut coolant cock (1).
Disconnecting radiator filler from radiator

Disconnect the radiator filler from the radiator and remove it from the
vehicle.
Check the coolant level; top up if necessary. (Cooling system must be filled
with coolant up to the lower edge (arrow) of coolant filler neck (1).)
General consumable
Antifreeze and corrosion inhibitor 83 51 2 445 463
Install the radiator cap

Install the radiator cap (2).
Remove hose clip (No. 13 3 010) from overflow hose (1).

(-) Filling expansion tank
Install bolt (1).
Tightening torques
M6 x 20 8 Nm
Fill expansion tank (2) with coolant and close lid (3).
Technical data
MAX mark on the
expansion tank
(-) Checking coolant level
Allow the engine to warm up until the fan cuts in.

Allow the engine to cool down.
Check the coolant level; top up if necessary.
Technical data
MAX mark on the
expansion tank
Follow-up work

17 11 008 Removing/installing radiator (without draining/refilling coolant system)

+ 17 11 508
CAUTION
Risk of burn injury
Preparatory work

Core activity
(-) Removing radiator
ATTENTION
Component damage
Release clamps (1) with pliers (No. 17 5 571).

Pull off coolant overflow hose (2) and coolant venting hose (3).
Loosen coolant expansion tank (4) from lug (arrow).

Loosen hose (1) for carbon canister from holder (2).

Loosen hose (3) for wastewater from holder (2) and remove.
Disconnect and remove plug connection (4) for the radiator fan.

Pull off coolant hose (2).
Release radiator bracket (1) from rubber grommet (arrow) of radiator (2).
Remove screws (1) and washers (2) with radiator (3) supported.
Disengage the locators (arrows).
Remove radiator (1) with fan.

(-) Installing radiator
ATTENTION
Component damage
Make sure that exhaust duct (1) is secured on lugs (arrows).
Fit radiator (1) with fan.
Fit radiator (3) and secure locators (arrows).

Install screws (1) and washers (2).
Tightening torques
Radiator to frame
M6 x 25 8 Nm

Secure radiator bracket (1) in rubber grommet (arrow) of radiator (2).
Connect clamp (1) on coolant hose (2).

Secure clamp (1) using pliers (No. 17 5 571) and thereby align on mark
(arrow).
Connect plug connection (4) for radiator fan and secure.

Install hose (3) for dirty water and secure in holder (2) and align with mark.
Secure hose (1) for carbon canister in holder (2).
Secure connector (1).

Secure cable for wheel speed sensor with cable strap (arrow).

Secure coolant expansion tank (1) on lug (2).

Slide on coolant overflow hose (3) and coolant venting hose (4) while
aligning recess at lugs (arrows).
Secure clamps (5) with pliers (No. 17 5 571).
Follow-up work

17 11 037 Replacing air inlet duct for radiator

+ 17 11 545
Preparatory work
Core activity
(-) Removing air deflector for radiator
Release hoses (1) for tank ventilation from air duct (2).
Remove screws (3).
Release left and right air duct (2) from rubber grommets (arrow) and
remove.
(-) Replacing air deflector for radiator
Transfer small parts to new air deflector (1), change if applicable:

6 x flat nut
(-) Installing air deflector for radiator
Fit air duct (2) and secure on left and right in rubber grommets (arrow).
Install screws (3).
Secure hoses (1) for tank ventilation in air duct (2).
Follow-up work


17 12 100 Replacing coolant hose from radiator (without draining/ refilling coolant system)
+ 17 12 600
CAUTION
Risk of burn injury
Preparatory work

Core activity
(-) Removing coolant hose, return
Unlock wire spring clip (1).

Loosen connector (2) and remove completely with coolant line (3).
(-) Install the coolant hose, return
Lubricate support ring (1) and O-ring (2).
Installation tool
Fit coolant line (3) with connector (2).

Push connector (2) on up to limit position.
Lock wire spring clip (1).

Follow-up work

17 12 105 Replacing coolant hose to radiator (without draining/ refilling coolant system)
+ 17 12 605
CAUTION
Risk of burn injury
Preparatory work

Core activity
(-) Removing coolant hose to radiator


(-) Installing coolant hose to radiator

(arrow).


(arrow).
Follow-up work

17 13 001 Replace expansion tank

+ 17 13 501
CAUTION
Risk of burn injury
Preparatory work
Core activity
(-) Removing expansion tank
Draw off coolant from expansion tank (1).

Pull off coolant hose (3) from expansion tank (1).
Remove bolt (4).
Remove expansion tank (1) from lug (arrow).
(-) Replacing expansion tank
Transfer reusable small parts to the new part (1) or replace the small parts
as necessary.
1 x bushing
2 x rubber grommet
(-) Installing expansion tank
Secure expansion tank (1) on lug (arrow).

Install bolt (4).
Tightening torques
M6 x 20 8 Nm

Secure coolant hose (3) on expansion tank (1).
Fill expansion tank (1) with coolant.
Technical data
MAX mark on the
expansion tank
Follow-up work

17 21 000 Removing/installing or replacing oil cooler

+ 17 21 501
CAUTION
Risk of burn injury
Preparatory work
Remove left front oxygen sensor
Core activity
(-) Removing oil cooler
Remove bolt (1).

Loosen feed line (2) with O-ring (3).
Remove bolt (1).

Disconnect return line (2).
Remove bolt (1).

Loosen return line (2) with O-ring (3).

Remove screws (1).

Disconnect oil cooler (2) from holder (3) and remove while pushing air
deflector (4) slightly forward.
(-) Installing oil cooler
Clean thread.
Fit oil cooler (2) and secure in holder (3) while pressing air deflector (4)
slightly to the front.
Install screws (1).
Tightening torques
Oil cooler to radiator
encapsulated)
Check O-ring (3) and renew where required..

Lubricate O-ring (3) with engine oil and install on return line (2).
Install return line (2).
Install bolt (1).
Tightening torques
M6 x 20 8 Nm
Clean thread.
Fit return line (2).
Install bolt (1).

Tightening torques
Return line for oil cooler to engine
encapsulated)
Check O-ring (3) and renew where required..

Lubricate O-ring (3) with engine oil and install on feed line (2).
Install feed line (2).
Install bolt (1).
Tightening torques
M6 x 20 8 Nm
Follow-up work
Installing the left front oxygen sensor

17 40 000 Removing/installing or replacing fan

+ 17 40 500
Preparatory work
Disengaging carbon canister
Core activity
(-) Removing fan
ATTENTION
Component damage
Remove bolt (1).
Release and disconnect plug connection (1) for the fan.

Disconnect hose (2) for wastewater from holder (arrow).
Remove bolt (3).
Release fan (1) from rubber grommet (arrow) and remove to the left.
Observe camshaft sensor (2) during this operation.

(-) Installing fan
Install fan (1) from the left. Observe camshaft sensor (2) during this
operation and insert in rubber grommet (arrow).
Install bolt (3).
Tightening torques
Fan to radiator
Secure hose (2) for dirty water in holder (arrow).

Connect and secure plug connection (1) for the fan.
Install bolt (1).
Tightening torques
Fan to radiator
Follow-up work
Securing radiator
Securing carbon canister

17 65 000 Replacing thermostat for coolant (without draining/ refilling coolant system)
+ 17 65 500
Preparatory work

Core activity
(-) Removing thermostat
Remove screws (1).

Loosen thermostat cover (2) with O-ring (3).
Remove thermostat (1).
(-) Installing thermostat
Install thermostat (1).
Check O-ring (3) and renew where required.

Installation tool
If necessary, install O-ring (3) on thermostat cover (2).

Fit thermostat cover (2).
Install screws (1).
Tightening torques
Thermostat cover to crankcase
M6 x 25 9 Nm
Follow-up work

18 51 000 Replacing silencer

+ 18 51 500
CAUTION
Hot exhaust system
Risk of burn injury
Preparatory work
Core activity
(-) Removing silencer
Slacken nut (1) and release clamp (2).

Remove bolts (3) and shaped washer (4).
Remove the silencer (5) from the front silencer (6).
(-) Replace the silencer
NOTICE
To ensure the leaktightness of the exhaust system, the exhaust clamps have
to be lubricated for installation.
It is particularly important to apply lubricant to the vicinity of the joint.
Thinly lubricate the inner surface (arrow) of the clamp (1).
Lubricant
Optimoly TA 18 21 9 062 599
Slide clamp (1) onto new silencer (2).
(-) Installing silencer
Push silencer (1) onto front silencer (2).

Install screw (3) and shaped washer (4).

Tightening torques
M8 x 40 19 Nm
Position clamp (5) with the recess in the lug (arrow).

Tighten the nut (6).
Tightening torques
M8 24 Nm
Follow-up work

18 51 001 Replacing exhaust manifold

+ 18 51 502
CAUTION
Hot exhaust system
Risk of burn injury
Preparatory work
Removing fuel tank
Removing silencer
Core activity
(-) Removing exhaust manifold
NOTICE
Support the exhaust system to make it easier to remove and install the
assembly.
Remove bolt (1) and washer (2).

Release exhaust manifold (3).

Remove nuts (1).

Remove exhaust manifold (2).
Remove exhaust manifold seals (1).
(-) Replacing exhaust manifold
Remove front oxygen sensors (1).

Remove monitoring oxygen sensors (2).
Remove flat nut (3).
Install flat nut (3) in new exhaust manifold (4), renew as needed.
Lightly lubricate thread of oxygen sensors (1) and (2).
Lubricant
Optimoly TA 18 21 9 062 599
Install oxygen sensors (2) in new exhaust manifold (4).
Tightening torques
M12 x 1.25 25 Nm

(Optimoly TA)
Install front oxygen sensors (1) in new exhaust manifold (4).
Tightening torques
M14 x 1.25 45 Nm
(Optimoly TA)
(-) Installing exhaust manifold
NOTICE
assembly.
Lubricate new seals (1) lightly and install in cylinder head making sure that
tabs (arrows) face up.
Lubricant
Optimoly TA 18 21 9 062 599
Hold exhaust manifold (2) in position.

Install nuts (1).
Tightening torques
M7 14 Nm
Clean thread.
Position exhaust manifold (3).
Install bolt (1) and washer (2).
Tightening torques
encapsulated)
Follow-up work
Securing radiator
Installing silencer

18 51 007 Replacing Bowden cable for exhaust-flow control valve

+ 18 51 510
CAUTION
Hot exhaust system
Risk of burn injury
Preparatory work
Removing actuator motor of exhaust-flow control valve
Core activity
(-) Replacing Bowden cable for exhaust-flow control valve
Remove screws (1).

Release servomotor (2) from holder (3).
Detach actuation cable (4) from pulley (5).
Remove old Bowden cable (6) from holder (3) and install new Bowden cable
(6) in holder (3).
Attach actuation cable (4) in pulley (5).
Insert servomotor (2) in holder (3).
Install screws (1).
Tightening torques
Follow-up work
Installing servomotor of exhaust-flow control valve

18 51 008 Replacing Bowden cable for exhaust-flow control valve return

+ 18 51 511
CAUTION
Hot exhaust system
Risk of burn injury
Preparatory work
Removing actuator motor of exhaust-flow control valve
Core activity
(-) Replacing Bowden cable for exhaust-flow control valve return
Remove screws (1).

Detach reset cable (4) from pulley (5).
Remove old reset Bowden cable (6) from holder (3) and install new reset
Bowden cable (6) in holder (3).
Attach reset cable (4) in pulley (5).
Insert servomotor (2) in holder (3).
Install screws (1).
Tightening torques
Follow-up work
Installing servomotor of exhaust-flow control valve

18 51 009 Replacing servomotor for exhaust-flow control valve

+ 18 51 512
CAUTION
Hot exhaust system
Risk of burn injury
Preparatory work
Core activity
(-) Removing actuator motor of exhaust-flow control valve
Unclip actuating cable (1) from holder (2).
Remove bolt (1).

Release servo motor (2).
Remove screw (3) and remove holder (4).
Pull servo motor (1) back and release from rubber grommets (2).
Disconnect connector (3) from servomotor (1) and thread out.
Remove servo motor (1) while guiding out retention (4) and actuating cable
(5).

(-) Replacing servomotor for exhaust-flow control valve
Remove screws (1).

Detach actuating cable (4) and return cable (5) from pulley (6).
Replace the servomotor (2).
Attach actuating cable (4) and return cable (5) in pulley (6).
Insert servomotor (2) into the holder (3).
Install screws (1).
Tightening torques
(-) Installing servomotor of exhaust-flow control valve
Lubricate rubber grommets (2).
Installation tool
Position servo motor (1) while inserting retention (4) and actuating cable (5).
Route connector (3) and connect to servomotor (1).
Fasten servomotor (1) in rubber grommets (2).
Position holder (1) noting the anti-twist lock (arrow).

Install bolt (2).
Tightening torques
M5 x 10 2 Nm
Align servomotor (3).

Install bolt (4).
Clip in actuator cable (1) in holder (2).

Follow-up work

Clutch and Gearbox
Repair Guide
BMW Motorrad
21 21 000 Removing and installing or replacing clutch

+ 21 21 606
Preparatory work
Disconnecting crankshaft sensor
Releasing the left engine housing cover
Removing right crankcase cover
Core activity
(-) Remove the pressure plate
Remove screws (1).

Remove retaining panel (2).
Remove compression springs (1) with spring retainers (2).

Remove the pressure plate (3).
(-) Removing plate cluster
Remove friction plate (1) (small segmentation).

Remove steel disc (2) (large inner diameter).

21 21 140 Removing and installing or replacing lined plates

+ 21 21 609
Preparatory work
Core activity
Remove screws (1).

Remove compression springs (1) with spring retainers (2).

Remove the pressure plate (3).
(-) Removing plate cluster


21 51 002 Replacing thrust piece

+ 21 51 729
Preparatory work
Core activity
Remove screws (1).

Remove pressure plate (3) with spring retainers (2) and compression
springs (1) .

(-) Changing the thrust piece
Remove O-ring (1) and thrust piece (2) from pressure plate (3).

Install thrust piece (2) and O-ring (1).
Make sure O-ring (1) is seated in groove (arrow).
(-) Installing pressure plate
Install friction plate (1) (small segmentation) on pressure plate (2).

Install steel disc (3) (large inner diameter) on pressure plate (2) while
allowing gearing (arrows) to engage.
Install pressure plate (1) with friction plate and steel disc in driver (2) and let
gearing engage.
Outer gearing (arrow) of friction plate must be installed offset to remaining
friction plates in clutch basket (3).
Install spring retainer (1) and compression springs (2).

Marks (arrows) on pressure plate (3) and spring retainer (1) face each other.
Lubricate bolts (1) with engine oil.

Position retaining panel (2) with bolts (1) with the labelling facing
outwards.
Tighten bolts (1) alternately and evenly.

Tightening torques
Pressure plate to driver
M6 x 25 10 Nm
Screws oiled
Follow-up work
Installing right crankcase cover
Checking/adjusting clutch-lever play

21 00 004 Adjusting clutch operating clearance

+ 21 00 500
Core activity
(-) Checking/adjusting clutch-lever play
Requirement
Engine is cold.
Operate clutch lever (1) several times till the limit position at the handle.
Operate clutch lever (1) until you feel resistance and hold it.
Check
Measure clutch lever clearance (B) between handlebar weight (2) and clutch
lever (1).
Technical data
Clutch-lever play measured on 3...5 mm
outer clutch
lever,
handlebars in
straight-
ahead
position, with
cold engine
Result:
Clutch lever clearance (B) is out of tolerance.
Measure:
NOTICE
Before the adjustment of the clutch cable, it must be ensured that a correct
adjustment range is available on the coupling hand armature.
Loosen lock nut (1)and adjust distance (A) using adjusting screw (2).
Technical data
Distance between 3+1.5 mm
adjusting screw and −1.5
handlebar fitting
(clutch-cable setting)
Tighten the lock nut (1).
Measure free travel/clutch play (B) between handlebar weight (2) and clutch
lever (1).
Technical data
Clutch-lever play 3...5 mm

measured on
outer clutch
lever,
handlebars in
straight-
ahead
position, with
cold engine
If necessary, re-adjust clutch play on engine.
If necessary, loosen adjusting nuts (1) and adjust clutch play until value on
clutch handlebar fitting is correct.
Tighten adjusting nuts (1).
Follow-up work

23 12 078 Replace shaft sealing ring of output shaft

+ 23 12 620
Preparatory work
Releasing pinion
Relieving chain tension
Removing pinion
Core activity
(-) Removing shaft sealing ring of output shaft
Remove spacer sleeve (1).

Remove shaft sealing ring (2) with suitable tool, for instance with hook (No.
33 6 761).
Remove O-ring (3).
(-) Installing shaft sealing ring of output shaft
Clean seat (1) in housing and deburr lightly.

Only lubricate the inner sealing lips (arrows) of shaft sealing ring (3) thinly or
install dry and free of lubricant.
Lubricant
Molykote 111 11 00 7 660 832
Lubricate new O-ring (2) with engine oil and insert.

Position new shaft sealing ring (3) with open side to the inside.
Install shaft sealing ring (3) with suitable tool to stop, such as with mounting
tool (No. 11 0 882) (without inner section).
Install new spacer sleeve (1).

Follow-up work
Installing pinion
Adjusting chain sag
Securing pinion
Installing chain drop guard
Installing gearshift lever with Gear Shift Assistant

23 14 006 Removing/installing shift assistant

+ 23 14 509
ATTENTION
Change to length setting of the shift assistant
Component damage
Do not change the length setting of the shift assistant.
Preparatory work
Core activity
(-) Removing shift assistant

Unlock and disconnect connector (1) for Gear Shift Assistant.
Push protective cap (1) up.

Remove bolt (2) and take off washer (3).
Loosen gearshift rod (4).
Push protective cap (1) down.

Remove Gear Shift Assistant (4).

(-) Installing shift assistant
Clean the threads.

Push protective cap (1) down.
Fit Gear Shift Assistant (4) with washer (3).
Install bolt (2).
Tightening torques
encapsulated)
Push on protective cap (1).

Adjusting height of shift lever
NOTICE
A poorly adjusted shift lever has a negative effect on the shiftability of the
gearbox.

Slacken lock nut (2), counter-holding at mounting flats (3) and back off the
lock all the way toward the ball joint (4).
The height of the gearshift lever can be adjusted by twisting the ball joint (4).
Do not slacken the nut (5) on top of Gear Shift Assistant, adjustments not
possible.
Ensuring that shift-assistant settings do not exceed maximum

Do not exceed maximum shift-assistant setting distance A at the lower ball
joint.
Technical data
Selector-rod-end setting free length 6+2 mm
of thread on −2
lower ball
joint

Tighten lock nut (2) while counter-holding at mounting flats (3).
Fit gearshift rod (4) with washer (3).

Install bolt (2).
Tightening torques
Gearshift rod to gearshift lever
encapsulated)
Connect and lock connector (1) for Gear Shift Assistant.

Follow-up work

23 14 051 Replacing potentiometer for gear indicator

+ 23 14 507
Preparatory work
Core activity
(-) Removing potentiometer for gear indicator

Unlock and disconnect connector (1) for potentiometer for gear indicator.
Remove screws (2).
Remove potentiometer for gear indicator (3), paying attention to the O-ring
(4).
(-) Installing potentiometer for gear indicator

Lubricate O-ring (4) and install on potentiometer for gear indicator (3).
Installation tool
Install potentiometer for gear indicator (3), paying attention to the O-ring (4)
and anti-twist lock (5).
Install screws (2).
Tightening torques
Gearbox potentiometer to selector-drum carrier
M5 x 14 - 10.9 5 Nm
Connect connector (1) for potentiometer for gear indicator and lock.
Follow-up work


23 21 503 Removing/installing transmission shafts (engine removed)
Preparatory work
Removing potentiometer for gear indicator
Removing left crankcase cover
Partially disassemble the engine
Removing bottom crankcase half
Remove the selector shaft
Removing locking lever
Removing selector star
Core activity
(-) Removing gearbox output shaft
Remove transmission output shaft (1) while working the gearshift forks (2)
free.
(-) Removing lower shift forks
Remove bolt (1) and lock washer (2).

Remove gearshift rail (3), working gearshift forks (4) free from grooves
(arrows) of selector drum (5).
(-) Removing upper gearshift rail

Remove gearshift rail (3), working out gearshift fork (4).

23 31 130 Replacing selector shaft

+ 23 31 904
Preparatory work
Disconnecting crankshaft sensor
Releasing the left engine housing cover
Loosening the gearshift lever from gearshift shaft
Removing complete clutch
Core activity
(-) Remove the selector shaft
Remove bolt (1).

Remove complete gearshift shaft (2) along with lock plate (3).
(-) Installing selector shaft
Fit lock plate (1) on gearshift shaft (2).

Install complete gearshift shaft (2) along with lock plate (1). Make sure that
selector star and selector shaft are engaged (arrows).
Align driver (arrows) of gearshift shaft (2) with shift star (3).
Install bolt (4).
Tightening torques
Gearshift shaft (retaining plate) to crankcase
M6 x 16 9 Nm
Follow-up work
Installing complete clutch

Securing the gearshift lever on the gearshift shaft
Securing left engine housing cover
Connect crankshaft sensor

23 31 626 Replacing shift drum (engine removed)
Preparatory work
Removing potentiometer for gear indicator
Removing left crankcase cover
Partially disassemble the engine
Removing bottom crankcase half
Remove the selector shaft
Removing locking lever
Removing selector star
Removing gearbox output shaft
Removing shaft sealing ring for gearbox output shaft
Removing lower shift forks
Core activity
(-) Removing upper gearshift rail

Remove gearshift rail (3), working out gearshift fork (4).
(-) Removing selector drum
Remove bolt (1).

Release gearshift fork (2) from selector drum (3) where required.
Remove selector drum (3) with bearing support (4).
Release gearshift fork (2) from gear (5) and remove.
(-) Replacing the selector drum
Remove selector drum (1) from bearing support (2).

Remove O-ring (3) and change.
Lubricate O-ring (3) with engine oil and install on bearing support (2).
Install selector drum (1) on bearing support (2).
(-) Installing selector drum
Insert gearshift fork (2) and position gear (5).

Install selector drum (3) with bearing support (4) up to stop.
Install bolt (1).
Tightening torques
Bearing carrier, selector drum, to crankcase
M6 x 25 9 Nm
(-) Installing upper gearshift rail

Lubricate O-ring (1) with engine oil and, if necessary, install in groove
(arrow) of gearshift rail (2).
Position gearshift fork (1) in gear (2) and selector drum (3).
Install gearshift rail (4) while working into gearshift fork (1).
If necessary, align gearshift rail (4), fit lock washer (5) and install bolt (6).
Tightening torques
Locking plate of gearshift rail to crankcase
M5 x 12 5 Nm
Follow-up work
Installing bottom shift forks

Installing shaft sealing ring, gearbox output shaft
Installing gearbox output shaft
Installing selector star
Installing locking lever
Installing selector shaft
Install the bottom crankcase half
Assembling engine
Installing left crankcase cover
Installing potentiometer for gear indicator

23 41 300 Removing/installing or replacing gearshift lever

+ 23 41 551
Preparatory work
Core activity
(-) Removing gearshift lever

Remove bolt (1).

Take off gearshift lever (2) and mount (3).
(-) Installing threaded bush
Fit gearshift lever (1) and mounting (2) with shouldered side (arrow) to
gearshift lever (1).
Install bolt (3).
Tightening torques
M8 x 65 19 Nm
Clean thread.
Install bolt (2).

Tightening torques
encapsulated)
Follow-up work

23 41 329 Replacing shift lever on selector shaft

+ 23 41 556
Preparatory work
Disengaging shift assistant
Core activity
(-) Removing gearshift lever from gearshift shaft
Remove bolt (1).

Remove gearshift lever (2) from gearshift shaft (3).
(-) Connecting shift lever to selector shaft
Install gearshift lever (1) on gearshift shaft (2) while aligning clamping gap
with mark (arrow).
Install bolt (3).
Tightening torques
Gear selector lever to gearshift shaft
M6 x 25 8 Nm
Follow-up work
Securing shift assistant

Wheels - Suspensions - Brakes
Repair Guide
BMW Motorrad
31 42 005 Oil change in telescopic front forks

+ 31 42 899
Preparatory work
Removing bracket for engine spoiler on right and left
Installing engine lifter
Releasing front brake calipers
Removing front-wheel cover
Removing front wheel
Disengaging front wheel-speed sensor
Removing left fork leg
Removing right fork leg
Core activity
(-) Oil change in telescopic forks
Draining oil from left fork leg
Removing left threaded bush
Remove bolts (1) and threaded bush (2) from forkleg (3).
Record position of adjusting screw (1) for compression-stage damping.

Turn adjusting screw (1) for compression-stage damping into position 1
(arrow).
ATTENTION
Component damage

31 42 321 Replacing both steering-head bearings

+ 31 42 879
Preparatory work
Slacken lock nut on upper fork bridge
Removing the fork partition
Removing fork legs
Removing air guide for radiator
Removing mounted parts, bottom fork bridge
Release right handlebar half
Release the top fork bridge
Remove the bottom fork bridge
Core activity
(-) Removing top steering-head bearing
Remove cover plate (1).

Remove inner ring (2) and ball cage (2).
(-) Removing outer races for top and bottom steering-head

bearings
Pull out outer ring (1) with support ring (No. 36 6 640), internal puller (No. 00
8 561) and reaction support (No. 00 8 562).

Pull out outer ring (1) with support ring (No. 36 6 640), internal puller (No. 00
8 561) and reaction support (No. 00 8 562).
(-) Removing inner race for bottom steering-head bearing
Clamp the handlebar tube (1) in a vice, while doing so, place a block of
wood (2) as protection between the handlebar tube and face.
ATTENTION
Driving out steering-head bearing with a punch that is too small
Damage to fork bridge
Use a punch that is a snug fit the hole.
Use a punch to remove cover plate (3) and inner ring (4) preventing the
inner ring (4) from tilting by alternating from one bore hole to the other.
Technical data
Diameter (A) of 4 mm
punch
(-) Installing inner race for bottom steering-head bearing
Install new cover plate (1) making sure that flanging (arrow) faces up.
Heat inner ring (2).
Technical data
Release/mating 80 °C
temperature
ATTENTION
Installation of the inner ring of the steering-head bearing not in
compliance with correct procedure
Damage to the inner ring
Use a suitable tool, do not subject the tyre tread of the inner ring to load.

Install inner ring (2) on handlebar tube, tap lightly if necessary to seat the
inner ring.
Make sure that inner ring (2) is correctly seated.
(-) Installing outer races for top and bottom steering-head

bearings
Clean the bearing seats.

From below, fit long spindle (No. 36 5 551), pressure disc with thread 55 mm
(No. 36 5 553) and outer ring (1).
From above, position pressure disc without thread 55 mm (No. 36 5 554)
and pull-in nut (2) and install steering-head bearing outer ring (1) until
seated.
When pulling in the steering-head bearing outer ring (1), make sure that it is
not tilted and correct position of pressure disc as needed.
Remove the tools and turn them round the other way.
Install upper outer ring (3) in the same way.
(-) Installing top steering-head bearing
Lubricate and install ball cage (3).
Lubricant
Acid-free friction-bearing grease 81 22 9 407 174
Install inner ring (2).

Lay cover plate (1) in position.
Follow-up work
Installing bottom fork bridge
Holding top fork bridge in position
Secure right handlebar half
Install the mounted parts, bottom fork bridge
Installing air duct for radiator
Installing fork legs
Installing the fork partition
Securing front wheel-speed sensor
Install the front wheel
Install front-wheel cover
Securing front brake calipers
Bedding in brake pads
Removing engine lifter
Installing the holder for the left and right engine spoiler
31 42 341 Removing/installing left fork leg

+ 31 42 841
Preparatory work
Core activity
(-) Removing left fork leg
Loosen bolt (1).

NOTICE
If the fork legs are going to be disassembled for further work, the fork caps
have to be slackened beforehand prior to removal of the assembly.
Slacken bolts (2) and remove fork leg (3).

NOTICE
Do not lay down or turn over removed fork legs in order to prevent air from
entering the damping system. Store upright.
(-) Installing left fork leg

Alignment of fork legs
Completely release the spring preload on the right fork leg and note setting
(scale turns with it).
Before tightening the fork clamps, make sure that the fork legs are aligned
symmetrically via the octagonal tool handle of covers (1) and (2):
Scales (3) and (4) face with the 10 (arrows) toward the driver.
After tightening the fork clamps, bring the spring preload on the right fork leg
to the noted setting (scale turns with it).
The fork-tube projection (A) is measured between fork bridge (1) and upper
edge of the fork leg (2) without lid:
from top second groove (arrow) in fork leg (2) is flush with upper edge of
fork bridge (1)

Install fork leg (1) and adjust fork-tube projection (A).
Technical data
Projection of fork tube measured 6 mm
in fork bridge, top without fork
cover
Tighten screws (2) hand-tight.

NOTICE
If the fork has been dismantled, the fork caps are tightened in the installed
state with torque.
If required, the clamping bolts of the upper fork bridge are tightened after the
fork caps.
Tighten bolts (2) alternately to the specified tightening torque.
Tightening torques
M8 x 35 Tightening
sequence: Tighten
screws six times in
alternate sequence
19 Nm
Tighten the screw (3).
Tightening torques
M8 x 25 19 Nm
Follow-up work


31 42 342 Removing/installing right fork leg

+ 31 42 842
Preparatory work
Core activity
(-) Removing right fork leg
Loosen bolt (1).

NOTICE
If the fork legs are going to be disassembled for further work, the fork caps
have to be slackened beforehand prior to removal of the assembly.
Slacken bolts (2) and remove fork leg (3).

NOTICE
Do not lay down or turn over removed fork legs in order to prevent air from
entering the damping system. Store upright.
(-) Install the right fork leg

Alignment of fork legs
Completely release the spring preload on the right fork leg and note setting
(scale turns with it).
Before tightening the fork clamps, make sure that the fork legs are aligned
symmetrically via the octagonal tool handle of covers (1) and (2):
Scales (3) and (4) face with the 10 (arrows) toward the driver.
After tightening the fork clamps, bring the spring preload on the right fork leg
to the noted setting (scale turns with it).
The fork-tube projection (A) is measured between fork bridge (1) and upper
edge of the fork leg (2) without lid:
from top second groove (arrow) in fork leg (2) is flush with upper edge of
fork bridge (1)

Install fork leg (1) and adjust fork-tube projection (A).
Technical data
Projection of fork tube measured 6 mm
in fork bridge, top without fork
cover
Tighten screws (2) hand-tight.

NOTICE
If the fork has been dismantled, the fork caps are tightened in the installed
state with torque.
If required, the clamping bolts of the upper fork bridge are tightened after the
fork caps.
Tighten bolts (2) alternately to the specified tightening torque.
Tightening torques
M8 x 35 Tightening
sequence: Tighten
screws six times in
alternate sequence
19 Nm
Tightening torques
M8 x 25 19 Nm
Follow-up work


31 42 514 Adjusting steering-head bearing (with checking steering-head bearing)
Preparatory work
Disengaging top fork bridge
Core activity
(-) Adjusting steering-head bearing
Remove lock plate (1).

Remove slotted nut (2) with pin wrench (No. 31 3 721) and rubber washer
(3).
Adjust the steering-head bearing at slotted nut (4) with pin wrench (No. 31 3
721), install rubber washer (3) and slotted nut (2) with pin wrench (No. 31 3
721).
Tightening torques
Bottom slotted nut, M30 x 1 (forks turned fully to
right), 15 Nm
Rubber ring
Top slotted nut, M30 x 1 Tightening torque,
Secure with circlip 1 Nm
turn further until
circlip can be installed
Ensure that the grooves (arrows) of the slotted nuts (2) and (4) align.
Install lock plate (1).
Follow-up work
Securing top fork bridge

31 42 515 Checking steering head bearing (for maintenance)
Core activity
(-) Checking steering-head bearing
Requirement
No weight on front wheel.
Check
Take a grip of the fixed fork tubes and pull the forks back and forth.
Result:
Steering-head bearing evinces play.
Measure:
=> 31 42 514, Adjusting steering-head bearing (with checking steering-head
bearing) (Billed as a separate item)
Check
Turn the handlebars to full left and right lock.
NOTICE
The steering must move smoothly from lock to lock. There should be no
perceptible catching and no notching at the straight-ahead position.
The steering-head bearing must be free of play.
Result:
Dirt or old, solidified grease makes the handlebars stiff, or there is a
perceptible notching effect when the handlebars reach the straight-ahead
position.
Measure:
=> 31 42 879, Replacing both steering-head bearings (Billed as a separate
item)

31 42 516 Disassembling and assembling left fork fork leg (fork leg removed)
Core activity
(-) Disassembling left fork leg

(arrow).
ATTENTION
Component damage
Release fork cover (1) with special wrench (No. 31 1 532) from fixed fork
tube (2) and lower fixed fork tube (2) to forkleg.
Drain the oil from the fork leg into a suitable container.
Insert fork leg (1) in the pre-tensioning tool (No. 31 3 712) , with the forkleg
on locking pin (A).
Secure fork leg (1) with rubber retainer (2).

31 42 517 Disassembling and assembling right fork fork leg (fork leg removed)
Core activity
(-) Disassembling right fork leg
Remove screws (1).
Record position of adjusting screw (1) for rebound-stage damping.

Turn adjusting screw (1) for rebound-stage damping into position 1 (arrow).
Turn adjuster (2) for spring preload counter-clockwise up to the stop while
counting and recording rotations.
ATTENTION
Component damage
on locking pin (A).
Insert claw (No. 31 3 718) in fork spring (1).

Position press-down device (B), insert mountings (D) in claw (No. 31 3 718)
and fix with knurled screws (E).
Pre-tension fork spring (1) with press-down device (B) and spindle (C).
Pull fork cover (1) up to make lock nut (2) accessible with open-end
spanner.
Slacken lock nut (2) while counter-holding fork cover (1) with special wrench
(No. 31 1 532).
Remove fork cover (1).
Turn back press-down device (B) with spindle (C) and release fork spring
(1).
Loosen knurled screws (E) and release mountings (D) from claw (No. 31 3
718).
Remove claw (No. 31 3 718) from fork spring (1).
Remove fork spring (1) and spacer bush (2).

Remove spacer sleeve (3) from fixed fork tube (4).
Move pump at damper rod (5) to empty damper unit and pour out oil.
Pull off fixed fork tube (1) from slider tube (2).

DANGER
Connection between fork leg and slider tube loosens in case of
overheating.
Risk of falling
Do not heat fork leg.
Remove bolt (1) with sealing ring (2).

Remove damper unit (3).
Drain off the rest of the oil.
Remove upper sliding bush (1), with suitable tool, if necessary, from fixed
fork tube (2) to the top.
ATTENTION
Component damage
Remove dust boot (1) with a suitable tool.

Mask off the fixed fork tube to prevent scratches.
Place support ring (No. 36 6 640) on the fixed fork tube to prevent damage.
Using a mounting lever, carefully remove sealing ring (3).
Remove support disc (4).
Remove lower sliding bush (1), with suitable tool, if necessary, from fixed
fork tube (2).

Cleaning components.
(-) Assembling right fork leg
Clean the threads.

Hexagon head (arrows) on damper unit (1) and forkleg (2) must be observed
during installation and fitted inside of each other.
Damper unit and fork base are not damaged.
Renew O-ring (1) and lubricate.

Position damper unit complete with hexagon head (2) with counter
support (No. 31 3 641) in forkleg (arrows). Make sure that the damper unit
(2) can no longer be twisted.
Install bolt (3) with a new sealing ring (4). At the same time, hold the damper
unit (2) pressed in the direction of installation to prevent it from loosening
from the recess (arrow).
Tightening torques
M8 x 25 25 Nm
encapsulated)
Lubricate lower sliding bush (1) with fork oil.

Install lower sliding bush (1) in fixed fork tube (2).
Push a new dust boot (1) and circlip (2) onto the slider tube (3).

Lightly lubricate sealing lips of new sealing ring (4) with fork oil.
Slide sealing ring (4) with spring (arrow) toward dust boot (1) onto slider tube
(3).
Slide support disc (5) onto slider tube (3).
Slide fixed fork tube (1) onto slider tube (2).

Push support disc (3) and sealing ring (4) with narrow shoulder of impact
bush (No. 31 3 711) into its mounting in fixed fork tube (1).
Remove impact sleeve (No. 31 3 711).
Install circlip (1), making sure it is correctly seated in fixed fork tube (2).
Turn impact bush (No. 31 3 711) around and push dust boot (3) into fixed
fork tube (2).
Lubricate upper sliding bush (1) with fork oil.

Install upper sliding bush (1) with spacer sleeve (2) in fixed fork tube (3) up
to the stop, pulling the fixed fork tube (3) up slightly as needed.
Insert fork leg in pre-tensioning tool (No. 31 3 712).

Lower fixed fork tube (1) completely to forkleg.
Lubricate O-ring (2) with fork oil.
Pour the correct quantity of oil into the slider tube.

Technical data
Fork oil, capacity of approx. 350 ml
right fork leg Telescopic fork oil (Telescopic fork oil, type 2)
Move damper rod (3) up and down until air bubbles stop to emerge from the
damper unit.
Allow the oil to settle for a few minutes.
Insert filler dipstick (No. 31 6 551) in telescopic fork and draw off excess fork
oil.
Technical data
Level of fork oil in Forks fully 135+2 mm
right fork leg (air compressed −2
chamber) and damper
unit bled,
compression
spring and
spacer bush
removed
Pull damper rod (1) upwards.

Install spacer bush (2) and fork spring (3).

Pull damper rod (1) up with suitable tool until the for cover (2) can be fitted.
Screw fork cover (2) approx. 2 turns onto the damper rod (1).
Pull fork cover (2) with damper rod (2) up to make lock nut (3) accessible
and insert open-end spanner.
Tighten fork cover (2) to stop.
NOTICE
Screw on the fork cover on the damper rod to the stop.

Make sure that the fork cover is not seated against the lock nut before the stop
is reached.
Tighten lock nut (3) while counter-holding fork cover (2) with special wrench
(No. 31 1 532).
Tightening torques
Lock nut (on damper rod) to fork-leg cap
15 Nm
Relieve the pressure on the fork spring (1) with press-down device (B) and
spindle (C) while positioning fork spring (1) on fork cover (2).
Unscrew knurled screws (E) to stop and release mountings (D) from claw
(No. 31 3 718).
Turn back press-down device (B) with spindle (C).
Loosen rubber retainer (2).

Remove fork leg (1) from pre-tensioning tool (No. 31 3 712), checking
locking pin (A).

ATTENTION
Component damage

Push fixed fork tube (2) up and install fork cover (3) with special wrench (No.
31 1 532).
Tightening torques
Cover to fixed fork tube
20 Nm
Turn adjusting screw (1) for rebound-stage damping back to the previously
noted position.
Adjuster for spring preload (2) is not adjusted to the previously noted
preload until after installation of the fork leg.
Install screws (1), but do not tighten.

31 42 524 Replacing seal for right fork leg (fork leg removed)
Preparatory work
Drain the oil from right fork leg
Core activity
(-) Removing seal of fork leg
ATTENTION
Component damage

fork tube (2).

(-) Installing seal of fork leg
Check lower sliding bush (1) and renew as needed.

(3).

fork tube (2).

Check upper sliding bush (1) and renew as needed.

Follow-up work
Pouring oil into right fork leg

31 42 525 Replacing seal for left fork leg (fork leg removed)
Preparatory work
Core activity
(-) Removing seal of fork leg
ATTENTION
Component damage

fork tube (2).

(-) Installing seal of fork leg
Check lower sliding bush (1) and renew as needed.

(3).

fork tube (2).

Check upper sliding bush (1) and renew as needed.

Follow-up work
Pouring oil into left fork leg

31 42 902 Changing fluid in telescopic forks (for maintenance)
Preparatory work
Removing left fork leg
Removing right fork leg
Core activity
(-) Oil change in telescopic forks

(arrow).
ATTENTION
Component damage

on locking pin (A).

spanner.
(No. 31 1 532).
Remove washer (3).
(1).
718).


Do not pull too far up when draining the fork leg fixed fork tube (1) to prevent
upper sliding bush (2) from being pushed out through slider tube (3).
Pouring oil into left fork leg
Technical data
left fork leg Telescopic fork oil (Telescopic fork oil, type 2)
damper unit.

oil.
Technical data
Level of fork oil in left Forks fully 135+2 mm
fork leg (air chamber) compressed −2
and damper
unit bled,
compression
spring and
spacer bush
removed


Install washer (1).

NOTICE
is reached.
(No. 31 1 532).
Tightening torques
15 Nm
Relieve the pressure on fork spring (1) with press-down device (B) and
spindle (C), positioning fork spring (1) and washer (2) on fork lid (3).
(No. 31 3 718).

locking pin (A).

ATTENTION
Component damage
31 1 532).
Tightening torques
20 Nm
Turn adjusting screw (1) for compression-stage damping back to the

previously noted position.

Installing left threaded bush

Insert threaded bush (2) into forkleg (3) until seated and install bolts (1).
Tightening torques
M8 x 35 Tightening
sequence: Tighten
screws six times in
alternate sequence
19 Nm
Drain the oil from right fork leg
Remove screws (1).
Record position of adjusting screw (1) for rebound-stage damping.

Turn adjusting screw (1) for rebound-stage damping into position 1 (arrow).
Turn adjuster (2) for spring preload counter-clockwise up to the stop while
counting and recording rotations.
ATTENTION

Component damage
on locking pin (A).

spanner.
(No. 31 1 532).
(1).
718).


Do not pull too far up when draining the fork leg fixed fork tube (1) to prevent
upper sliding bush (2) from being pushed out through slider tube (3).
Pouring oil into right fork leg
Technical data
right fork leg Telescopic fork oil (Telescopic fork oil, type 2)
damper unit.

oil.
Technical data
Level of fork oil in Forks fully 135+2 mm
right fork leg (air compressed −2
chamber) and damper
unit bled,
compression
spring and
spacer bush
removed


NOTICE
is reached.
(No. 31 1 532).
Tightening torques
15 Nm

Relieve the pressure on the fork spring (1) with press-down device (B) and
spindle (C) while positioning fork spring (1) on fork cover (2).
(No. 31 3 718).

locking pin (A).

ATTENTION
Component damage
31 1 532).
Tightening torques
20 Nm
Turn adjusting screw (1) for rebound-stage damping back to the previously
noted position.
Adjuster for spring preload (2) is not adjusted to the previously noted
preload until after installation of the fork leg.
Install screws (1), but do not tighten.
Follow-up work
Install the right fork leg
Installing left fork leg

32 71 042 Replacing the handlebar weight on the right

+ 32 71 542
Preparatory work
Removing right multifunction switch
Disengaging throttle twistgrip
Core activity
(-) Remove the right handlebar weight
Remove bolt (1) bracing on mounting flats (arrow).

Remove handlebar weight (2).
(-) Installing right handlebar weight
Hold handlebar weight (2) in position.

Install bolt (1) bracing on mounting flats (arrow).
Tightening torques
M8 x 35 19 Nm
Follow-up work
Securing throttle twistgrip
Installing right multifunction switch

32 71 060 Replace clutch lever protector

+ 32 71 560
Preparatory work
Removing screw for grip unit
Core activity
(-) Removing clutch lever protector

Remove clutch lever protector (2) and handlebar weight (3).
(-) Installing clutch lever protector
Install handlebar weight (1) and handbrake lever protector (2) with bolt (3)
hand-tight.
Align brake lever protector (2) with position of brake lever (4).
Tighten bolt (3), bracing on mounting flats (arrow).
Tightening torques
M8 x 40 20 Nm
Follow-up work
Installing screw for grip unit

32 71 061 Replace brake lever protector

+ 32 71 561
Preparatory work
Core activity
(-) Removing the brake lever protector

Remove handbrake lever protector (2) and handlebar weight (3).
(-) Installing the brake lever protector
Install handlebar weight (1) and handbrake lever protector (2) with bolt (3)
hand-tight.
Tightening torques
M8 x 40 20 Nm
Follow-up work

32 71 063 Renewing handlebar weight

+ 32 71 515
Preparatory work
Core activity
(-) Remove the left handlebar weight

(-) Installing left handlebar weight

Tightening torques
M8 x 35 19 Nm
Follow-up work

32 71 150 Removing/installing or replacing handlebar, left

+ 32 71 525
Preparatory work
Remove the left handlebar weight
Core activity
(-) Releasing left handlebar half
Releasing handlebar fitting for clutch
Remove screws (1) and clamp (2).
Remove clutch lever fitting (3) and hang it to the side.
Remove clamping bolt (1), then remove threaded bolt (2).

Release handlebar half (3) complete with grip unit (4).
(-) Removing left handlebar
Remove handlebar half (1) from grip unit (2).

(-) Removing left handlebar
Lubricate damper rubber (arrow).
Installation tool
Push the grip unit (1) onto handlebars (2) while taking care of the damper
rubber (arrow).
(-) Secure left handlebar half
Fit handlebar half (3) complete with grip unit (4).

Install threaded bolt (2), then install clamping bolt (1).
Tightening torques
Securing handlebar fitting for clutch

Position clutch lever fitting (1).
Fit clamp (2) observing mounting orientation: arrow (3) points up.
Align clamp (2) with clutch lever fitting (1) on mark (arrow).
Install screws (4).
Tightening torques
Clutch lever fitting to handlebar
M6 x 20 Tightening
sequence: tighten
top until fully closed
8 Nm
Follow-up work
Installing left handlebar weight

32 71 160 Removing/installing or replacing handlebar, right

+ 32 71 527
Construction status:
December 2020
Preparatory work
Remove the right handlebar weight
Disconnecting cable for throttle grip
Removing throttle grip
Release the handbrake lever fitting
Core activity
(-) Removing right handlebar

Remove handlebar half (3).
(-) Installing right handlebar
Fit handlebar half (3).

Tightening torques
Follow-up work
Securing handbrake lever fitting
Installing throttle grip
Securing cable for throttle grip

Installing right handlebar weight

32 71 160 Removing/installing or replacing handlebar, right

+ 32 71 527
Preparatory work
Core activity
(-) Removing right handlebar

Remove handlebar half (3).
(-) Installing right handlebar
Fit handlebar half (3).

Tightening torques
Follow-up work
Securing handbrake lever fitting
Installing throttle grip

32 72 001 Replacing throttle twistgrip

+ 32 72 620
December 2020
Preparatory work
Core activity
(-) Disconnecting cable for throttle grip
Disconnect connector (1) for throttle grip.

Loosen cable (2) from holder (3).
Remove the cable strap (arrows).

Remove the tensioning strap (2).
Work cable (1) clear to the front.
(-) Removing throttle grip
Remove throttle grip (1).

(-) Installing throttle grip
Install new throttle grip (1) without plug connection.
(-) Securing cable for throttle grip
Route cable (1) and secure with cable strap (arrow) on brake line (3).
Install tensioning straps (2).
If necessary, remove and dispose of old adapter cable.

Connect connector (1) for throttle grip.
Install cable (2) and secure with cable straps (arrows).
Secure the clutch cable (2) in holder (3).
Follow-up work


32 72 001 Replacing throttle twistgrip

+ 32 72 620
Preparatory work
Core activity
(-) Installing throttle grip
Install new throttle grip (1) without plug connection.
(-) Securing cable for throttle grip
Route cable (1) and secure with cable strap (arrow) on brake line (3).

If necessary, remove and dispose of old adapter cable.

Connect connector (1) for throttle grip.
Install cable (2) and secure with cable straps (arrows).
Follow-up work

32 72 070 Replace clutch lever

+ 32 72 627
Preparatory work
Removing the cover for clutch switch
Core activity
(-) Removing clutch lever
Insert adjusting screw (1) and lock nut (2) as far as possible and align in
such a way that all the recesses align with clutch lever fitting (arrow) .
Press release lever (3) forward with a suitable tool and simultaneously feed
clutch cable (4) out of adjusting screw (1), clutch lever fitting (arrow) and
clutch lever (5) and detach.
Remove nut (1) and bolt (2).

Remove clutch lever (3) while noting the switch tongue of clutch switch (4).
(-) Installing clutch lever
Lubricate clutch lever (3) and bolt (2).
Lubricant
Universal lubricant spray 81 22 9 407 711
Insert clutch lever (3), noting switching elements of clutch switch (4).
Install bolt (2) and new nut (1).
Tightening torques
M6, Renew nut Tightening
Thread-locking compound sequence: Tighten
(mechanical) the nut, counter-
holding the bolt

6 Nm
Use suitable tool to push release lever (3) forward attaching clutch cable (4)
in clutch lever (5), clutch lever fitting (arrow) and adjusting screw (1) and
feed in.
Turn back lock nut (2) and adjusting screw (1) again.
(-) Adjusting clutch play
NOTICE
Loosen lock nut (1)and adjust distance (A) using adjusting screw (2).
Technical data
handlebar fitting
lever (1).
Technical data
outer clutch
lever,
handlebars in
straight-
ahead
position, with
cold engine


Follow-up work
Installing the cover for clutch switch

32 72 076 Replacing lever for front-wheel brake

+ 32 72 576
Preparatory work
Core activity
(-) Removing lever for front brake
Remove nut (1), counter-holding screw (2).

Remove bolt (2).
Remove lever (3).
(-) Installing lever for front brake
Lubricate bolt (2) and deflection (arrow).
Lubricant
Teflon spray 83 23 0 154 884
Install lever (3), making sure that pushrod is located (4) in deflection (arrow).
Install bolt (2) and nut (1).
Tightening torques
M6, Screw 1 Nm
holding the bolt
6 Nm
Follow-up work

32 72 078 Replacing brake handlebar fitting for front wheel

+ 32 72 578
Preparatory work
Drain the brake fluid reservoir on handbrake lever fitting
Loosen brake line from brake fitting for front wheel
Core activity
(-) Removing brake fitting for front wheel
Remove bolt (1) with nut (2) and release expansion tank (3).
Remove screws (4) and clamp (5).
Remove brake fitting (6) with expansion tank (3).
(-) Installing brake fitting for front wheel
Position brake fitting (1) with expansion tank (2).

Fit clamp (3) while observing the mounting orientation: UP - arrow points
up.
Align brake fitting (1) with clamp (3) at mark (arrow) and install bolts (4).
Tightening torques
Handbrake fitting to handlebars
M6 x 20 Tightening
sequence: tighten
top until fully closed
8 Nm
Secure expansion tank (2) with bolt (5) and nut (6).
Tightening torques
Expansion tank to bracket
M5 x 18 5 Nm
Follow-up work
Secure brake line to brake fitting for front wheel
Removing reservoir cap
Filling and bleeding brake fitting

32 73 000 Removing/installing or replacing clutch cable

+ 32 73 500
Preparatory work
Removing side panel, right, complete with engine spoiler
Core activity
(-) Removing clutch cable
Slacken adjusting nuts (1) and turn all the way forward.
Back off adjusting nut (2) completely.
Detach and remove clutch cable (3) from lever (4).
Unclip clutch cable (1) from holders (arrows).
Align adjusting nut (1) and lock nut (2) so that all recesses are flush with the
clutch lever fitting (arrow).
Work clutch cable (3) out of adjusting screw (1), clutch lever fitting (arrow)
and clutch lever (4) and detach.
Loosen clutch cable (1) from holder (2).

Work clutch cable (1) out of recess (arrow) of exhaust duct (3) and remove.

(-) Installing clutch cable
Work clutch cable (1) into recess (arrow) of exhaust duct (3).
Work clutch cable (1) into clutch lever (2), clutch lever fitting (arrow) and
adjusting screw (3) and attach.
Clip clutch cable (1) into holders (arrows).

Attach clutch cable (3) in lever (4).
Hand-tighten adjusting nuts (1) and (2).

Follow-up work
Install the side panel, right, complete with engine spoiler

32 76 000 Replacing steering damper

+ 32 76 500
Preparatory work
Core activity
(-) Removing steering damper
Slacken bolts (1) and (2) to last thread starts.

Unscrew bolts (1) and (2) completely and remove together with steering
damper (3), damping discs (4), shouldered bushings (5) and spacers (6).
(-) Installing steering damper
Clean the threads.

Fit steering damper (3) together with bolts (1) and (2), damping discs (4),
shouldered bushing (5) and spacer (6).
Tighten screws (1) and (2).
Tightening torques
encapsulated)
Steering damper to frame
encapsulated)
Follow-up work

33 35 000 Replacing rear wheel swinging arm

+ 33 35 501
Preparatory work
Removing chain guard
Removing rear-wheel cover
Splitting drive chain
Remove the rear wheel
Removing spring strut
Core activity
(-) Removing rear wheel swinging arm
ATTENTION
Component damage
Remove bolt (1) and bush (2).

Disengage attachment rod (3).
Remove rear-wheel stand (No. 36 3 971).
Remove nut (1) and washer (2).

Remove swinging arm axle (3) while supporting the rear wheel swinging arm
(4).
Remove rear wheel swinging arm (4) while working the drive chain (5) free.
(-) Replacing rear wheel swinging arm
Remove expanding rivets (1) and chain slide rail (2).

Install chain slide rail (2) and expanding rivets (1) in new rear wheel
swinging arm.
Remove expanding rivet (1) and chain slide rail (2).

Install chain slide rail (2) and expanding rivet (1) in new rear wheel swinging
arm.
Remove adjusting screws (1) with lock nuts (2) and install in new rear wheel
swinging arm.
Attach badges (3) and (4) on new rear wheel swinging arm.
NOTICE
Faces that will be in contact with the adhesive must be dry, clean and free
from dust and grease.
(-) Installing rear swinging arm
Lubricate swinging arm axle (3).

Lubricant
Optimoly TA 18 21 9 062 599
Clean and lubricate the threads in the frame.
Lubricant
Unirex N3 83 19 2 160 349
Fit rear wheel swinging arm (4) while working in the drive chain (5).
Install swinging arm axle (3).
Tightening torques
Swinging arm axle to frame
M27 x 1.25 Tightening torque,
15 Nm
Loosen, 120°
Tightening torque,
5 Nm
Install nut (1) and washer (2) while counter-holding on swinging arm axle.
Tightening torques
Nut on swinging arm axle
M18 x 1.5, Replace nut 100 Nm
(mechanical)
Install rear-wheel stand (No. 36 3 971).
Position jointed rod (3).

Install the bolt (1) and bush (2) and tighten.
Tightening torques
Pivot strut to rear wheel swinging arm
encapsulated)
Follow-up work
Installing spring strut
Install the rear wheel
Joining drive chain
Installing rear-wheel cover
Installing chain guard
Adjusting chain sag

33 35 001 Replacing swinging-arm bearing

+ 33 35 502
Preparatory work
Removing rear-wheel cover
Removing spring strut
Removing rear wheel swinging arm
Remove the chain slide rail
Core activity
(-) Removing bearing bushes
Remove bearing bushes (1) and thrust washers (2).
(-) Assembling threaded spindle, spreader sleeve and reaction

support
Install threaded spindle (No. 11 6 562) in spreader sleeve (No. 11 6 565).

Install threaded spindle (No. 11 6 562) in reaction support (No. 00 8 562).
(-) Removing right swinging-arm bearing
Lay support ring (No. 36 6 610) on swinging arm (1).

Insert spreader sleeve (a), with flanks behind needles (arrows), into
swinging-arm pivot mount(2).
Pretension spreader sleeve (a) with nut (c).
Pretension reaction support (b).
Remove swinging-arm pivot mount (2) from rear wheel swinging arm (1).
Remove spacer sleeve (1).
(-) Removing left swinging-arm bearing
Lay support ring (No. 36 6 610) on swinging arm (1).

Insert spreader sleeve (a), with flanks behind needles (arrows), into
swinging-arm pivot mount(2).
Pretension spreader sleeve (a) with nut (c).
Pretension reaction support (b).
Remove swinging-arm pivot mount (2) from rear wheel swinging arm (1).
(-) Install the left swinging-arm bearing
Install bearing (1) in bearing seat with labelling (arrow) facing out.
Install long spindle with pull-in nut (No. 36 5 551) washer without thread (No.
36 5 554) and washers with thread (No. 36 5 553):
Washer with thread, dia. 25 mm

Washer without thread, dia. 45 mm
Pull in bearing (1) up to the limit position.
Lubricate camshaft bearing (1).
Lubricant
(-) Install the right swinging-arm bearing
Install spacer sleeve (1).

NOTICE
Outer diameter of spacer sleeve is larger than inner diameter of the swinging-
arm pivot mount.
Install spacer sleeve before installing the second swinging-arm pivot mount.
Install bearing (1) in bearing seat with labelling (arrow) facing out.
Insert bearing (1) into the bearing seat. Install long spindle with pull-in nut
(No. 36 5 551) washer without thread (No. 36 5 554) and washers with
thread (No. 36 5 553):
Washer without thread, dia. 45 mm
Pull in bearing (1) up to the limit position.
Lubricate camshaft bearing (1).
Lubricant
(-) Installing bearing bushes and spacer bush
Check

Check bearing bushes (1) for damage.
Result:
Bearing bushings are damaged.
Measure:
Replace bearing bushings.
Install thrust washers (2).

Lubricate bearing bushes (1) and install.
Lubricant
Follow-up work
Installing chain slide rail
Installing rear swinging arm
Installing spring strut
Installing rear-wheel cover
Adjusting chain sag

33 54 000 Replacing rear spring strut

+ 33 54 500
ATTENTION
Component damage
Preparatory work
Core activity
(-) Removing spring strut

Release rear wheel swinging arm (3) of spring strut (4).
Lower scissor-type lifter until bolt (1) is accessible.

Release spring strut (3) and set it down, making sure that no components
are scratched.
Lift scissor-type lifter until spring strut (1) can be removed.

Remove spring strut (1).

(-) Installing spring strut
Clean the threads.

Install the spring strut (1).
Lower scissor-type lifter ensuring that there are no components with
scratches.
Lower scissor-type lifter until bolt (1) can be installed.

Position spring strut (3).
Install the bolt (1) and bush (2).
Tightening torques
Spring strut at deflection lever
M12 x 75 - 10.9 100 Nm
encapsulated)
Raise scissor-type lifter until bolt (1) can be installed.

Align rear wheel swinging arm (3) and spring strut (4) to each other.
Install the bolt (1) and bush (2).
Tightening torques
Spring strut to swinging arm
encapsulated)
Follow-up work

33 54 002 Removing/installing relay lever

+ 33 54 503
ATTENTION
Component damage
Preparatory work
Removing fuel tank
Releasing brake-fluid reservoir, rear
Disengaging and lifting rear frame
Releasing spring strut
Disengaging link strut
Core activity
(-) Removing relay lever
Remove bolt (1) while counter-holding bearing journal (2).

Remove bearing journal (2).
Remove deflection lever (3).
(-) Removing link strut
Remove screw (1) and bush (2) while counter-supporting pivot strut (4) or
clamping into vice.
Remove pivot strut (3).

(-) Installing link strut
Clean the threads.

Insert pivot strut (1) in deflection lever (2) with BMW badge (arrow) facing
up.
Install screw (3) and bush (4) while counter-supporting pivot strut (2) or
clamping into vice.
Tightening torques
encapsulated)
(-) Installing relay lever
Clean the threads.

Lubricate bearing journal (2).
Lubricant
Optimoly TA 18 21 9 062 599
Fit deflection lever (3).

Install bearing journal (2).
Install bolt (1) while counter-holding bearing journal (2).
Tightening torques
encapsulated)
Follow-up work
Securing link strut
Securing spring strut
Lowering and securing rear frame
Securing rear brake-fluid reservoir


33 54 005 Replacing link strut

+ 33 54 508
ATTENTION
Component damage
Preparatory work
Removing fuel tank
Releasing spring strut
Disengaging link strut
Core activity
(-) Removing relay lever
Remove bolt (1) while counter-holding bearing journal (2).

Remove bearing journal (2).
Remove deflection lever (3).
(-) Removing link strut
Remove screw (1) and bush (2) while counter-supporting pivot strut (4) or
clamping into vice.
Remove pivot strut (3).

(-) Installing link strut
Clean the threads.

Insert pivot strut (1) in deflection lever (2) with BMW badge (arrow) facing
up.
Install screw (3) and bush (4) while counter-supporting pivot strut (2) or
clamping into vice.
Tightening torques
encapsulated)
(-) Installing relay lever
Clean the threads.

Lubricate bearing journal (2).
Lubricant
Optimoly TA 18 21 9 062 599
Fit deflection lever (3).

Install bearing journal (2).
Install bolt (1) while counter-holding bearing journal (2).
Tightening torques
encapsulated)
Follow-up work
Securing link strut
Securing spring strut


33 81 000 Replacing chainset

+ 33 81 500
Preparatory work
Releasing pinion
Core activity
(-) Splitting drive chain
Preassembling chain splitting/joining tool for splitting drive chain with
press-out pin
Insert rivet die (No. 27 1 577) into basic tool (No. 27 1 561).
Insert screw (No. 27 1 562) with press-out pin (No. 27 1 572) into basic tool
(No. 27 1 561).
Secure locator for press-out pin (No. 27 1 573) with bore hole over chain
rivet (1).
Press out chain rivet (1) with press-out pin (No. 27 1 572).
Remove the tool and loosen chain link plates (2).
Take removed chain rivet (1) out of the tool.
(-) Removing drive chain
ATTENTION
Component damage
Remove drive chain (1) from the vehicle.

(-) Remove the rear wheel
Push brake caliper (1) against brake disc (2) to push back the brake piston.
Loosen lock nuts (1) and tensioning screws (2) on the left and right.
Remove nut (1) with washer (2) and slider (3).
Remove quick-release axle (1) with slider (2).

Remove rear wheel (3) and at the same time disengage complete brake
caliper (4) and leave it hanging to the side.

Remove right spacer bush (1).

Remove chain sprocket support (2) with spacer bush (3).
Remove judder damper elements (4).
(-) Removing sprocket
Clamp chain sprocket support (1) in a vice fitted with vice law protectors.
Remove nuts (2).
Remove chain sprocket (3).
(-) Removing pinion
Remove nut (1) and locking washer (2).

Remove pinion (3).
(-) Installing pinion
Install pinion (1), with lower collar (arrow) outwards.

Install new locking washer (2) and nut (3), do not tighten.
(-) Installing sprocket
Place chain sprocket (3) in position.

Install new nuts (2).
Tightening torques
M12 x 1.5 - 10, Renew nut Tightening
Thread-locking compound sequence: tighten in
(mechanical) diagonally opposite
sequence
110 Nm
Remove chain sprocket support (1) from vice.
(-) Install the rear wheel

Lubricate the bearing bushing and radial shaft sealing ring of sprocket
carrier
Remove all dirt and old lubricant from bearing bush (1) and radial shaft seal
(2).
Lubricate bearing bush (1) and radial shaft seal (2) on marked surfaces
(arrows).
Lubricant
Unirex N3 83 19 2 160 349
Check the judder damper elements (4) for damage, deformation and wear,
replace if necessary.
Lubricate and install judder damper elements (4).
Installation tool
Install chain sprocket support (2).

Ensure that the spacer bush (3) is installed.
Install right spacer bush (1).

Install rear wheel (1), so that the brake caliper (2) is set completely with
support and ensure that the support is located in guide (arrow).
Lubricate quick-release axle (3) and install using sliding piece (4).
Lubricant
Optimoly TA 18 21 9 062 599
Install sliding piece (3) and washer (2).

Install nut (1), do not tighten.
(-) Installing drive chain
ATTENTION
Component damage
Feed in drive chain (1), for this place it on chain sprocket (2), feed through
and pull until pinion (3).
(-) Joining drive chain
Position sealing rings (1) on chain joining link (2), thicker sealing bead
(arrow) points to the outer tab of the chain joining link (2).
Insert chain joining link (2).
Install sealing rings (1), thick sealing bead (arrow) facing out.
Position insert (No. 27 1 571) in chain splitting and joining tool (No. 27 1
561).
Position outside tab of chain joining link (1)plate in insert (No. 27 1 575).

Position insert (No. 27 1 575) in thrust screw (No. 27 1 562).
Join chain joining link (1) with insert (No. 27 1 571)and insert (No. 27 1 575).
Tighten thrust screw (No. 27 1 562) until fully tightened.
Back off the thrust screw and remove insert (No. 27 1 575) and insert (No.
27 1 571).
Insert rivet die (No. 27 1 574) in thrust screw (No. 27 1 562).

Position insert with bore (No. 27 1 576) in the chain splitting and joining
tool.
Position insert (No. 27 1 573) with the square head (arrow) on chain joining
link (1).
Press-fit chain joining link (1) with rivet die (No. 27 1 574).
Technical data
Tightening torque for 50 Nm
installing rivets in
chain joining link
Back off thrust screw (No. 27 1 562), turn rivet die (No. 27 1 574) through
90° and again press-fit the rivet.
Back off thrust screw (No. 27 1 562).
Reposition the tool and press-fit the second rivet in the same way.
Remove the tools.
Checking security of drive-chain link

Check
Result:
Pin head not adequately secured.
Measure:
Repeat the process step and seat the pin head more securely.
Check
Result:
Pin head cracked, irregularly flattened or rounded.
Measure:
Remove the chain link and re-join the chain, using a new chain joining link.
Follow-up work
Securing pinion
Adjusting chain sag

33 81 501 Replacing chainset (for maintenance)
Preparatory work
Releasing pinion
Core activity
(-) Splitting drive chain
Preassembling chain splitting/joining tool for splitting drive chain with
press-out pin
Insert rivet die (No. 27 1 577) into basic tool (No. 27 1 561).
Insert screw (No. 27 1 562) with press-out pin (No. 27 1 572) into basic tool
(No. 27 1 561).
Secure locator for press-out pin (No. 27 1 573) with bore hole over chain
rivet (1).
Press out chain rivet (1) with press-out pin (No. 27 1 572).
Remove the tool and loosen chain link plates (2).
Take removed chain rivet (1) out of the tool.
(-) Removing drive chain
ATTENTION
Component damage
Remove drive chain (1) from the vehicle.



(-) Removing sprocket
Clamp chain sprocket support (1) in a vice fitted with vice law protectors.
Remove nuts (2).
(-) Removing pinion
Remove nut (1) and locking washer (2).

Remove pinion (3).
(-) Installing pinion
Install pinion (1), with lower collar (arrow) outwards.

Install new locking washer (2) and nut (3), do not tighten.
(-) Installing sprocket


Tightening torques
sequence
110 Nm

carrier
(2).
(arrows).
Lubricant
Unirex N3 83 19 2 160 349
Installation tool

Lubricate quick-release axle (3) and install using sliding piece (4).
Lubricant
Optimoly TA 18 21 9 062 599

(-) Installing drive chain
ATTENTION
Component damage
Feed in drive chain (1), for this place it on chain sprocket (2), feed through
and pull until pinion (3).
(-) Joining drive chain
Position sealing rings (1) on chain joining link (2), thicker sealing bead
(arrow) points to the outer tab of the chain joining link (2).
Insert chain joining link (2).
Install sealing rings (1), thick sealing bead (arrow) facing out.
Position insert (No. 27 1 571) in chain splitting and joining tool (No. 27 1
561).
Position outside tab of chain joining link (1)plate in insert (No. 27 1 575).
Position insert (No. 27 1 575) in thrust screw (No. 27 1 562).
Join chain joining link (1) with insert (No. 27 1 571)and insert (No. 27 1 575).
Tighten thrust screw (No. 27 1 562) until fully tightened.

Back off the thrust screw and remove insert (No. 27 1 575) and insert (No.
27 1 571).
Insert rivet die (No. 27 1 574) in thrust screw (No. 27 1 562).

Position insert with bore (No. 27 1 576) in the chain splitting and joining
tool.
Position insert (No. 27 1 573) with the square head (arrow) on chain joining
link (1).
Press-fit chain joining link (1) with rivet die (No. 27 1 574).
Technical data
Tightening torque for 50 Nm
installing rivets in
chain joining link
Back off thrust screw (No. 27 1 562), turn rivet die (No. 27 1 574) through
90° and again press-fit the rivet.
Back off thrust screw (No. 27 1 562).
Reposition the tool and press-fit the second rivet in the same way.
Remove the tools.
Checking security of drive-chain link
Check
Result:

Pin head not adequately secured.
Measure:
Repeat the process step and seat the pin head more securely.
Check
Result:
Pin head cracked, irregularly flattened or rounded.

Measure:
Remove the chain link and re-join the chain, using a new chain joining link.
Follow-up work
Securing pinion
Adjusting chain sag

33 83 000 Adjusting chain tension

+ 33 83 500
Core activity
(-) Adjusting chain sag
Requirement
Make sure the surface is level and firm and place the motorcycle on its side
stand.
Loosen nut (1).

Release lock nuts (2) on left and right.
ATTENTION
Rear wheel skewed at a slight angle because tensioning screws not
adjusted to same setting
Accelerated wear at rear wheel and chain drive
Make sure that the rear wheel is aligned to track correctly (same scale
reading on both sides of the rear wheel swinging arm).
Adjust chain tension (A) with tensioning screw (3) on left and right, making
sure the toe adjustment (same scale value (4) on both sides of the rear
wheel swinging arm) is correct.
Technical data
Chain deflection Motorcycle 45...50 mm
with no
weight
applied,
supported on
its side stand
Tighten lock nuts (2) on left and right, counter-holding tensioning screws (3).
Tightening torques
M8 19 Nm
Tightening torques
M24 x 1.5 125 Nm
(mechanical)
Follow-up work
Lubricating drive chain

33 85 001 Replacing chain slide rail

+ 33 85 501
Preparatory work
Removing front left footrest plate
Core activity
(-) Remove the chain slide rail
Remove expanding rivet (1).

Lift rear-wheel cover (2) and remove chain slide rail (3).
(-) Installing chain slide rail
Lift rear-wheel cover (2) and install chain slide rail (3).
Install expanding rivet (1).
Follow-up work
Installing front left footrest plate

33 85 005 Replacing radial shaft sealing ring, sprocket carrier

+ 33 85 510
Preparatory work
Core activity
(-) Removing radial shaft sealing ring for sprocket carrier
Remove radial shaft seal (1) using a suitable tool. In doing so, make sure
the chain sprocket support (2) is not damaged. If necessary, cover or mask
off chain sprocket support (2).
(-) Replacing radial shaft sealing ring for sprocket carrier
Fit radial shaft seal (1) with open side (arrow) facing inward.
Install short spindle with pull-in nut (No. 36 5 552) washer without thread dia.
57 (No. 36 5 554) and washer with thread dia. 57 (No. 36 5 553).
Pull radial shaft seal (1) evenly until seated.
Follow-up work
Adjusting chain sag

34 00 010 Change brake fluid in entire system

+ 34 00 504
Preparatory work
Core activity
(-) Changing brake fluid, front, and bleeding brake system
WARNING
Water ingress in the brake fluid due to air humidity
Decrease in the boiling point, formation of vapour bubbles reduces the
effectiveness of the brakes.
Use only fresh brake fluid from an unopened container.
NOTICE
This description applies for brake filling and bleeding units with vacuum
extraction. If other devices are used, comply with the manufacturer's
instructions.
Adjust brake lever (1) to maximum distance through knurled wheel (2).

Remove bolt (1) and remove retaining bracket (2).
ATTENTION
Brake fluid on painted surfaces, plastic and rubber components
Material damage
Do not allow brake fluid to come into contact with painted surfaces, plastic or
rubber components.
Wash components immediately with clear water if required.
Remove the reservoir cap (3) with support disc (4) and gaiter (5).
Draw off the old brake fluid and clean the reservoir.

Release cable (1) for the wheel speed sensor from the holder (arrow).
Remove screws (2).
Remove cable guide (3).

34 00 048 Changing brake fluid, front brakes

+ 34 00 548
Preparatory work
Core activity
(-) Changing brake fluid, front, and bleeding brake system
WARNING
NOTICE
instructions.

ATTENTION
Material damage
rubber components.

Remove screws (2).

34 00 049 Changing brake fluid, rear brakes

+ 34 00 549
Preparatory work
Core activity
(-) Changing brake fluid, rear, and bleeding brake system
WARNING
NOTICE
instructions.
ATTENTION
Material damage
rubber components.
Remove lid (1) while counter-holding expansion tank (2).

Remove support disc (3) and gaiter (4).
Draw off old brake fluid from expansion tank (2) and clean tank.
Activate footbrake lever (1) by approximately half of the lever travel and with
suitable materials fix (arrows) between footbrake lever(1) and footrest plate
(2).
Connect hose (1) from bleeder unit to bleeder screw (2).

Slightly open the bleeder screw (2).
Push brake caliper (3) against brake disc (4), pressing the brake fluid
through hose (1) while doing so.
Piston is pressed back.
Close the bleeder screw (2).

WARNING
Top up with fresh brake fluid level to the MAX mark.
Remove auxiliary materials (arrows) between footbrake lever (1) and

footrest plate(2).
Connect bleeder unit to bleeder screw (1).

WARNING
Diminished braking effect
Ingress of air into brake system
The outlet hole must always be covered with brake fluid, top up brake fluid if
required.
Draw off brake fluid from the brake system until it is seen that new brake
fluid exits or the required amount of fluid has passed through.
Technical data
Amount of liquid for around three fillings
changing/bleeding of brake fluid
the brake system reservoir
End vacuum extraction.
WARNING

Air bubbles difficult to recognise in brake fluid drawn off by vacuum
extraction
Braking power is reduced due to insufficient brake system bleeding.
In the final step, bleed the system manually (without vacuum extraction) until
the fluid emerging is bubble-free.
Connect vent hose (1) to bleeder screw (2) and route upwards.
Rising air bubbles can be observed in a better way.
Operate footbrake lever till pressure point and open bleeder screw (2) for a
short time.
Press down footbrake lever till limit position and close bleeder screw (2).
NOTICE
Always open bleeder screw wide and pull through lever wide in order to
increase the flow rate of the brake fluid.
Operate footbrake lever until a pressure point can be traced and bleed
again.
Repeat the process until no air bubbles (arrow) escape and a clearly
noticeable pressure point is reached with the bleeder screw (2) closed.
Tighten bleeder screw (2).
Tightening torques
M10 14 Nm
Top up the brake fluid level to the MAX mark.
Clean all components and tank edge.

Insert gaiter (4) and support disc (3).
Install lid (1) while counter-holding expansion tank (2).
Check
Check brake pressure by operating the brakes.

Result:
Low brake pressure

Measure:
Repeat the brake-bleeding process.
Follow-up work

34 00 514 Bleeding rear brake system (for replacing component)
Core activity
(-) Bleeding brake system
WARNING
Hydraulic fluid
Brake fluid, DOT4
During the bleeding procedure, make sure that the brake fluid level does not
fall below the MIN minimum mark and top up the brake fluid if necessary.
Operate the footbrake lever several times until the brake pads are bedded.
Connect vent hose (1) to bleeder screw (2).
Route vent hose (1) up.
Rising air bubbles (arrow) can be observed better in this way.
short time.
Press down footbrake lever till limit position and close bleeder screw (2).
NOTICE
again.
Activate footbrake lever (1) by approximately half of the lever travel and with
suitable materials fix (arrows) between footbrake lever(1) and footrest plate
(2).

Push brake caliper (3) against brake disc (4), pressing the brake fluid
through hose (1) while doing so.

Tightening torques
M10 14 Nm
Remove auxiliary materials (arrows) between footbrake lever (1) and

footrest plate(2).
Operate the footbrake lever (1) several times until seated on the brake pads.
Top up the brake fluid level to the MAX mark.

Install cap (1) while counter-holding expansion tank (2).
Check
Perform a functional check of the brake system.

Result:
Low brake pressure
Measure:


34 00 515 Bleeding front brake system (for replacing component)
Core activity
(-) Filling/bleeding front brake system
Insert reset tool (No. 34 1 531) in both brake callipers.

Push back the brake pistons.
Turn the handlebars to a position in which the brake fluid tank (1) is
horizontal.
WARNING
Top up with fresh brake fluid to the MAX mark (arrow).
Hydraulic fluid
Brake fluid, DOT4
Connect the bleeder unit to bleeder screw (1) on the left brake calliper.
Slightly open the bleed screw.
WARNING
required.
Continue bleeding the brake system until fresh brake fluid emerges.
Close the bleed screw in the left brake calliper.
Connect the bleeder unit to bleeder screw (1) on right brake calliper.
Close the bleed screw in the right brake calliper.

Connect the bleeder unit to bleeder screw (1) in the handbrake cylinder.
Continue drawing off the brake system until the fresh brake fluid emerges
clear and free from bubbles.
Remove reset tool (No. 34 1 531) from both brake callipers.
Installing front brake pads

Check spring (1) for correct fit.
The lugs (arrow) point in direction of rotation of the front wheel.
Install brake pads (3).

Check locking pins (2) before installation; replace attachment set as needed:
Damage, such as grooves

Wear
Corrosion
Install locking pins (2).
Install circlips (1).
Install brake pads on the right brake calliper in the same way.

Position brake calliper (4).
Position the cable routing (3) and install screws (2).
Tightening torques
M10 x 65 38 Nm
Secure the cable (1) in the holder (arrow).

Install screws (1).
Tightening torques
M10 x 65 38 Nm
WARNING
extraction
Connect vent hose (1) to bleeder screw (2) on the handbrake cylinder and
route it to the top.
WARNING

required.
Operate brake lever several times until a pressure point can be perceived.
Operate brake lever till the pressure point and open bleeder screw (2) for a
short time.
Pull brake lever till the grip and close bleeder screw (2).
Release the brake lever.
Tightening torques
M7 5 Nm
Connect vent hose (1) to bleeder screw (2) on the left brake calliper and
Operate brake lever several times until a pressure point can be felt.
short time.
NOTICE

Tightening torques
M6 6 Nm
Connect vent hose (1) to bleeder screw (2) on the left brake calliper and
short time.
NOTICE


Tightening torques
M6 6 Nm
Top up brake fluid tank (1) to the MAX mark (arrow).
Hydraulic fluid
Brake fluid, DOT4
Clean the rim of the reservoir.

Clean and install gaiter (5), support disc (4) and reservoir cap (3).
Install retaining bracket (2) and bolt (1).
Place the motorcycle on its side stand.
Hold the handlebars in the straight-ahead position.
Check

Result:
Low brake pressure
Measure:
Repeat the brake bleeding procedure without removing the brake pads.

34 00 583 Draining/filling/bleeding front brake system
NOTICE
instructions.
Core activity
(-) Drain the front brake system

ATTENTION
Material damage
rubber components.

Remove screws (2).
Disengage brake caliper (4) and allow it to dangle to one side.
Remove screws (1).


Removing front brake pads

Remove circlips (1).
Remove (2) locking pins.
Remove brake pads (3).
Remove brake pads on the right brake calliper in the same way.
Insert reset tool (No. 34 1 531) in both brake callipers.

Push back the brake pistons.
Draw off the backflow brake fluid and clean brake fluid tank (1).
Connect the bleeder unit to bleeder screw (1) on the left brake calliper.

Draw off brake fluid until it ceases to emerge.
Close the bleed screw in the left brake calliper.
Repeat this procedure at the second brake calliper until the brake system is
completely drained.
(-) Filling/bleeding front brake system
Turn the handlebars to a position in which the brake fluid tank (1) is
horizontal.
WARNING
Top up with fresh brake fluid to the MAX mark (arrow).
Hydraulic fluid
Brake fluid, DOT4
Connect the bleeder unit to bleeder screw (1) in the handbrake cylinder.
Continue drawing off the brake system until the fresh brake fluid emerges
clear and it is free from bubbles.
Connect the bleeder unit to bleeder screw (1) on the left brake caliper.
WARNING
required.
Close the bleed screw in the left brake caliper.
Connect the bleeder unit to bleeder screw (1) on right brake caliper.

Bleed the brake system until new brake fluid escapes or the required
amount of fluid has passed through.
Technical data
Close the bleed screw in the right brake caliper.

Remove reset tool (No. 34 1 531) from both brake calipers.
Installing front brake pads


Wear
Corrosion
Install brake pads on the right brake calliper in the same way.

Tightening torques
M10 x 65 38 Nm

Install screws (1).
Tightening torques
M10 x 65 38 Nm
WARNING
extraction
Connect vent hose (1) to bleeder screw (2) on the handbrake cylinder and
WARNING
required.
Operate brake lever several times until a pressure point can be perceived.
short time.
Tightening torques

M7 5 Nm
Connect vent hose (1) to bleeder screw (2) on the left brake caliper and
short time.
NOTICE

Tightening torques
M6 6 Nm
Connect vent hose (1) to bleeder screw (2) on the left brake caliper and
short time.
NOTICE

Tightening torques
M6 6 Nm
Top up the brake fluid tank (1) to the MAX mark (arrow).
Hydraulic fluid
Brake fluid, DOT4

Clean the rim of the reservoir.

Clean and install gaiter (5), support disc (4) and reservoir cap (3).
Install retaining bracket (2) and bolt (1).
Hold the handlebars in the straight-ahead position.
Check

Result:
Low brake pressure
Measure:
Repeat the brake bleeding procedure without removing the brake pads.

34 00 584 Draining/filling/bleeding rear brake system
NOTICE
instructions.
Core activity
(-) Draining rear brake circuit
ATTENTION
Material damage
rubber components.
Remove lid (1) while counter-holding expansion tank (2).

Remove support disc (3) and gaiter (4).
Draw off the brake fluid from expansion tank (2).
Press the brake calliper (1) against the brake disc (2).
Draw off the brake fluid that has flown back and clean the expansion tank
(1).

Draw off brake fluid until it ceases to emerge.

(-) Filling/bleeding rear brake system
WARNING

WARNING
required.
Draw off brake fluid from the brake system until new brake fluid escapes or
the require amount of fluid has passed through.
Technical data
WARNING
extraction
Connect vent hose (1) to bleeder screw (2) and route upwards.

short time.
Move footbrake lever till limit position and close bleeder screw (2).
NOTICE
again.
Tightening torques
M10 14 Nm

Install cap (1) while counter-holding expansion tank (2).
Check

Result:
Low brake pressure
Measure:

34 11 001 Measuring front brake-disc run-out

+ 34 11 844
Preparatory work
Installing front-wheel stand
Core activity
(-) Check the front brake discs for runout
Requirement
No burrs or scoring on brake disc, brake disc thickness above minimum.
Raise the front wheel clear of the ground so that it can turn freely.
Check
Check the mounts of the brake disc.
Components of the rivet-package mounts (cannot be disassembled):
Washer(1)
Spring washers (2)
Thrust washers (3)
Rivets (4)
Result:
Individual components missing, broken or installed in wrong sequence.

Measure:
Brake-disc runout cannot be measured.
Result:
Brake-disc mounts are OK
Measure:
Measuring brake-disc run-out
Raise the front wheel clear of the ground so that it can turn freely.
Install extension (No. 00 2 504) with clamping pieces (No. 00 2 505) and
(No. 00 2 506).
Seat dial gauge (No. 00 2 510) in clamping piece (No. 00 2 506).
Align dial gauge in such a way that the tip is in contact with the brake disc
close to the outer edge (arrow) and the dial gauge is slightly preloaded.

Check
Set the dial gauge to "0".

Slowly turn the wheel through at least one complete revolution and
observe the dial gauge reading.
The sum of the positive and negative dial-gauge readings is the total run-
out.
Repeat this check on the other brake disc.
Technical data
Brake disc lateral removed, at max 0.1 mm
runout, front outer
diameter,
components
cooled down
installed, at max 0.15 mm
outer
diameter,
components
cooled
Result:
Lateral run-out is excessive.
Measure:
Check positioning of the brake disc/wheel rim.
Check the wheel rim for damage.
If necessary, check the brake disc.
See the "Diagnosis tree, braking torque fluctuations" overview for further
information.
=> 34 11 840, Removing/installing front brake discs (Billed as a separate item)
Follow-up work
Removing front-wheel stand

34 11 002 Replacing front left sealing kit for brake calliper (without bleeding)
+ 34 11 845
CAUTION
Handling harmful operating fluids
Damage to health
Observe safety regulations/safety data sheets, use personal protective
equipment (e.g., gloves, safety goggles) where required.
ATTENTION
Damage to surfaces due to sharp-edged tools
Component damage
Use wooden or plastic tools to remove sealing rings from the brake calliper.
Use plastic or wooden tools to clean the sealing ring grooves.
Preparatory work
Releasing left front brake calliper
Removing front brake pads
Securing the brake lever
Loosening brake line and removing brake calliper on left
Core activity
(-) Removing seals set for brake calliper
Requirement
Thoroughly clean the brake calliper and remove all traces of foreign matter.
Once work has been completed on one side of the brake calliper, the
following operations have to be performed on the other side.
Secure brake piston (1) with cable strap (2).
Position air gun (3) with a suitable rubber adapter (arrow) on the brake line
connection and push the brake pinion (4) out with it.
Perform the following operations on all brake-piston bores:

Remove small sealing ring (1) and large sealing ring (2), taking care not to
damage brake calliper (3).
Clean brake calliper (3) inside.

Cleaner
(-) Installing seals set for brake calliper
ATTENTION
Material damage
rubber components.
Perform the following operations on all brake-piston bores:

Lubricate large sealing ring (1) and small sealing ring (2) lightly with brake
fluid / lubricant provided.
Install large sealing ring (1).
Install small sealing ring (2) with groove (arrow).
Lubricate brake piston (1) with brake fluid and install, noting sealing rings (2)
and (3).
After installation of all brake pistons, clean brake callipers carefully outside
with water and dry without compressed air.
Cover brake line connection in this process.
Follow-up work
Securing brake line to left brake calliper
Release the brake lever
=> Bleeding front brake system (for replacing component)

(Description in item: 34 00 515, Billed as a separate item)

Follow-up work

34 11 060 Replacing front brake caliper (without bleeding brakes)

+ 34 11 560
Preparatory work
=> Draining/filling/bleeding front brake system (Description

in item: 34 00 583, Billed as a separate item)
Core activity
(-) Removing front brake calliper
ATTENTION
Material damage
rubber components.
Loosen holder (3).

Remove banjo bolt (4) with sealing rings (5).
Remove brake line (6).
Remove screws (2) and brake calliper (1).
(-) Installing front brake calliper
ATTENTION
Material damage
rubber components.
Position brake caliper (1) and install screws (2) hand-tight.

Position brake line (6).
Install banjo bolt (4) with new sealing rings (5).
Tightening torques
M10 x 1 24 Nm
Secure holder (3).

Remove screws (2).
Follow-up work

34 11 220 Removing/installing front brake discs

+ 34 11 840
Preparatory work
Core activity
(-) Remove the front left brake disc
Remove screws (1).

Remove the brake disc (2).
(-) Removing front right brake disc
Remove screws (1).

(-) Install the front right brake disc
Clean the threads.

Place brake disc (2) with labelling facing outward onto the wheel rim.
Install screws (1).
Tightening torques
M8 x 27 - 10.9, Renew screw Tightening
Thread-locking compound (micro- sequence: tighten in
encapsulated) diagonally opposite
sequence

19 Nm
(-) Install the front left brake disc
Clean the threads.

Install screws (1).
Tightening torques
sequence
19 Nm
(-) Install the front wheel
Lubricate quick-release axle (2).
Lubricant
Optimoly TA 18 21 9 062 599
ATTENTION
Installation of front wheel not in compliance with correct procedure
Damage to wheel speed sensor
Note the wheel-speed sensor when rolling in the front wheel.
Install the front wheel (3).

Install quick-release axle (2) with hexagon head (No. 36 3 692).
Tightening torques
M24 x 1.5 50 Nm
Tighten screws (1).
Tightening torques
M8 x 35 Tightening
sequence: Tighten
screws six times in
alternate sequence
19 Nm
Follow-up work

34 21 005 Replacing sealing kit for brake calliper (without bleeding)

+ 34 21 505
ATTENTION
Material damage
rubber components.
ATTENTION
Damage to surfaces due to sharp-edged tools
Component damage
Use wooden or plastic tools to remove sealing rings from the brake calliper.
Use plastic or wooden tools to clean the sealing ring grooves.
Preparatory work
Removing rear brake pads
Disengaging rear brake line from brake calliper
Core activity
(-) Removing seals set for brake calliper
Requirement
Thoroughly clean the brake calliper and remove all traces of foreign matter.
CAUTION
Sudden shooting out of brake pistons
Danger of injury
Do not reach into the brake calliper.
Catch brake piston on a padded surface.
Pull off brake calliper (1) from brake-calliper support (2).
CAUTION
Sudden shooting out of a brake piston
Danger of injury
Secure brake piston, e.g. with wooden part.
Catch brake piston on a padded surface.
Insert wooden strip (1) or similar in brake calliper.

Position air gun (2) with a suitable rubber adapter (arrow) on the brake line
connection and push the brake pinion (3) out with it.
Remove small sealing ring (1) and large sealing ring (2), and in doing so, do
not damage the brake cylinder (arrows).
Clean brake cylinder (arrows).
Cleaner
(-) Installing seals set for brake calliper
Lubricate large sealing ring (2) and small sealing ring (1) lightly with brake
fluid / lubricant provided (3).
Install large sealing ring (2).
Install small sealing ring (1) with groove (arrow).
Lubricate brake piston (1) and sealing rings (2) and (3) lightly with brake
fluid / lubricant provided (3).
Install bake piston (1) observing sealing rings (2) and (3).
Push brake piston (1) back completely and remove emerged brake fluid.
Check gaiters (1) and (2), replace if necessary.

Clean and thinly lubricate bolts (3).

Lubricant
Optimoly TA 18 21 9 062 599
Slide brake calliper (4) onto brake-calliper support (5).

Make sure gaiters (1) and (2) are sealing correctly.
Follow-up work
Securing rear brake line to brake calliper
Installing rear brake pads
Adjusting chain sag
=> Bleeding rear brake system (for replacing component)


34 21 031 Measuring rear brake-disc run-out

+ 34 21 774
Preparatory work
Core activity
(-) Checking rear brake disc for run-out
Requirement
No burrs or scoring on brake disc, brake disc thickness above minimum.
Positioning of the brake disc/wheel rim has been checked.
Wheel rim has been checked for damage.
Make sure that clearance from chain tensioner (1) is sufficient; if necessary
adjust the rear wheel and tighten.
Insert dial gauge (No. 00 2 510) with clamping pieces (No. 00 2 505) and
(No. 00 2 506) in rear wheel swinging arm (2).
Align the slightly preloaded dial gauge (No. 00 2 510) with measuring
adapter (No. 34 2 510) in such a way that the measuring adapter is in
contact with the brake disc close to the outer circumference (arrow).
Check
Set the dial gauge to "0".

Slowly turn the wheel through at least one complete revolution and
observe the dial gauge reading.
The sum of the positive and negative dial-gauge readings is the total run-
out.
Technical data
Brake disc lateral removed, at max 0.1 mm
runout, rear outer
diameter,
components
cooled down
installed, at max 0.15 mm
outer
diameter,
components
cooled
Result:
Lateral run-out is excessive.
Measure:
See Service Information No. 03/2011 for further information.
=> 34 21 772, Removing/installing rear brake disc (Billed as a separate item)

Follow-up work

34 21 060 Replacing rear brake caliper (without bleeding brakes)

+ 34 21 560
ATTENTION
Material damage
rubber components.
Preparatory work
=> Draining/filling/bleeding rear brake system (Description in

Removing rear brake pads
Core activity
(-) Replacing rear brake calliper
Remove bleeder screw (1) from brake caliper (2).

Remove screw (3) and holder (4).
Remove bolt (5) and release wheel speed sensor (6).
If no new brake caliper (1) is being used, clean the threads.

Install bleeder screw (2) in new brake caliper (1).
Insert wheel speed sensor (3) in new brake caliper (1).
Install bolt (4).
Tightening torques
encapsulated)
Route cable of wheel speed sensor (3).

Position holder(5) while paying attention to anti-twist lock (arrow) and install
screw (6).

Tightening torques
encapsulated)
Follow-up work
Installing rear brake pads
Adjusting chain sag

34 21 200 Replacing rear brake pads

+ 34 21 769
Preparatory work
Core activity
(-) Removing rear brake pads
Push brake calliper (1) against brake disc (2) to push back the brake piston.
Remove split-pin keeper (3).
Using a suitable tool, drive out locking pin (4) toward the wheel side.
Clean brake calliper (1).
Check locking pin (4) for damage/wear and replace as needed.
(-) Installing rear brake pads

Check locking pin (2) before installation, replace, if necessary:
Wear
Corrosion
Using a suitable tool, drive in retaining pin (2) until seated.
Install the split-pin keeper (3).
Follow-up work

34 21 301 Removing/installing rear brake disc

+ 34 21 772
Preparatory work
Core activity
(-) Removing rear brake disc
Remove screws (1).

(-) Installing rear brake disc
Clean the threads.

Place brake disc (2) with labelling to the outside in position.
Install screws (1).
Tightening torques
M6 x 18, Renew screw Tightening
sequence
8 Nm
Follow-up work
Adjusting chain sag

34 31 002 Replacing footbrake cylinder (without bleeding brakes)

+ 34 31 502
Preparatory work
Emptying the rear brake fluid tank
Disconnect rear hose from expansion tank
Disconnecting brake line from the footbrake cylinder
Core activity
(-) Removing footbrake cylinder
Remove bolt (1) and pressure disc (2).

Remove bolts (3) and release footrest plates (4) completely.
Detach spring (1) and remove.

Unclip locking clip (2) from pushrod (3) and remove it from pushrod (3) and
footbrake lever (4).
Remove bolts (1) and retaining plate (2).

Remove footbrake cylinder (3) while paying attention to the heel guard (4).
(-) Installing footbrake cylinder
Clean thread.

Fit footbrake cylinder (3) and heel guard (4).
Fit retaining plate (2) and install bolts (2).
Tightening torques
encapsulated)
Hold pushrod (3) in position on footbrake lever (4).

Install locking clip (2) and clip in on pushrod (3).
Engage spring (1).
Hold footrest plate (4) in position and install screws (3).
Tightening torques
M8 x 25 19 Nm
Install pressure disc (2) and screw (1).
Tightening torques
M8 x 40 19 Nm
Follow-up work
Secure brake line of footbrake cylinder
Connecting rear hose to expansion tank
=> Bleeding rear brake system (for replacing component)

Adjusting play of footbrake lever

34 32 040 Replacing front brake line to pressure modulator (without bleeding brakes)
+ 34 32 640
December 2020
ATTENTION
Material damage
rubber components.
Preparatory work

Removing fuel tank
Disengaging right cable duct
Removing screw connection on cylinder head
Core activity
(-) Removing front brake line to pressure modulator
Remove the straps (1).

Remove banjo bolt (1) with sealing rings (2)
Release brake line (3) from brake fitting (4) and thread to the rear.

Catch the escaping brake fluid.
Unclip brake line (1) from holders (2) and (3).

Release brake line (3).
Remove screw (1) and release holder (2).

Release brake lines (3) and (4) from holder (2) and remove holder (2).
Unclip brake line (1) from holder (2) between frame (3) and cylinder head (4)
and release to the top.

Cut through brake line (1) in the area shown (arrow) and remove line parts.
(-) Installing front brake line to pressure modulator
Seal off coolant vent hose (1) with hose clip (No. 13 3 010).
Pull off coolant vent hose (1) and work through frame thread through frame
(3) to the rear.
Work new brake line (1) in with line section without coating (arrow) from
the top between frame (2) and throttle valve assembly (3).
Work new brake line (1) further through at engine screw connection (4)
between frame (2) and engine (5) toward the bottom and route.
Work brake line (1) through between frame (2) and cable duct (3) and route.

Position brake line (1) between frame (3) and cylinder head (4) and clip into
holder (2).
Clip brake line (1) in holders (2) and (3).
Secure brake lines (3) and (4) in holder (2).

Tightening torques

Install banjo bolt (2) with new sealing rings (3), noting the torsional stop
(arrow) while doing so.
Tightening torques

M10 x 1 24 Nm
Work coolant vent hose (1) toward the front through the frame (3) and slide
onto connecting branch while aligning recess on lug (arrow).
Remove hose clip (No. 13 3 010) from coolant vent hose (1).
Work brake line (1) toward the front.

Fit brake line (1) with banjo bolt (2) and new sealing rings (3) on brake fitting
(4) while observing the torsional stop (5).
Tighten the banjo bolt (2).
Tightening torques
M10 x 1 24 Nm
Follow-up work
Installing screw connection on cylinder head
Securing right cable duct


34 32 040 Replacing front brake line to pressure modulator (without bleeding brakes)
+ 34 32 640
ATTENTION
Material damage
rubber components.
Preparatory work

Removing fuel tank
Disengaging right cable duct
Removing screw connection on cylinder head
Core activity
(-) Removing front brake line to pressure modulator

Remove banjo bolt (1) with sealing rings (2)
Release brake line (3) from brake fitting (4) and thread to the rear.
Catch the escaping brake fluid.
Unclip brake line (1) from holders (2) and (3).



and release to the top.
Cut through brake line (1) in the area shown (arrow) and remove line parts.

(-) Installing front brake line to pressure modulator
Seal off coolant vent hose (1) with hose clip (No. 13 3 010).
Pull off coolant vent hose (1) and work through frame thread through frame
(3) to the rear.
Work new brake line (1) in with line section without coating (arrow) from
the top between frame (2) and throttle valve assembly (3).
Work new brake line (1) further through at engine screw connection (4)
between frame (2) and engine (5) toward the bottom and route.
Work brake line (1) through between frame (2) and cable duct (3) and route.
holder (2).

Clip brake line (1) in holders (2) and (3).

Tightening torques

Tightening torques
M10 x 1 24 Nm
Work coolant vent hose (1) toward the front through the frame (3) and slide
onto connecting branch while aligning recess on lug (arrow).
Remove hose clip (No. 13 3 010) from coolant vent hose (1).

Work brake line (1) toward the front.

Fit brake line (1) with banjo bolt (2) and new sealing rings (3) on brake fitting
(4) while observing the torsional stop (5).
Tighten the banjo bolt (2).
Tightening torques
M10 x 1 24 Nm
Follow-up work
Installing screw connection on cylinder head
Securing right cable duct

34 32 044 Replacing front brake line from pressure modulator (without bleeding brakes)
+ 34 32 644
ATTENTION
Material damage
rubber components.
Preparatory work

Removing fuel tank
Removing screw connection on crankcase
Core activity
(-) Removing front brake line from pressure modulator



Releasing the front brake line from the brake callipers

Position brake calliper (1) and install screws (2) hand-tight.
Loosen holder (3).
If necessary, catch escaping brake fluid.
Position brake calliper (1) and install screws (2) hand-tight.

Unclip brake line (1) from holder (arrows).

Remove bolt (2) and detach brake line (1).
Unclip brake line (1) from holder (3).
and release to the bottom.

Thread the brake line (1) through in the steering head area between frame
(2) and radiator (3) to the right side.
Thread out brake line (1) together with access lines for brake callipers (4)
and (5) between frame (2) and clutch cable (6) further to the right side.
Cut through brake line (1) in the area of the engine screw connection (2)
(arrow) and remove line parts.
(-) Install the front brake line from pressure modulator
Work new brake line (1) with connection for pressure modulator through to
the rear between frame (2) and engine (3).
Work brake line (1) with line section without coating (arrow) through to the
top at engine screw connection (4) between frame (2) and engine (3) and
route.
Work brake line (1) together with connecting lines for brake callipers (4) and
(5) through between frame (2) and clutch cable (6).
Work brake line (1) through the steering head area without connecting lines
for brake callipers (4) and (5) between frame (2) and radiator (3).

Work connecting cables for brake callipers (4) and (5) through to the front
and install.
holder (2).
Clip brake line (1) in holder (3).

Fit brake line (1) and install bolt (2).
Tightening torques
M6 x 16 8 Nm
Route brake line (1) and clip into holder (arrows).
Securing the front brake line to the brake callipers

Tightening torques
M10 x 1 24 Nm
Remove (2) bolts and release brake calliper (1).

Tightening torques
M10 x 1 24 Nm
Secure holder (3).


Tightening torques

Tightening torques
M10 x 1 24 Nm
Follow-up work
Installing screw connection on crankcase
Securing radiator

34 32 050 Replacing rear brake line to pressure modulator (without bleeding brakes)
+ 34 32 650
ATTENTION
Material damage
rubber components.
Preparatory work

Core activity
(-) Removing rear brake pipe to pressure modulator

Remove banjo bolt (1) with sealing rings (2) and detach brake line (3).
Open holder (1) and unclip brake line (2) from holder (1).
Work brake line (2) clear and remove it.

(-) Install the rear brake line to pressure modulator
Work in and route brake line (2). Make sure that brake line is routed (2)
without tension and cannot chafe.
Clip brake line (2) into holders (1) and close holders (1).

Install banjo bolt (1) with new sealing rings (2). Make sure that brake line (3)
does not turn at the same time.
Tightening torques
M10 x 1 24 Nm

Tightening torques
M10 x 1 24 Nm
Follow-up work

34 32 051 Replacing rear brake line from pressure modulator (without bleeding brakes)
+ 34 32 651
ATTENTION
Material damage
rubber components.
Preparatory work

Core activity
(-) Removing rear brake line from pressure modulator

Lift rear-wheel cover (4) and detach brake line (1) from holders (5).

Open holder (3) and unclip brake line (1) from holder (3).


Remove banjo bolt (1) with sealing rings (2) and detach brake line (3).
Work brake line (3) clear and remove it.
(-) Installing rear brake line from pressure modulator
Work in and route brake line (1). Make sure that brake line (1) is routed free
of strain and cannot chafe.
Tightening torques
M10 x 1 24 Nm

Install banjo bolt (2) with new sealing rings (3). At the same time, observe
the torsional stop (arrow).
Tightening torques
M10 x 1 24 Nm
Lift rear-wheel cover (4) and secure brake line (1) in holders (5).

Clip brake line (1) into holders (3) and close holders (3).
Follow-up work

34 51 011 Replacing pressure modulator (without bleeding/testing software/ programming)

+ 34 51 511
ATTENTION
Material damage
rubber components.
Preparatory work


Disconnecting brake lines from pressure modulator
Core activity
(-) Removing pressure modulator
Press lock (arrow) and fold out retaining clip (1).

Disconnect connector (2) from pressure modulator (3).
Push wiring harness (1) slightly to the side to make access to the right bolt
(2) easier.
Remove screws (2).
Remove pressure modulator (3).
(-) Installing pressure modulator
Fit pressure modulator (3).

Push wiring harness (1) slightly to the side to make access for the right
screw connection easier.
Install screws (2).
Tightening torques
Connect connector (2) to pressure modulator (3).

Close retaining clip (1) completely until lock (arrow) engages.
Follow-up work
Connect the brake lines to pressure modulator

a separate item)

separate item)

35 21 000 Removing/installing or replacing footbrake lever

+ 35 21 531
Preparatory work
Releasing right footrest plate
Core activity
(-) Removing footbrake lever
Disengage spring (1).

Remove locking clip (2).
Remove screw (3) with bearing bush (4).
Remove footbrake lever (5).
(-) Installing footbrake lever
ATTENTION
Damage of the bearing due to lubricants.
Component damage, stiff movement
Lubricants can damage the coating chemically.
Lubricant bind dirt particles and increase the wear by this.
A PTFE-bearing is maintenance free; do not lubricate the bearing.
If necessary clean bearing bush (1) and footbrake lever (2).

Feed footbrake lever (2) into mounting (3) and manoeuvre it into position.
Install bearing bush (1) in footbrake lever (2).
Install bolt (4).
Tightening torques
encapsulated)
Install locking clip (5).

Engage spring (6).
Follow-up work
Secure the right footrest plate
Adjusting play of footbrake lever


36 20 510 Replacing RDC control unit (without checking software/programming)

0530 - Tyre pressure control (RDC)OE
Core activity
(-) Remove the RDC control unit

Remove screws (2).
Remove the RDC control unit
(-) Install the RDC control unit
Hold RDC control unit in position.

Install screws (2).
Tightening torques
RDC control unit to bracket
M5 x 14 2 Nm

Follow-up work
a separate item)

separate item)

36 20 554 Replacing front RDC sensor (tyre removed)

Core activity
(-) Removing RDC sensor
Remove the nut (1).

Remove RDC sensor (2) and valve (3).
(-) Installing RDC sensor
Clean the seat for RDC sensor.
Insert valve (1), RDC sensor (2) and new nut (3).
If necessary, note the distance from the rim flange (arrows) and tighten nut
(3).
Tightening torques
M8, Renew nut 6 Nm
encapsulated)
Follow-up work
Teaching in RDC sensor at control unit

36 20 555 Replacing rear RDC sensor (tyre removed)

Core activity
(-) Removing RDC sensor
Remove the nut (1).

Remove RDC sensor (2) and valve (3).
(-) Installing RDC sensor
If necessary, note the distance from the rim flange (arrows) and tighten nut
(3).
Tightening torques
M8, Renew nut 6 Nm
encapsulated)
Follow-up work
Teaching in RDC sensor at control unit

36 23 001 Replacing wheel-speed sensor, front

+ 36 23 601
Preparatory work
Removing left side panel
Core activity
(-) Removing front wheel-speed sensor

Disconnect plug connection (1) for wheel speed sensor and release.
Disengage cable (2) from retaining clips (3) and holder (4) and guide out.
Remove bolt (1) with suitable tool extension from the right side of the vehicle
and take off cable routing (2).
Release cable (3) from cable routing (4).
Remove bolt (5).
Remove wheel speed sensor (6).
(-) Installing front wheel-speed sensor
Clean the threads.

Insert wheel speed sensor (6) and install screw (5).
Tightening torques
encapsulated)
Lay cable (3) and secure in cable routing (4).

Position cable routing (2) and install screw (1) with suitable tool extension
from the right side of the vehicle.
Tightening torques

M5 x 10 5 Nm
Route cable (2), thread in, and secure in holder (4) and in retaining clips (3).
Secure and connect plug connection (1) for wheel speed sensor.
Follow-up work
Installing left side panel

36 23 002 Replacing wheel-speed sensor, rear

+ 36 23 602
Preparatory work
Core activity
(-) Removing rear wheel-speed sensor

Disconnect and release plug connection (1) of wheel speed sensor.
Thread out the cable (2).

Release cable (1) from holder (2).
ATTENTION
Component damage

Remove bolt (3).
Remove wheel speed sensor (4).
(-) Installing rear wheel-speed sensor
Clean the threads.

Position wheel speed sensor (1).
Install bolt (2).

Tightening torques
encapsulated)
Route the cable from wheel speed sensor (1).

Position holder (3), while taking acre of anti-twist lock (arrow) and install bolt
(4).
Tightening torques
encapsulated)
Route cable (1) and secure in holder (2).

Feed in cable (2).

Secure plug connection (1) for wheel speed sensor and connect.
Follow-up work

36 23 003 Replacing sensor ring, front

+ 36 23 603
Preparatory work
Core activity
(-) Removing front sensor ring
Remove screws (1).

Remove sensor ring (2).
(-) Installing front sensor ring
Fit sensor ring (2).

Install screws (1).
Tightening torques
M5 x 10 5 Nm
Follow-up work

36 23 004 Replacing sensor ring, rear

+ 36 23 604
Preparatory work
Core activity
(-) Removing rear sensor ring
Remove screws (1).

(-) Installing rear sensor ring
Position sensor ring (2).

Install screws (1).
Tightening torques
M5 x 10 5 Nm
Follow-up work
Adjusting chain sag

36 30 300 Removing/installing front wheel

+ 36 30 628
Preparatory work
Core activity
(-) Removing front wheel
ATTENTION
Incorrect gap between sensor ring and wheel speed sensor due to
misaligned threaded bush in front suspension
Damage to wheel speed sensor. ABS malfunction
Left clamp locates the threaded bush; do not loosen or remove this clamp.
Loosen screws (1).

Remove quick-release axle (2) using hexagon head (No. 36 3 692).
ATTENTION
Removal of front wheel not in compliance with correct procedure
Note the wheel-speed sensor when rolling out the front wheel.
Remove front wheel (3).
Lubricant
Optimoly TA 18 21 9 062 599
ATTENTION

Tightening torques
M24 x 1.5 50 Nm
Tighten screws (1).

Tightening torques
M8 x 35 Tightening
sequence: Tighten
screws six times in
alternate sequence
19 Nm
Follow-up work

36 30 320 Removing/installing rear wheel

+ 36 30 629
Preparatory work
Core activity

Remove chain (3) from chain sprocket .



carrier
(2).
(arrows).
Lubricant
Unirex N3 83 19 2 160 349
Installation tool


Place chain (3) over chain sprocket.
Lubricate quick-release axle (4) and install with sliding piece (5).
Lubricant
Optimoly TA 18 21 9 062 599

Follow-up work
Adjusting chain sag

36 30 508 Balancing front wheel (statically) (wheel removed)
Core activity
(-) Statically balancing front wheel
Align balancing jig (No. 36 3 601) by adjusting adjustable feet (1), if

required.
Remove old adhesive weights (2).
Insert balancing shaft (No. 36 5 571) in front wheel and secure it with
tensioning device (No. 36 5 572), making sure that front-wheel bearing is
lightly preloaded.
Place the front wheel on the balancing jig (No. 36 3 601) and allow it to
come to rest.
Clean the attachment points for the adhesive weights.
Affix new adhesive weights (2) opposite the heaviest point of the wheel.
Technical data
Permissible front- max 5 g
wheel imbalance
Balance weight for max 80 g
front wheel
Weights have to be
affixed with one half
on the left and one
half on the right, in
other words centred
on the rim
Repeat the balancing procedure as a check.

36 30 518 Balancing rear wheel (statically) (wheel removed)
Core activity
(-) Statically balancing rear wheel

required.
Insert balancing shaft (No. 36 5 571) into rear wheel and secure it with
tensioner (No. 36 5 572), making sure that the rear-wheel bearing is lightly
preloaded.
Place the rear wheel on the balancing jig (No. 36 3 601) and allow it to come
to rest.
Technical data
Permissible rear- max 5 g
wheel imbalance
rear wheel
Weights have to be
on the left and one
other words centred
on the rim

36 30 601 Replacing rim for front wheel (wheel removed)
Preparatory work
Removing front sensor ring
Core activity
Remove screws (1).

Remove screws (1).

(-) Removing front tyre
ATTENTION
Component damage
Remove the tyre with commercially available tools.
(-) Installing rubber valve
ATTENTION
Component damage
Lubricate new rubber valve (1) and install using a suitable tool.

Care products
(-) Installing front tyre
ATTENTION
Component damage
Use commercially available tools and work to the manufacturer's

specifications to fit the tyres, and make sure that the direction-of-rotation
arrows on tyre and rim point in the same direction.
Manufacturer-specific tyre mark for imbalance must be toward the valve.
Check
Inflate the tyre to test pressure and check the valve for leaks.
Technical data
Wheel valve test 4 bar
pressure
Result:
Valve is leaking.
Measure:
Replace the valve insert.
Result:
Valve is leak tight.

Measure:
Correct the tyre pressure.
Technical data
Tyre pressure, front with cold tyre; 2.5 bar
one-up and
two-up
Install screws (1).
Tightening torques

sequence
19 Nm
Install screws (1).
Tightening torques
sequence
19 Nm
Follow-up work
Installing front sensor ring
Statically balancing front wheel

36 30 611 Replacing rim for rear wheel (wheel removed)
Preparatory work
Removing rear sensor ring
Core activity
Remove screws (1).

(-) Removing rear tyre
ATTENTION
Component damage
(-) Installing rubber valve
ATTENTION
Component damage
Care products
(-) Installing rear tyre
ATTENTION
Component damage


Check
Technical data
pressure
Result:
Valve is leaking.
Measure:
Result:
Valve is.
Measure:
Technical data
Tyre pressure, rear with cold tyre; 2.9 bar
one-up and
two-up
Check the tyre and make sure the line is at a uniform distance from the rim
flange all the way round.
Place brake disc (2) with labelling to the outside in position.

Install screws (1).
Tightening torques
sequence
8 Nm
Follow-up work
Installing rear sensor ring
Statically balancing rear wheel

36 31 851 Renewing front wheel bearing (wheel removed)
ATTENTION
Component damage
Core activity
(-) Remove the left and right shaft sealing rings
Remove left and right shaft sealing ring (1) with a suitable tool.
(-) Removing wheel bearings for front wheel
Remove left and right wheel bearings (1) with reaction support (No. 00 8
562), internal puller (No. 00 8 573) and support ring (No. 31 5 708).
Remove spacing bushing (2).
(-) Installing wheel bearings for front wheel

Fit left wheel bearing (1) on bearing seat. Install long spindle (No. 36 5 551)
with pull-in nut (A), pressure disc without thread (No. 36 5 554) and pressure
discs with thread (No. 36 5 553):
Pressure disc (B) without thread, dia. 47 mm
Pressure disc (C) with thread, dia. 25 mm
Pressure disc (D) with thread, dia. 47 mm
Pull in wheel bearing (1) until seated.
Remove the tools.

Insert long spindle (No. 36 5 551) with pressure disc without thread (No. 36
5 554) and pressure discs with thread (No. 36 5 553) in left wheel bearing
(1):
Pressure disc (E) without thread, dia. 25 mm
Install spacer bush (2).
Spacer bush (2) is centred by pressure disc (C) and rests flat without tilting
on the left wheel bearing (1).
Fit right wheel bearing (3) on bearing seat.
Pull in wheel bearing (3) with pressure disc without thread (No. 36 5 554)
and pull-in nut (A) until seated against spacer bush (2).
Remove the tools.
(-) Installing left and right shaft sealing rings
Install shaft sealing ring (1) on left and right with open side (arrow) facing
inward using suitable tool (2) flush with wheel rim.

36 31 861 Replace wheel bearing for rear wheel (wheel removed)
ATTENTION
Component damage
Core activity
(-) Removing shaft sealing ring and circlip
Remove shaft sealing ring (1) with a suitable tool.

(-) Remove wheel bearing for rear wheel
Remove left and right wheel bearings (1) with reaction support (No. 00 8
562), internal puller (No. 00 8 563) and support ring (No. 36 6 640).
Remove spacing bushing (2).
(-) Installing wheel bearings for rear wheel

Fit right wheel bearing (1) on bearing seat. Install long spindle (No. 36 5
551) with pull-in nut (A), pressure disc without thread (No. 36 5 554) and
pressure discs with thread (No. 36 5 553):
Pull in wheel bearing (1) until seated.
Remove the tools.

Insert long spindle (No. 36 5 551) with pressure disc without thread (No. 36
5 554) and pressure discs with thread (No. 36 5 553) in right wheel bearing
(1):
Pressure disc (E) without thread, dia. 28 mm
Install spacer bush (2).
Spacer bush (2) is centred by pressure disc (C) and rests flat without tilting
on the right wheel bearing (1).
Fit left wheel bearing (3) on bearing seat.
Pull in wheel bearing (3) with pressure disc without thread (No. 36 5 554)
and pull-in nut (A) until seated against spacer bush (2).
Remove the tools.
(-) Install the shaft sealing ring and circlip
Install circlip (1) in groove (2).

Install shaft sealing ring (3), with the open side (arrow) inside, using suitable
tool (4).

36 32 501 Renewing front tyre (wheel removed)
ATTENTION
Component damage
Core activity
(-) Replacing rubber valve
ATTENTION
Re-use of tyre valve
Pressure loss in tyre
When fitting a new tyre, also install a new tyre valve.
Use a suitable tool to remove rubber valve (1).

Care products

Check
Technical data
pressure
Result:
Valve is leaking.
Measure:
Result:
Measure:
Technical data

one-up and
two-up

required.
lightly preloaded.
come to rest.
Technical data
wheel imbalance
front wheel
Weights have to be
on the left and one
other words centred
on the rim

36 32 511 Removing rear tyre (wheel removed)
ATTENTION
Component damage
Core activity
(-) Replacing rubber valve
ATTENTION
Re-use of tyre valve
Pressure loss in tyre
When fitting a new tyre, also install a new tyre valve.

Care products

Check
Technical data
pressure
Result:
Valve is leaking.
Measure:
Result:
Valve is.
Measure:
Technical data

one-up and
two-up

required.
preloaded.
to rest.
Technical data
wheel imbalance
rear wheel
Weights have to be
on the left and one
other words centred
on the rim

Frames - Fairing
Repair Guide
BMW Motorrad
46 51 050 Replacing rear frame

+ 46 51 563
Preparatory work
Removing left rear trim panel
Removing right rear trim panel
Removing centre rear trim panel
Removing number-plate carrier
Removing tail bottom section
Removing bearing support for tail-hump cover/passenger seat
Removing rear carrier
Releasing rear carrier
Core activity
(-) Removing rear frame
Remove screws (1).

Remove the rear frame (2) to the rear.
(-) Replacing rear frame
Transfer the small parts to the new rear frame (1), renew if applicable.
3 x flat nut
Clean the surfaces for adhesion.
NOTICE
Install protective film on rear frame (1).
(-) Installing rear frame

Fit rear frame (2) from the rear and position.
Install screws (1).
Tightening torques
Rear frame to frame
M10 x 35 38 Nm
Follow-up work
Securing rear carrier
Installing rear carrier at rear
Installing bearing support for tail-hump cover/passenger seat
Installing tail bottom section
Installing number-plate carrier
Installing centre rear trim panel
Installing right rear trim panel
Installing left rear trim panel

46 51 120 Removing/installing frame

+ 46 51 575
Preparatory work
Removing fuel tank
Removing windscreen
Removing the air inlet cover
Removing left mirror
Removing right mirror
Remove air inlet with fairing top sections
Removing air duct
Removing front panel carrier
Removing front air intake duct
Remove rear air intake duct
Disconnecting starter motor
Removing carbon canister with tank vent valve
Removing handlebar half and left multifunction switch
Disengaging wiring harness from handlebar, right
Releasing wiring harness for ignition steering lock
Releasing wiring harness
Drain the front brake system
Draining rear brake circuit
Removing rear frame
Removing front suspension
Removing silencer
Removing front right footrest plate
46 51 180 Checking motorcycle with frame- measuring system

+ 46 51 676
Preparatory work
Core activity
(-) Checking vehicle with frame measuring system
Use the frame measuring system recommended by BMW Motorrad.
Follow-up work

46 51 520 Replacing frame (frame removed)
Preparatory work
Removing the brake lines
Core activity
(-) Replacing frame
If necessary, use foil to mask off vehicle identification number (1) on new
frame (2).
Affix type plate (3) at the appropriate position.
Dispose of the old frame in accordance with locally applicable legislation.
Transfer stud bolt (1) to new frame (3).
Tightening torques
Stud bolt for tank fastening to frame
M8 19 Nm
Transfer bolt (2) to new frame (3).
Transfer reusable small parts to new frame (1) or renew.

1 x holder for brake line
1 x holder for brake lines
1 x holder for lockable brake lines
2 x rubber grommet
Follow-up work
Installing outer races for top and bottom steering-head bearings
Removing inner race for bottom steering-head bearing
Installing inner race for bottom steering-head bearing
Install brake line

46 52 510 Removing and installing the rear-wheel stand special tool (motorcycles without centre
stand)
Core activity
(-) Installing rear-wheel stand
Installing adapter in basic stand
Release knurled screw (1) and remove mounting (2) from mounting (No. 36
3 974).
Insert the mounting (No. 36 3 974) in the base stand (No. 36 3 971) and
secure with fuse (3).
Mount the service adapter, rear, (No. 36 3 979) on the swinging arm.
Insert the mounting (No. 36 3 975) in to the base stand (No. 36 3 971),
adjust to suit the width of the swinging arm and secure with bolts (1).
Adjust the rear-wheel stand to the correct height.
Slide the rear-wheel stand under the rear wheel swinging arm and position
on service adapters (No. 36 3 979).
ATTENTION
Vehicle toppling to side
Risk of damage to parts if vehicle topples
Make sure that the vehicle is secured so that it cannot topple sideways.
Hold the motorcycle upright and at the same time press the stand down until
the motorcycle is level and the handle of the rear-wheel stand is on the
ground.
(-) Removing rear-wheel stand
Extend the side stand.

Secure the motorcycle to ensure that it cannot topple and slowly lower the
rear-wheel stand, then remove basic stand (No. 36 3 971) and adapter (No.
36 3 975).
Remove the service adapter (No. 36 3 979) from rear wheel swinging arm.

46 53 000 Removing/installing or replacing side stand

+ 46 53 601
Preparatory work
Disengage the side-stand switch
Core activity
(-) Removing side-stand pivot mount with side stand
CAUTION
Components spring-loaded
Risk of injury caused by flying parts
Carefully relieve and, as applicable, apply spring tension.
Remove tension springs (1) using hook (No. 46 5 721).

Remove screws (2).
Remove side-stand pivot mount using side stand (3).
(-) Removing side stand
Remove bolt (1).

Remove side stand (2) from bearing support (3).
(-) Check the bearing bushing
Check
Check bearing bushes (1) for scoring, damages, etc.

Result:
Bearing bushings are worn.
Measure:
=> 46 53 501, Replacing pivot mount for side stand (side stand removed)
(Billed as a separate item)
(-) Replacing side stand
Install spacer buffer (1) in the new side stand (2).
(-) Installing side stand
ATTENTION
Lubricate side stand (1) and bearing support (2) where marked (arrows).
Lubricant
Unirex N3 83 19 2 160 349
Insert bearing support (2) into side stand (1).

Install the bolt (3) and tighten.
Tightening torques
M10 x 1 35 Nm
(-) Installing side-stand pivot mount with side stand
Clean the threads.

Position the side-stand pivot mount with side stand (3).
Install screws (2).
Tightening torques

encapsulated)
CAUTION
Attach tension springs (1) with hooks (No. 46 5 721).
Follow-up work
Securing side-stand switch

46 53 007 Replacing side stand pivot

+ 46 53 507
Preparatory work
Disengage the side-stand switch
Core activity
(-) Removing side-stand pivot mount with side stand
CAUTION
Remove tension springs (1) using hook (No. 46 5 721).

Remove screws (2).
Remove side-stand pivot mount using side stand (3).
(-) Removing side stand
Remove bolt (1).

Remove side stand (2) from bearing support (3).
(-) Replacing bearing bushing of side stand
Using a suitable tool, remove bearing bushings (1).

Install new bearing bush (1).

(-) Installing side stand
ATTENTION
Lubricate side stand (1) and bearing support (2) where marked (arrows).
Lubricant
Unirex N3 83 19 2 160 349
Insert bearing support (2) into side stand (1).

Install the bolt (3) and tighten.
Tightening torques
M10 x 1 35 Nm
(-) Installing side-stand pivot mount with side stand
Clean the threads.

Position the side-stand pivot mount with side stand (3).
Install screws (2).
Tightening torques
encapsulated)
CAUTION
Attach tension springs (1) with hooks (No. 46 5 721).
Follow-up work
Securing side-stand switch

46 53 501 Replacing pivot mount for side stand (side stand removed)
Core activity
(-) Replacing bearing bushing of side stand
Using a suitable tool, remove bearing bushings (1).

Install new bearing bush (1).

46 61 000 Removing/installing front-wheel cover

+ 46 61 500
NOTICE
During the replacement, any installed reflectors must be re-installed in the
same position.
Preparatory work
Core activity
(-) Removing front-wheel cover
Remove bolts (1) and remove front wheel cover (2).
(-) Install front-wheel cover
Clean the threads.

Insert front-wheel cover (2) and install screws (1).
Tightening torques
encapsulated)
Follow-up work

46 62 000 Replacing rear-wheel cover

+ 46 62 502
Preparatory work
Core activity
(-) Removing rear-wheel cover
Release locator (arrow) of rear-wheel cover (1) and chain guard (2).
Remove expanding rivet (1) and expanding rivet (2).

Remove rear-wheel cover (3).
(-) Installing rear-wheel cover
Install rear-wheel cover (3) and fasten brake line (4) in holders (5) at the
same time.
Install the expanding rivets (2) and (1).
Secure locator (arrow) of rear-wheel cover (1) and chain guard (2).

Follow-up work

46 62 001 Replacing rear carrier

+ 46 62 511
Preparatory work
Removing tail bottom section
Removing bearing support for tail-hump cover/passenger seat
Core activity
(-) Removing rear carrier
Remove cable straps (arrows) and release connectors (1), (2) and (3).
Release connector (1) from rear carrier (2).

Remove screws (3).
Lift rear of rear carrier (2) slightly and pull to the rear and release from tabs
(arrows) at the same time.
Remove rear carrier (2).
(-) Replacing rear carrier, rear
Remove screws (1).

Transfer holder (2) for diagnostic socket and, if necessary, USB charging
socket to new rear carrier (3).
Install screws (1).
Tightening torques
On-board diagnosis connector to rear carrier
Clean the surface for gluing.

NOTICE
Install sign (4) in rear carrier (3).

Transfer the small parts to the new rear carrier (3), change if applicable.
1 x holder for cable tie
2 x retaining clip
2 x flat nut
(-) Installing rear carrier at rear
Fit rear carrier (2) and slide into tabs (arrows).

Position rear carrier (2) and install bolts (3).
Tightening torques
M5 x 20 2 Nm
Secure connector (1) on rear carrier (2).
Position connector (1), (2) and (3) and secure cable straps (arrows).
Follow-up work
Installing bearing support for tail-hump cover/passenger seat
Installing tail bottom section

46 62 016 Removing/installing or replacing rear carrier

+ 46 62 513
Preparatory work
Removing fuel tank
Disconnecting brake lines from pressure modulator
Removing battery
Disengage the rear wiring harness
Core activity
(-) Removing rear carrier
Remove screws (1).

Remove screws (2).
Pivot rear carrier (3) in front to the top and release from journals (arrows) at
the same time.

Remove nuts (1).
Release voltage regulator (2) and set aside.
Remove rear carrier (3).
(-) Replacing rear carrier
Remove screws (1).

Remove pressure modulator (2) from rear carrier (3).
Transfer cap (1) for fuse carrier and holder (2) for voltage regulator to new
rear carrier (3).
Transfer rubber decouplers (4) and spacer bush (5) to new rear carrier (3).
Position pressure modulator (2) in rear carrier (3).

Install screws (1).
Tightening torques
(-) Installing rear carrier
Fit rear carrier (3).

Position voltage regulator (2).
Install nuts (1).
Tightening torques
M6, Renew nut 8 Nm
(mechanical)

Slide rear carrier (1) at rear onto journal (arrows) and pivot forward down
and position at the same time.
Install screws (2).

Tightening torques
Install screws (3).
Tightening torques
M5 x 20 2 Nm
Follow-up work
Securing rear wiring harness
Installing battery
Connect the brake lines to pressure modulator
Filling/bleeding rear brake system
Filling/bleeding front brake system

46 62 050 Renewing number plate carrier

+ 46 62 508
Preparatory work
Core activity
(-) Removing number-plate carrier


Release and disconnect plug connection (1) for left tail lamp from holder (2).
Work the cable (3) out to the rear.

Disconnect plug connection (1) for number plate light and feed out cable (2)
to the rear.

Release and disconnect plug connection (1) for right tail lamp from holder
(2).
46 62 054 Replacing bottom section of tail

+ 46 62 514
Preparatory work
Core activity
(-) Removing tail bottom section
Remove screws (1) and (2).
Remove screws (1).

Pull tail bottom section (2) slightly to the rear while releasing retaining lugs
(arrows).
Remove tail bottom section (2).
(-) Replace the tail bottom section
Remount the small parts over the new tail bottom section (1), replace if
necessary:
2 x slip-in retainer
4 x flat nut
2 x flat nut, thin

(-) Installing tail bottom section
Position tail bottom section (2) while inserting retaining lugs (arrows) in
mountings.
Install screws (1).
Install screws (2), and (1).
Follow-up work

46 63 031 Replacing windscreen

+ 46 63 830
Preparatory work
Core activity
(-) Removing windscreen
Remove screws (1).

Remove windscreen (2) and, if required, remove rubber nuts (3) from air
inlet.
(-) Replacing windscreen
Transfer small parts to the new windscreen (1), change as needed:

4 x rubber nuts
(-) Install the windscreen
Place windscreen (2) in position and insert rubber nuts (3) in air inlet.
Install screws (1).
Tightening torques
M5 x 16 1 Nm
Follow-up work

46 63 059 Replacing front panel carrier

+ 46 63 733
Preparatory work
Removing windscreen
Removing top trim panel, left
Removing top section of fairing, right
Removing the air inlet
Removing air duct
Removing headlight
Removing instrument panel
Releasing fairing bracket
Core activity
(-) Removing front panel carrier
Turn the handlebars all the way to the right.

Bolts (1) are accessible.
Remove screws (1).
Remove front panel carrier (2) to the front, and work fairing bracket (3) with
wiring harnesses (4) and (5) and horn (6) clear.
(-) Replacing front panel carrier
Clean the surfaces for adhesion.

NOTICE
Attach signs on front panel carrier (1).

Transfer small parts to new front panel carrier (1); change as needed.
2 x decoupling element
3 x grommet, small
2 x shouldered bushing
2 x grommet, large

(-) Installing front panel carrier
Clean the threads.

Fit front panel carrier (1) while working through fairing bracket (2) with wiring
harnesses (3) and (4) and horn (5).
Align front panel carrier (1) at stops (arrows).
Turn the handlebars all the way to the right.
Bolting points for bolts (6) are accessible.
Install screws (6).
Tightening torques
Front panel carrier to main frame
encapsulated)
Follow-up work
Securing fairing bracket
Installing instrument panel
Installing headlight
Installing air duct
Installing the air inlet
Installing top section of fairing, right
Install the top section of fairing, left
Installing right mirror
Installing left mirror
Installing air inlet cover
Install the windscreen
Checking headlight beam throw

46 63 189 Replacing top section of fairing, right

+ 46 63 987
Preparatory work
Removing windscreen
Core activity
(-) Removing top section of fairing, right
Remove bolt (1).

Unclip fairing top section (2) from slip-in retainers (arrows) and remove.
(-) Installing top section of fairing, right
Position fairing top section (2) and clip in slip-in retainers (arrows).
Install bolt (1).
Follow-up work

46 63 190 Replacing top section of fairing, left

+ 46 63 986
Preparatory work
Removing windscreen
Core activity
(-) Removing top trim panel, left
Remove bolt (1).

Unclip and remove fairing top section (2) from slip-in retainers (arrows).
(-) Install the top section of fairing, left
Position fairing top section (2) and clip into slip-in retainers (arrows).
Install bolt (1).
Follow-up work

46 63 200 Replacing fuel-tank cover, middle

+ 46 63 860
Preparatory work
Core activity
(-) Removing the centre cover of fuel tank
Remove nuts (1) and screws (2).

Lift centre fuel-tank cover (3) at the edges and release hook and loop tape
(4).
Unclip retaining lugs (5) and remove centre fuel-tank cover (3) noting the
locators (arrows).
(-) Replace the centre cover of fuel tank
Transfer small parts to new cover (1), change as needed:

1 x grommet
2 x hook and loop tape
(-) Installing centre cover of fuel tank
Fit centre fuel tank cover (3), noting locators (arrows).

Clip in retaining lugs (5).
Position centre fuel tank cover (3) and secure hook and loop tape (4).
Install bolt (9 mm collar) (2) and bolts (3 mm collar) (1).
Follow-up work

46 63 204 Replacing fuel-tank cover, left

+ 46 63 704
Preparatory work
Core activity
(-) Removing left cover of fuel tank
Remove screws (1).

Release the left fuel tank cover (1) and unhook fixtures (arrows).
Remove left fuel tank cover (1).
(-) Replacing left cover of fuel tank
Unclip trim (1) from slip-in retainers (arrows) and remove from fuel tank
cover (2).
Remount the small parts on the new fuel tank cover (1), replace if
applicable:

Position trim (1) on fuel tank cover (2) and clip into slip-in retainers (arrow).
(-) Installing left cover of fuel tank
Place left fuel tank cover (1) in position and hook in fixtures (arrows).
Secure fixtures (arrows).

Install screws (1).
Follow-up work

46 63 208 Replacing fuel-tank cover, right

+ 46 63 708
Preparatory work
Core activity
(-) Removing right fuel-tank cover
Remove screws (1).

Release right fuel-tank cover (1) and detach locators (arrows).

Remove right fuel-tank cover (1).
(-) Replacing right cover of fuel tank
Unclip trim (1) from slip-in retainers (arrows) and remove from fuel tank
cover (2).
Transfer small parts to new fuel tank cover (1), change as needed:

Fit trim (1) on fuel tank cover (2) and clip into slip-in retainers (arrows).
(-) Installing right fuel-tank cover
Fit right fuel-tank cover (1) and attach locators (arrows).
Secure locators (arrows).

Install screws (1).
Follow-up work

46 63 307 Replacing rear centre trim panel

+ 46 63 740
Preparatory work
Core activity
(-) Removing centre rear trim panel
Remove screws (1) and (2).
Unclip tabs (1) from cover of fuel tank, bend slightly to the outside and
release centre rear trim panel (2).
Slide centre rear trim panel (2) forwards and unhook lug (arrow).
Remove centre rear trim panel (2).
(-) Replacing rear centre trim panel
Remount the small parts on the new rear trim panel (1), replace if applicable:

(-) Installing centre rear trim panel
Place centre rear trim panel (2) in position and hook in lug (arrow).
Bend tabs (1) of cover of fuel tank slightly to the outside and install centre
rear trim panel (2).
Clip in tabs (1) of cover of fuel tank.
Install screws (3 mm collar) (2).

Follow-up work

46 63 324 Replacing left rear trim panel

+ 46 63 824
Preparatory work
Core activity
(-) Removing left rear trim panel
Remove bolt (1).

Release retaining lug (2), then retaining lugs (3) and finally retaining lugs (4)
and remove rear trim panel (5).
(-) Installing left rear trim panel
Position rear trim panel (1) with retaining lugs (2) and engage.Next, engage
retaining lugs (3) and retaining lug (4) last.
Install bolt (5).
Follow-up work

46 63 333 Replacing side panel, left

+ 46 63 900
Preparatory work
Core activity
(-) Removing left side panel
Remove screws (1).

Remove screws (2).
Release engine spoiler (1) bend downwards slightly and remove bolt (2).
Release fairing side panel (3) from grommets (4), feed out downwards
(arrow) and remove.
(-) Replacing side panel, left
Remove bolt (1).

Unclip fairing side panel (2) from slip-in retainers (arrows) and remove off
top fairing side panel (3).
Remount the small parts on the new fairing side panel (1), replace if
applicable:
1 x spacer buffer
1 x rubber grommet

5 x flat nut
1 x BMW badge
Position fairing side panel (2) on top fairing side panel (3) and clip into slip-in
retainers (arrows).
Install bolt (1).
(-) Installing left side panel
While installing fairing side panel (1) make sure that lug (2) engages in
holder (arrow).
Place fairing side panel (3) in position, feed in at bottom (arrow) and secure
in grommets (4).
Bend engine spoiler (1) slightly downwards and install bolt (2).
Position engine spoiler (1).


Follow-up work

46 63 334 Replacing side panel, right

+ 46 63 901
Preparatory work
Core activity
(-) Removing right side panel
Remove screws (1).

Remove screws (2).
Release engine spoiler (1) and bend slightly down and remove bolt (2).
Release fairing side panel (3) from grommets (4), work clear on the bottom
(arrow) and remove.
(-) Replacing right side panel
Remove bolt (1).

Unclip fairing side panel (2) from slip-in retainers (arrows) and take it off the
fairing side panel at top (3).
Transfer small parts to the new fairing side panel (1), change as needed:
1 x spacer buffer
1 x rubber grommet
5 x flat nut

1 x BMW badge
Fit fairing side panel (2) on top fairing side panel (3) and clip into slip-in
retainers (arrows).
Install bolt (1).
(-) Installing right side panel
When installing fairing side panel (1), make sure that lug (2) engages in
holder (arrow).
Fit fairing side panel (3), work in at bottom (arrow) and secure in grommets
(4).
Bend engine spoiler (1) down slightly and install bolt (2).
Install bolts (3 mm collar) (2).


Follow-up work

46 63 359 Replacing left top side panel

+ 46 63 515
Preparatory work
Core activity
Remove screws (1).

Remove screws (2).
(arrow) and remove.
(-) Replacing left top side panel
Remove bolt (1).

Transfer small parts to the new top fairing side panel (1), change as needed:
1 x flat nut

retainers (arrows).
Install bolt (1).
While installing fairing side panel (1) make sure that lug (2) engages in
holder (arrow).
Place fairing side panel (3) in position, feed in at bottom (arrow) and secure
in grommets (4).
Bend engine spoiler (1) slightly downwards and install bolt (2).


Follow-up work

46 63 360 Replacing the fairing side panel at the top right

+ 46 63 792
Preparatory work
Core activity
Remove screws (1).

Remove screws (2).
(arrow) and remove.
(-) Replace fairing side panel, top right
Remove bolt (1).

1 x flat nut

retainers (arrows).
Install bolt (1).
holder (arrow).
(4).


Follow-up work

46 63 366 Replace engine spoiler, right

+ 46 63 961
Preparatory work
Core activity
(-) Removing right engine spoiler
Remove bolt (1).

Remove bolt (2).
Remove screws (3).
Remove screws (4).
Unclip locator (arrow).
Remove the engine spoiler (5).
(-) Replacing right engine spoiler
Transfer small parts to new engine spoiler (1); change as needed:

2 x rubber grommet
1 x flat nut
(-) Installing right engine spoiler

Clip in locators (arrow).
Install bolt (6 mm collar) (2).
Install screw (without collar) (1).
Follow-up work

46 63 367 Replace engine spoiler, left

+ 46 63 911
Preparatory work
Core activity
(-) Removing left engine spoiler
Remove bolt (1).

Remove bolt (2).
Remove screws (3).
Remove screws (4).
Unclip locator (arrow).
Remove the engine spoiler (5).
(-) Replacing left engine spoiler
Transfer small parts to new engine spoiler (1); change as needed:

2 x rubber grommet
2 x flat nut
(-) Installing left engine spoiler

Clip in locators (arrow).
Install bolt (6 mm collar) (2).
Install screw (without collar) (1).
Follow-up work

46 71 029 Replacing front left footrest

+ 46 71 838
Preparatory work
Core activity
(-) Removing left footrest

Remove bolts (2).
Remove footrest (3) with spring (4).
(-) Install the front left footrest
Clean and lubricate components.
Lubricant
Staburags NBU 30 PTM 07 55 9 056 992
Position footrest (3) with spring (4).

Install bolts (2).
Blocking folding mechanism of footrests (for racetrack)
NOTICE
The mechanism can be blocked to prevent unwanted folding in of the
footrests.
When cornering, rigid footrests facilitate a hard set-down in a steep sloping
position.
Remove circlip (1) and bolts (2).

Remove footrest (3).
Install stud bolt (4).
Install footrest (3).
Install bolts (2) and circlip (1).
Footrest can no longer be folded in.
Install stud bolt (4) on the other side in the same way.

Follow-up work

46 71 060 Replacing front right footrest

+ 46 71 839
Preparatory work
Core activity
(-) Remove the right footrest

Remove bolts (2).
(-) Installing front right footrest
Lubricant
Position footrest (3) with spring (4).

Install bolts (2).
Blocking folding mechanism of footrests (for racetrack)
NOTICE
footrests.
position.


Follow-up work

46 71 200 Replacing front left footplate

+ 46 71 821
Preparatory work
Removing left footrest
Core activity
(-) Removing front left footrest plate
Remove screws (1).

Remove footrest plate (2) together with heel guard (3).
(-) Replacing the front left footrest plate
Remove screws (1).

Transfer heel guard (2) to new footrest plate (3).
Install screws (1).
Tightening torques
Heel deflector, left, to footrest plate
M6 x 20 8 Nm
(-) Installing front left footrest plate
Position footrest plate (2) together with heel guard (3).

Install screws (1).
Tightening torques
M8 x 25 19 Nm
Follow-up work

Install the front left footrest

46 71 204 Replacing front right footplate

+ 46 71 822
Preparatory work
Remove the right footrest
Core activity
(-) Removing front right footrest plate
Remove bolt (1) and pressure disc (2).

Disengaging footbrake lever

Remove spring (1).
Remove screw (2) with bearing bush (3).
Disengage footbrake lever (4).
Remove bolts (1) and take off retaining plate (2).

Remove footbrake cylinder with footbrake lever (3) complete with heel guard
(4) from footrest plate (5).
(-) Replacing front right footrest plate

Transfer spacer sleeve (1) and rubber decoupler (2) to new footrest plate
(3).
(-) Installing front right footrest plate
Position footbrake cylinder with footbrake lever (3) complete with heel guard
(4) on footrest plate (5).
Fit retaining plate (2) and install bolts (1).
Tightening torques
encapsulated)
Securing footbrake lever
Clean thread.
ATTENTION
If necessary clean bearing bush (3) and footbrake lever (4).

Position footbrake lever (4) and install bearing bush (3) in footbrake lever
(4).
Install bolt (2).
Tightening torques
encapsulated)
Install spring (1).
Hold footrest plate (4) in position and install screws (3).
Tightening torques
M8 x 25 19 Nm
Install pressure disc (2) and screw (1).
Tightening torques
M8 x 40 19 Nm
Follow-up work
Installing front right footrest

46 71 208 Replacing rear left foot support

+ 46 71 823
0413 - Two-up riding packageOE
Preparatory work
Core activity
(-) Removing rear left footrest
Remove lock washer (1) and bolts (2).

Remove footrest (3) with guide (4).
(-) Removing rear left footrest bracket
Remove screws (1).

Remove footrest bracket (2).
(-) Installing rear left footrest bracket
Fit footrest bracket (2).

Install screws (1).
Tightening torques
Rear footrest holder to rear frame
M8 x 25 19 Nm

(-) Installing rear left footrest
Lubricate bolt (2).
Lubricant
Install footrest (3) with guide (4).

Install bolts (2) with lock washer (1).
Follow-up work

51 16 044 Replacing left mirror

+ 51 16 554
Preparatory work
Removing windscreen
Core activity
(-) Removing left mirror
Disconnect plug connection (1) for left turn indicator.
Remove nuts (1).

Release mirror (2) and feed out cable (3) for turn indicator.
Remove mirror (2).
(-) Installing left mirror
Position mirror (2) and feed in cable (3) for turn indicator.
Install mirror (2).
Install nuts (1).
Tightening torques
Mirror to front panel carrier
M6, Replace nut 8 Nm
(mechanical)
Connect plug connection (1) for left turn indicator.

Follow-up work

51 25 020 Replacing lock barrel for fuel tank

+ 51 25 591
WARNING
Preparatory work
Core activity
(-) Removing lock barrel for fuel filler cap
Open fuel filler cap (1).

Cover the fuel filler neck.
ATTENTION
Component damage
Push the latching tab (arrow) down using a suitable tool until holes (2) are
aligned.
Secure the latching tab (arrow) using drill (3) into fuel filler cap (1).
Technical data
Drill-bit diameter 2 mm
Turn key (4) to the "Open" position and remove lock barrel (5).
(-) Installing lock barrel for fuel filler cap
Lubricant
MI-Setral-43 N 83 23 2 152 082
Install lock barrel (5) in fuel filler cap (1) in the "Open" position.
The lock barrel (5) sits flush in fuel filler cap (1).
Turn key (4) to the "Closed" position and remove drill (3) from fuel filler cap
(1).
Remove the cover from fuel filler neck and close fuel filler cap (1).
Follow-up work

51 25 041 Replacing ignition switch/steering lock including ring aerial

+ 51 25 606
Preparatory work
Removing top fork bridge
Core activity
(-) Replace ignition steering lock incl. ring aerial
Remove bolt (1).

Remove guide (2) for clutch cable .
Punch-mark shear screws (1) in the centre (arrows).

First pre-drill shear screws (1) with a small drill and then drill them out with
a larger drill.
Technical data
Ignition (Pilot) hole min 10 mm
switch/steering lock - diameter 2 mm
drilling depth for
drilling out tamper- Hole 10 mm
proof shear screws diameter 5 mm
Heat the area around the thread of shear screws (1) without overheating the
ignition steering lock.
Technical data
Release/mating 80 °C
temperature
Remove shear screws (1) with a suitable screw extractor.

Remove ignition steering lock (2).
Transferring lock barrel, steering lock housing

Insert the ignition key (1) and turn it to the ON position.
Push in the retainer (2) by inserting a length of stiff wire (3) or similar as far
to the outside as possible into the hole (arrow).
Pull out lock barrel (4) with ignition key (1).

Lubricant
MI-Setral-43 N 83 23 2 152 082
Use the ignition key (1) to insert the lock barrel (4) in the ON position into the
new steering-lock housing (5).
Push the lock barrel (4) down.
Fuse (2) engages.
Turn the ignition key (1) to the OFF position.
Clean the threads.

Fit ignition steering lock (1) on fork bridge (2).
Install shear screws (3) and tighten until the tool engagement (arrow) tears
off head (4).
Tightening torques
Ignition/steering lock to fork bridge
M8 x 18, Renew screw Tighten bolt until tool
Thread-locking compound (micro- handle shears off.
encapsulated)
Fit guide (2) for clutch cable.

Install bolt (1).
Tightening torques
Guide clip for clutch cable to upper fork bridge
M5 x 16 2 Nm
Follow-up work
Installing top fork bridge

Electrical System
Repair Guide
BMW Motorrad
61 11 013 Wiring-harness repair

+ 61 11 513
Core activity
(-) Installing wiring harness repair kit
Cut out the defective plug or length of cable, if possible making the cut at
some point along a straight run where the wiring harness can be firmly
secured.
Cut the individual cores staggered along the length of a shrink-on hose (1)
so that the repaired points are not beside each other.
Correlate the numbered cores of the repair kit with the corresponding cable
colours of the original plug and cut them back to the appropriate staggered
lengths.
NOTICE
The cables are not colour-coded; instead, they have code numbers to ensure
the universal usability of the repair kits.
Set stripping pliers (No. 61 0 511) to the correct wire diameter.

Use stripping pliers (No. 61 0 511) to strip the ends of the wires.
Slip shrink-on hoses (1) into position.

Insert the ends of the wires into the corresponding crimp connectors (2),
note that insulation and core must both be secured (detail).
Secure crimp connectors (2) with pliers (No. 61 4 342) with crimping head
(No. 61 4 343) to the stripped ends of the wires, noting the cable cross-
section.
Slip shrink-on hose (1) into position over the repair and heat the hose.
Shrink-on hose (1) contracts to a tight fit.
Hot glue (arrows) escapes between shrink-on hose (1) and wire (2).

Wrap fibre-reinforced insulating tape (No. 61 0 631) around the repair.

ATTENTION
Electrical wiring not routed in compliance with correct procedure
Open circuit and chafing
Carefully route electrical wiring correctly.
Make sure that no lines can chafe or are kinked on installation.
Secure the repair to the vehicle.

61 11 100 Removing/installing or replacing main wiring harness

+ 61 11 509
Preparatory work
Removing battery
Removing fuel tank
Removing windscreen
Remove air inlet with fairing top sections
Removing air duct
Removing engine control unit with holder and control unit basic module
Disconnecting starter motor
Disengaging shift assistant
Disengage the rear wiring harness
Releasing front carrier
Releasing cable for voltage regulator
Disengaging wiring harness from handlebar, left
Releasing wiring harness for ignition steering lock
Disengaging wiring harness from handlebar, right
Disengaging cable legs from front panel carrier
Core activity
(-) Remove the wiring harness

ATTENTION
procedure
tab.

connector (2).
Disconnect connector (1) for side-stand switch.

Release cable (2) from holder (arrow) and work clear.

Unlock and disconnect connector (1) for transmission potentiometer.

Disconnect connector (1) for coolant temperature sensor.
Remove cable strap (arrow)

Release cable (1) for alternator and wiring harness (2).
Unlock plug connection (3) for left monitoring oxygen sensor and
disconnect.

Press locks (4) and pull off relay carrier (5) upward from holder (6) and hang
to the side.

Disconnect plug (1) for crankshaft sensor.
Unlock plug connection (1) for left front oxygen sensor and disconnect.

Disconnect connector (1) from knock sensor (2).
Release wiring harness (1) from holder (2) and work clear via engine screw
connection (arrow).

Remove bolt with washer (1) and release grounding cable (2).
Disconnect plug (3) from camshaft sensor (4).

Unlock plug connection (2) for right front oxygen sensor and disconnect.
Release wiring harness (3) from holder (4) and work clear.
Disconnect connector (1) from blind cap (2).
Disconnect plug connection (1) for radiator fan.

Disconnect plug connection (2) for wheel speed sensor.

Release cable (1) from holder (2).

Release wiring harness (3) from holder (4) and work clear between frame (5)
and radiator (6).
Disconnect exhaust duct (1) from lugs (arrows) and work wiring harness (2)
clear.
Remove bolt (1).

Release switching cam sensor (2) with O-ring (3).
Disconnect connector (4) and remove switching cam sensor (2).
ATTENTION
procedure

tab.

connector (2).
Disconnect connectors (1) for switching cam adjusters.

Disconnect connector (2) for direct ignition coils.
Remove bolt (1) and pull servomotor (2) with holder (3) slightly to the rear.
Disconnect connector (4) from servomotor (2).
Release cable (5) from holder (arrow) and work clear.
Remove cable strap (arrow) and disconnect the connector (1).

Unlock plug connection (1) for right monitoring oxygen sensor and
disconnect.
Release wiring harness (2) from holder for cable strap (3).

Working front wiring harness clear

Release cable duct (2) with front wiring harness (3).
Work cable harnesses (4) and (5) with cable duct (2) out from the frame (6).
Working rear wiring harness clear

Remove bolt (1) and expanding rivet (2).
Pull cable duct (3) with wiring harness (4) forward and release cable duct (3)
with retaining lugs (arrows) from frame (5).

Work cable harnesses (1) and (2) clear from rear carrier (3) to the front and
set aside.
Remove wiring harness (1) with cable ducts (2), (3) and (4).

(-) Replacing the wiring harness
Reconnect relay (1) on new wiring harness (2).

Transfer cable ducts (3), (4) and (5) to new wiring harness (2).
(-) Installing wiring harness

housing (2).
is visible

Position wiring harness (1) with cable ducts (2), (3) and (4) and route.
Working in rear wiring harness

Work wiring harnesses (1) and (2) in through rear carrier (3) to the rear and
route.
Fit cable duct (3) with wiring harness (4) and secure with retaining lugs
(arrows) on frame (5) pulling the cable duct (3) to the rear.
Install bolt (1) and expanding rivet (2).
Work in front wiring harness

Work cable harnesses (4) and (5) with cable duct (2) in through the frame
(6).
Position cable duct (2) with front wiring harness (3).
Route the wiring harness (2).

Connect and lock plug connection (1) for right monitoring oxygen sensor.

Position wiring harness (2) on holder for cable strap (3).
Fit connector (1) and secure cable strap (arrow).
Work in cable (1) and secure in holder (arrow).

Pull servomotor (2) with holder (3) slightly to the rear and connect connector
(4) with servomotor (2).
Position servomotor (2) with holder (3) noting anti-twist lock (5).
Install bolt (6).
Tightening torques
M5 x 10 2 Nm

housing (2).
is visible


Connect connectors (1) for switching cam adjusters.

Connect connector (2) for direct ignition coils.

Installation tool

Install switching cam sensor (2) with O-ring (3).
Install bolt (1).
Tightening torques
M6 x 16 5 Nm
Work in wiring harness (2) and attach exhaust duct (1) on lugs (arrows).
Work wiring harness (3) through to the front between frame (5) and radiator
(6) and secure in holder (4).

Route cable (1) and secure in holder (2).
Connect plug connection (2) for wheel speed sensor.

Form excess length of cable into loops and secure cable strap (arrow).
Connect plug connection (1) for radiator fan.
Connect connector (1) to blind cap (2).
Work wiring harness (1) into position and route.

Align wiring harness (1) with white mark (2) on holder (3) and secure.
Secure wiring harness (1) in holder (4).
Connect and lock plug connection (5) for right front oxygen sensor.
Connect plug (3) to camshaft sensor (4).

Position grounding cable (2) and install bolt with washer (1).
Tightening torques
Engine wiring harness (earth) to cylinder head
M5 x 10 5 Nm
Work wiring harness (1) in over engine screw connection (arrow) and route
it.
Secure wiring harness (1) in holder (2).
Connect connector (1) with knock sensor (2).

Connect and lock plug connection (1) for left front oxygen sensor.
Connect connector (1) for crankshaft sensor.


Slide relay carrier (5) onto the holder (6) from the top until locks (4) engage
with an audible click.
Connect and lock plug connection (3) for left monitoring oxygen sensor.
Route wiring harness (2) for side-stand switch and Gear Shift Assistant and
cable (1) for alternator and secure with cable strap (arrow).
Connect connector (1) for coolant temperature sensor.

Connect and lock connector (1) for transmission potentiometer.

Work in cable (2) and secure in holder (arrow).

Connect connector (1) for side-stand switch.

Follow-up work
Securing wiring harnesses on front panel carrier
Secure the wiring harness to handlebar, right
Securing wiring harness for ignition steering lock
Securing wiring harness to handlebar, left
Securing cable for voltage regulator
Securing front carrier
Securing rear wiring harness
Installing chain drop guard
Securing shift assistant
Connecting starter motor
Install the engine control unit with holder and control unit basic module
Installing air duct
Installing air inlet with fairing top sections
Installing battery


61 21 005 No-load current test, complete vehicle

+ 61 21 505
Preparatory work
Core activity
(-) Measuring battery voltage
NOTICE
Battery voltage and standby current can be measured with various devices
(observe respective operating instructions):
Conventional multimeter
BMW Motorrad MBOX (Measurement Box)
ICOM Next
Set expected voltage range on the measuring device (1).

Position gauge tip (2) on positive terminal (3) of the battery and position
gauge tip (4) on negative terminal (5) of the battery.
Enter the measured battery voltage in the measured-data record.
Check
Check the battery voltage.
Result:
Measured battery voltage < 12.5 V.
Measure:
Charge battery fully, note charging date on battery (label).
(-) Idle-current measurement
Requirement
Motorcycle's ignition is switched OFF.
Battery is fully charged.
NOTICE
To prevent activation of the control units, do not disconnect the battery from
the wiring harness. A cable jumper must ensure the current flow when
connecting/disconnecting.
Wait until the ZFE control unit has switched off before starting measurement.
Technical data
60 s
Deactivation delay, if no
Central Vehicle consumers
Electronics are active
Connect cable jumper (1) on the negative terminal of the battery (2) and on
the cable shoe of the wiring harness (3).
This is to prevent a reset of the electronic control units when the battery is
disconnected.
Remove bolt (4) and take off cable (3).
Set ammeter (5) to highest measuring range, connect terminals (6) to

battery negative terminal (2) and cable shoe of the wiring harness (3). It is
very important to check that the cables are correctly connected to the
ammeter and the battery.
Disconnect cable jumper (1) and read current level on scale (7).
Check
Perform two measurements:

with ignition OFF
with ignition switch/steering lock locked
Technical data
permissible standby with/without max 2 mA
current value anti-theft
alarm system
Result:
Ammeter shows a measured current of 0.0 A.

Measure:
Check the fuse in the ammeter; replace if necessary and repeat the
measurement.
Result:
No current or measured value is not shown correctly on the scale.
Measure:
Connect cable jumper (1).

This is to avoid a reset of the electronic control units when the ammeter is
set to the next lowest measuring range.
Set ammeter to the next lower measuring range (5).
Disconnect cable jumper (1) and read current level again.
Result:
Measured current is greater than permissible value.
Measure:
Enter the current in the measured-data record and use the measured-data
record to identify the cause of the fault.
The measured-data record is available in the Service Information No.
59/2005.
Follow-up work

61 21 011 Renewing battery

+ 61 21 522
Preparatory work
Core activity
(-) Removing battery
ATTENTION
Battery not disconnected in accordance with correct procedure
Risk of short-circuit
Always proceed in compliance with the specified disconnection sequence.
Remove bolt (1) and remove wiring harness negative terminal (2) and push
to the front.
Remove screw (3) and take off wiring harness positive terminal (4).
Remove the battery (5).
(-) Recharging battery
Set the BMW Motorrad battery charger to the correct charging

characteristic.
Workshop equipment
BMW Motorrad battery charger (version for Europe without GB)
BMW Motorrad battery charger (GB/AUS/NZL version)
BMW Motorrad battery charger (Japan version)
BMW Motorrad battery charger (USA/CAN version)
Charge new battery with BMW Motorrad battery charger observing
operating instructions.
Note the charge date on the battery (with separate label/tag).
(-) Installing battery
Install the battery (1).

ATTENTION
Battery not connected in accordance with correct procedure
Always proceed in compliance with specified installation sequence.
Position wiring harness positive terminal (2) and install bolt (3).
Tightening torques
M6 x 13,5 5 Nm
Position wiring harness negative terminal (4) and install bolt (5).
Tightening torques
M6 x 13,5 5 Nm
Follow-up work
Evaluation of transport readiness of lithium batteries at service outlets

61 21 019 Charging battery

+ 61 21 523
Preparatory work
Core activity

characteristic.
Workshop equipment
Follow-up work

61 21 502 Replace battery (check for battery)
Core activity
(-) Replacing battery
Dispose of battery in a manner compliant with national regulations.
(-) Evaluation of transport readiness of lithium batteries at service

outlets
NOTICE
Information on hazardous goods, explosives & air freight safety:
https://contenthub.bmwgroup.net/web/gefahrgut_explosivstoffe_luftfrachtsicherheit/gefahrgut
It is necessary to transport a used lithium battery for analytical or disposal

purposes. This lithium-ion based cell modules are classified as hazardous
goods in accordance with UN 38.3 and must only be transported subject to
specific requirements
Batteries with an energy content exceeding 100 Wh are considered as
lithium battery/high-voltage battery.
Corresponds to 12V lithium battery 10Ah
Batteries with energy content of 100 Wh or less are considered as small
batteries.
Corresponds to 12 Vlithium battery 5Ah
Damaged batteries are always considered as hazardous material.
The specially trained person is always responsible for maintaining the

certified transport readiness between determination and transfer of the
battery to disposal / transport companies. For shipment, the influence of the
storage conditions and other possibly occurring events on the established
transport readiness must be taken into account.
Transport in the sense of the Hazardous Goods Law is divided into three
areas:
1. Determination of transport readiness
2. Transport preparation
3. Transport performance
This document contains all necessary information to determine the transport
readiness of a used lithium battery. The transport preparation and
performance is notpart of this document.
For more information, refer to the product information in the ASAP.
NOTICE
Explanation of necessary measures for assuring transport readiness.
The details on how to perform this measure depend on the individual
conditions at the location and are not part of this document. These procedures
must be defined in compliance with the local regulations/laws and adopted in
the valid local work instructions.
Prerequisite from a safety perspective:

The expert is responsible for the certification of transport readiness.
Additionally, compliance with the following specifications for occupational
health and safety is required:
Storage of lithium batteries

This information is available under the product information in the ASAP.

61 31 001 Replacing multi-controller

+ 61 31 950
ATTENTION
Opening of switch unit
Damage to the conductors coated with protective sealing lacquer
Do not separate the top and bottom parts of the switch unit.
Preparatory work
Loosen handlebar on left
removing left grip unit
Core activity
(-) Removing left multifunction switch
Unclip the retaining tabs (arrows).

Remove cover (1).
Disconnect connector (1) for the multifunction switch.

Disconnect connector (2) for the heated grip.

Push up retainer (1).

Remove handlebar grip (2).
(-) Removing multi-controller
Remove screws (1).

Release connector (2) for heated grip.
Remove Multi-controller (3) from grip (4).
(-) Installing multi-controller
Position Multi-Controller (1) over the grip (2), ensuring that the recesses (3)
and retainers (4) engage each other.
Thread the connector (5) for heated grip through Multi-Controller (1).
Position connector (5) for heated grip and install screws (6), ensuring the
routing of grip-heating cable (arrow).
(-) Installing left multifunction switch

Install handlebar grip (1) , and at the same time insert connector (2) for the
heated grip.
Retaining lug (3) engages.
Lubricate the rubber pad (arrow).
Installation tool
Connect connector (2) for the heated grip.

Connect connector (1) for the multifunction switch.
Install the cover (1).

The retaining tabs (arrows) engage.
Follow-up work
Securing left grip unit
Secure left handlebar

61 31 009 Replacing rear ride-height sensor

+ 61 31 959
0223 - Dynamic Damping Control (DDC)OE
Preparatory work
Core activity
(-) Removing height sensor, rear
Remove nut (1), counter-holding on ball stud (2).

Release ball stud (2) with attachment rod.
Remove bolts (3) and release ride height sensor (4).
Disconnect connector (5) from ride height sensor (4) and remove ride height
sensor (4).
(-) Installing height sensor, rear
Clean the threads.

Position ride height sensor (4) and connect connector (5) with ride hide
sensor (4).
Fit ride height sensor (4) and install bolts (3).
Tightening torques
Ride-height sensor to bracket
M5 x 12 5 Nm
Oval-head screw for thermoplastic 2 Nm
plastic
Insert ball stud (2) with attachment rod in ride height sensor (4).
Install nut (1), counter-holding on ball stud (2).
Tightening torques
Ball stud to ride-height sensor
Nut, M6
Ball stud, M6 x 14, Renew ball stud 8 Nm
encapsulated)
Follow-up work

Calibrating ride-height sensor

61 31 012 Replacing actuator rod for rear ride-height sensor

+ 61 31 962
Preparatory work
Core activity
(-) Replacing actuator rod for ride-height sensor
Unclip attachment rod (1) from ball stud (arrows).

Fit new attachment rod (1) and clip in on ball stud (arrows).
Follow-up work

61 31 047 Replace operating facility for intelligent emergency call

+ 61 31 647
06AC - Intelligent emergency callOE
Preparatory work
Core activity
(-) Removing the operating facility for intelligent emergency call

Disconnect and release plug connection (1) for the operating facility.

Release cable (2) and feed out to the top.
Remove bolt (1).

Remove the operating facility for the intelligent emergency call (2).
(-) Installing the operating facility for intelligent emergency call
Position the operating unit for intelligent emergency call (2).

Install bolt (1).

Tightening torques
Switch for intelligent emergency call to adapter
M5 x 22 3 Nm
(mechanical)
Thread in cable (2) and route it down.

Secure the plug connection (1) for operating unit and connect.
Form excess length of cable into loops and secure cable strap (arrow).
Follow-up work

61 31 048 Replace impact sensor for intelligent emergency call

+ 61 31 648
ATTENTION
Component damage
Preparatory work
Removing fuel tank
Disconnecting crash sensor
Core activity
(-) Removing crash sensor
Remove bolt (1) and take off crash sensor (2).
(-) Installing crash sensor
Fit crash sensor (1) and allow lug (arrow) to engage in recess.
Install bolt (2).
Tightening torques
Crash sensor to frame
M6 x 25 8 Nm
Follow-up work
Connecting the crash sensor

61 31 063 Renewing complete multi-function switch on left handlebar

+ 61 31 904
ATTENTION
Opening of switch unit
Damage to the conductors coated with protective sealing lacquer
Do not separate the top and bottom parts of the switch unit.
Preparatory work
Loosen handlebar on left
removing left grip unit
Core activity

Remove cover (1).



(-) Installing left multifunction switch
heated grip.
Installation tool



Follow-up work
Securing left grip unit
Secure left handlebar

61 31 073 Renewing complete multi-function switch on right handlebar

+ 61 31 905
December 2020
Preparatory work
Core activity
(-) Removing right multifunction switch
Remove bolt (1).

Ease cover (2) down slightly until the multifunction switch is open (arrow).
Push cover (2) forward and up to remove, noting retaining tabs (3).
Unclip 2-pin connector (1) with blind cap.

Remove bolt (3).
Remove multifunction switch (4).
(-) Installing right multifunction switch
Hold the multifunction switch (4) in position.

ATTENTION
Screws overtightened past the specified value
Component damage
Tighten the screws only to their specified tightening torque.
Install bolt (3).
Tightening torques

Clip in 2-pin connector (1) with the blind cap.
Position cover (1) and push backwards and down, paying attention to
retaining catches(2).
Push cover (2) until the multifunction switch is closed.
ATTENTION
Component damage
Install bolt (3).
Tightening torques
Follow-up work

61 31 073 Renewing complete multi-function switch on right handlebar

+ 61 31 905
Preparatory work
Core activity
Disconnecting plug for throttle grip
Press top and bottom unlockings (Arrows) and disconnect connector (1) for
throttle grip.
Remove bolt (1).


Remove bolt (3).

ATTENTION

Component damage
Install bolt (3).
Tightening torques

ATTENTION
Component damage
Install bolt (3).
Tightening torques
Connect the plug for throttle grip
Connect the plug connection (1) for throttle grip. Make sure that cable (2) for
the throttle grip is routed in front of brake line(3).
Follow-up work

61 31 295 Removing/installing or replacing clutch switch

+ 61 31 911
Preparatory work
Core activity
(-) Removing clutch switch
Operate clutch lever (1) and fix it with a rubber band.

Remove bolt (3).
Remove clutch switch (4).
(-) Install the clutch switch
Position clutch switch (4).

Install bolt (3).
Tightening torques
Microswitch to clutch lever fitting
M2 x 22 0.3 Nm

Remove the rubber band from clutch lever (1).
Follow-up work

61 31 302 Replacing switch for side stand

+ 61 31 913
Preparatory work
Core activity
(-) Removing side-stand switch
Unlock and disconnect connector (1) for the side-stand switch.

Remove bolt (2).
Remove side-stand switch (3).
(-) Installing side-stand switch
Clean the threads.

Position side-stand switch (1), making sure that switch pin (2) rests in bore
hole (3) of the side stand.
Install bolt (4).
Tightening torques
Side-stand switch to pivot-bearing screw
encapsulated)
Connect the connector (5) for side-stand switch and lock.
Follow-up work

61 34 003 Replace USB-charging interface

+ 61 34 503
04U1 - USB charging interfaceOE
Preparatory work
Core activity
(-) Removing USB charging socket

Remove screws (2) and release the holder (3).
Disconnect plug connection (1).

Remove nut (2) and work USB charging socket (3) clear from holder (4).
(-) Installing USB charging socket
Work USB charging socket (3) into holder (4) and install nut (2) hand-tight.
Connect plug connection (1) for USB charging socket.
Position holder (3) and install screws (2).

Follow-up work

61 35 001 Setting limit for running-in rpm

+ 61 35 502
Preparatory work
Core activity
(-) Setting the running-in rpm with BMW Motorrad diagnosis
system
Set the limit for running-in rpm as follows:

Start the session.
Change to "Vehicle management" operating mode.

Select "Service function" menu.
Select "Activate running-in speed".
Follow the instructions of the diagnosis system, observe the final report.
Terminate the session.
Follow-up work

61 35 002 Replacing angular rate sensor

+ 61 35 652
Preparatory work
Removing fuel tank
Core activity
(-) Removing angular rate sensor

Disconnect plug connection (1) for angular rate sensor.
Remove screws (2) and angular rate sensor (3).
(-) Installing angular rate sensor
Position angular rate sensor (3) and install screws (2).
Tightening torques
Rotational speed sensor to frame
M6 x 20 8 Nm
Connect plug connection (1) for the angular rate sensor.

Follow-up work


61 35 003 Replacing control unit for electronic suspension adjustment

+ 61 35 655
Preparatory work
Removing fuel tank
Core activity
(-) Removing control unit for electronic suspension adjustment
Remove O-ring (1) and release control unit (2).

Disconnect connector (3) from control unit (2).
Remove the control unit (2).
(-) Install the control unit for electronic suspension adjustment
Connect connector (1) to the control unit (2).

Fit control unit (2) and install O-ring (3) noting locators (arrows).
Check that wiring harness (1) is routed with distance to crankcase (2).

Follow-up work

61 35 012 Setting calendar date

+ 61 35 506
Preparatory work
Core activity
(-) Restoring date with BMW Motorrad diagnostic system
Select Activities from the menu and call up the Service schedules.
Go to the Read and set service date menu option to calibrate the calendar
date in the vehicle with the calendar date of the BMW Motorrad diagnostic
system.
Follow-up work

61 35 028 Replace control unit for intelligent emergency call (without checking/programming
software)
+ 61 35 528
Preparatory work
Core activity
(-) Removing the control unit for intelligent emergency call
Release control unit (1) from holder (2) and pull out until the connector (3) is
accessible.
Disconnect connector (3) from control unit (1) and remove control unit (1).
(-) Installing the control unit for intelligent emergency call
Position control unit (1) and connect connector (2) to control unit (1).
Insert control unit (1) into holder (3) while noting the fixtures (arrows).
Follow-up work
Logging on to control unit for intelligent emergency call

61 35 505 Setting service-due date and service countdown distance with BMW Motorrad
diagnostic system (for maintenance)
Core activity
(-) Setting the service date and service for remaining distance with
BMW Motorrad diagnosis system
Start diagnosis system and perform the vehicle test.

Select Activities from the menu, call up the Service schedules and set the
service date and the countdown distance.

61 00 002 Testing software

+ 61 00 502
Preparatory work
Core activity
NOTICE
13 V.

NOTICE
instructions.
(-) Checking software
BMW Motorrad Start the diagnosis system.

Read out the software release.
Perform diagnosis. Rectify faults, if found, before starting
programming/coding.
=> Programming control units of vehicle (along with testing software)


Follow-up work


61 00 003 Resetting/learning adaptation values (with replacing component)

+ 61 00 503
Preparatory work
Core activity
NOTICE
13 V.

NOTICE
instructions.
(-) Perform the vehicle test with BMW Motorrad diagnostic system,
read out fault memory and reset adaptation values
NOTICE
When working with the BMW Motorrad diagnostic system, always follow the
instructions it issues.
Perform the vehicle test and read out the fault memory.
Perform all requisite repair work.
Reset the adaptation values.
This is the only way of ensuring correct operation of the vehicle.


Follow-up work

61 00 510 Programming control units of vehicle (along with testing software)
Core activity
(-) Programming vehicle control unit
Start the programming routine and follow the instructions issued by the
BMW Motorrad diagnostic system.

62 11 199 Replacing instrument cluster (without (testing software/programming)

+ 62 11 510
NOTICE
Preparatory work
Removing windscreen
Core activity
(-) Removing instrument panel
Disconnect connector (1) for instrument cluster.

Remove retaining clips (2).
Removing instrument cluster(3).
(-) Installing instrument panel
Position instrument cluster (3).

Install retaining clips (2).
Connect connector (1) for instrument cluster.
Follow-up work

a separate item)

separate item)

63 12 000 Adjust headlight

+ 63 12 500
Core activity
(-) Checking headlight beam throw
Stop the motorcycle on a smooth, level surface.

Set the spring preload to the basic setting.
Apply the rider's weight to the motorcycle.
Start the engine and check that the headlight setting.
Check
Setting dimensions for headlight:
(a): distance between headlight and vertical surface
(b): height of centre of headlight
(c): distance to light/dark cut-off
Check the setting of beam throw.
Technical data
Distance between 5m
headlight and vertical
surface
For headlight
adjustment
Distance from Chassis and 5 cm
light/dark limit to suspension in
upper edge of low- the basic
beam headlight light- setting and
emitting surface vehicle
subject to a
load of 85 kg
Result:
Headlight beam angle not correct.
Measure:
Correcting headlight beam angle
Adjust the height of the headlight beam throw by turning adjusting screw (1)
for both headlights.

63 12 091 Replacing headlight

+ 63 12 637
Preparatory work
Removing windscreen
Removing top trim panel, left
Removing top section of fairing, right
Removing the air inlet
Removing air duct
Core activity
(-) Removing headlight
Remove bolts (1) with washers (2) and secure headlight (3) from the bottom.
Remove headlight (3) while checking shouldered bushings (4).
(-) Installing headlight
Hold headlight (3) in position. Make sure shouldered bushings (4) are
installed from the bottom.
Install screws (1) with washers (2). While doing so, see that the shouldered
bushings (4) engage in the washers (2).
Tightening torques
Headlight to front panel carrier
M6 x 30 8 Nm
Follow-up work
Installing air duct
Installing the air inlet
Installing top section of fairing, right
Install the top section of fairing, left


63 21 012 Remove/install or replace left rear light completely

+ 63 21 512
Preparatory work
Disengaging number-plate carrier
Core activity
(-) Removing left tail lamp


Work the cable (3) clear and route to the rear.

Remove bolt (1) and nut (2).
Turn tail lamp (3) and detach.
Work cable (4) clear and remove tail lamp (3).
(-) Installing left tail lamp
Work cable (4) in and fit tail lamp (3).

Attach tail lamp (3) and turn into position.
Tightening torques
M6 x 20 3 Nm
Nut, M6
(mechanical)
Close cable straps (arrows).
Guide in and route cable (3).

Connect plug connection (1) for the left tail lamp and secure in holder (2).

Follow-up work
Securing number-plate carrier

63 21 013 Remove/install or replace right rear light completely

+ 63 21 513
Preparatory work
Core activity
(-) Removing rear tail lamp

(2).
Thread cable (1) through under rear trim panel (2).


(-) Installing right tail lamp

Tightening torques
M6 x 20 3 Nm
Nut, M6
(mechanical)
Close the cable strap (arrow).
Work in cable (1) and secure in holders (3).


Connect plug connection (1) for the right tail lamp and secure in holder (2).
Follow-up work

63 23 012 Replacing left rear turn indicator

+ 63 23 501
Preparatory work
Core activity
(-) Removing left tail lamp



(-) Installing left tail lamp

Tightening torques
M6 x 20 3 Nm
Nut, M6
(mechanical)
Close cable straps (arrows).

Connect plug connection (1) for the left tail lamp and secure in holder (2).

Follow-up work

63 23 013 Replacing right rear turn indicator

+ 63 23 510
Preparatory work
Core activity
(-) Removing rear tail lamp

(2).


(-) Installing right tail lamp

Tightening torques
M6 x 20 3 Nm
Nut, M6
(mechanical)
Close the cable strap (arrow).
Work in cable (1) and secure in holders (3).


Connect plug connection (1) for the right tail lamp and secure in holder (2).
Follow-up work

65 75 020 Replace batteries for control unit of anti-theft alarm system

+ 65 75 520
0603 - Anti-theft alarm (DWA)OE
Preparatory work
Core activity
(-) Loosen anti-theft alarm
Release the cable (1) from the holder (arrow).

Press away locks (2) and lift anti-theft alarm (3).
Detach anti-theft alarm (3) from holders (4) and feed out.
(-) Replace batteries of DWA-control unit
Remove screws (1).

Remove the cap (2).
WARNING
Attempt to charge dry batteries.
Heat development and explosion.
Do not attempt to charge dry batteries.
Remove batteries (3) and dispose of them in a manner compliant with

national regulations.
Install new batteries (3).
Install lid (2) with bolts (1).
(-) Secure the anti-theft alarm
Feed-in anti-theft alarm (3) and attach in holders (4).

Press anti-theft alarm down (3) and let the locks engage (2).
Secure the cable (1) in holder (arrow).

Follow-up work

65 75 510 Replacing control unit of anti-theft alarm (without testing software/ programming)
0603 - Anti-theft alarm (DWA)OE
NOTICE
Preparatory work
Core activity
(-) Removing anti-theft alarm
Release the cable (1) from the holder (arrow).

Press locks (2) away and lift anti-theft alarm (3).
Detach anti-theft alarm (3) from holders (4) and feed out.
Disconnect connector (1) and remove anti-theft alarm (2).
(-) Installing anti-theft alarm
Fit anti-theft alarm (2) and connect connector (1).

Work in anti-theft alarm (3) and attach in holders (4).

Push anti-theft alarm (3) down and let locks (2) engage.
Follow-up work

a separate item)

separate item)

Workshop installation instructions
Repair Guide
BMW Motorrad
77 11 010 Installing sports silencer

+ 77 11 510
CAUTION
Hot engine and/or hot exhaust system
Risk of burn injury
Allow engine and exhaust system to cool before starting work.
ATTENTION
Component damage
Preparatory work
Covering rear wheel swinging arm for protection
Core activity
(-) Removing silencer
Slacken nut (1) and release clamp (2).

Remove the screw (3) and shaped washer (4) ( save the components,
they will be reused).
Remove the silencer (5) from the front silencer (6).
(-) Installing sports silencer
ATTENTION
Use of unsuitable cleaning agents
Damage to the surface
Use only a care spray recommended by your authorised BMW Motorrad
dealer and a dry, soft cloth to clean the outside of the sports silencer and the
retaining clip.
NOTICE
The lifespan of the insulating material in the silencer depends on engine
performance and style of riding.
Consult an authorised BMW Motorrad dealer if the silencer becomes louder
or if its external appearance changes.
Note, however, that slight discolouration of the silencer is normal. This
discolouration is caused by the high temperature of the exhaust gas.
Thinly lubricate the inner surface (arrow) of the sports silencer (1).
Lubricant
Optimoly TA 18 21 9 062 599
Connect the sports silencer (1) to the exhaust pipe of the front silencer (2).
Position the shaped washer (3) and install the screw(4), do not tighten.
Tighten the clamp (5) hand-tight.
Align the sports silencer (1).

Tighten clamping collar (2).
Tightening torques
M8 24 Nm
Tightening torques
M8 x 40 19 Nm
Follow-up work
Removing protection form rear wheel swinging arm

77 11 011 Installing sport exhaust system

+ 77 11 511
CAUTION
Hot exhaust system
Risk of burn injury
Preparatory work
Removing fuel tank
Removing silencer
Core activity
(-) Removing exhaust manifold
NOTICE
assembly.
Remove and store bolt (1) and washer (2) (subsequently needed for
reassembly).
Release exhaust manifold (3).

Remove and store nuts (1) (will be reused).

Remove exhaust manifold (2).
Remove exhaust manifold seals (1) and dispose of them correctly.
(-) Transferring oxygen sensors to new exhaust manifold
Remove front oxygen sensors (1).

Remove monitoring oxygen sensors (2).
Lightly lubricate thread of oxygen sensors (1) and (2).
Lubricant
Optimoly TA 18 21 9 062 599
Install oxygen sensors (2) in new exhaust manifold (3).
Tightening torques
M12 x 1.25 25 Nm
(Optimoly TA)
Install front oxygen sensors (1) in new exhaust manifold (3).
Tightening torques
M14 x 1.25 45 Nm
(Optimoly TA)
(-) Installing exhaust manifold
NOTICE
assembly.
Lubricate new seals (1) lightly and install in cylinder head making sure that
tabs (arrows) face up.
Lubricant
Optimoly TA 18 21 9 062 599
Hold exhaust manifold (2) in position.

Install nuts (1).
Tightening torques
M7 14 Nm
Clean thread.
Position exhaust manifold (3).
Install bolt (1) and washer (2).
Tightening torques

encapsulated)
Follow-up work
Securing radiator
Installing sports silencer

77 12 009 Installing chain guard

+ 77 12 509
NOTICE
The two Carbon parts rear wheel cover and chain guard can be installed only
together.
Installation of only one or other of these parts is not possible.
Preparatory work
Core activity
(-) Remove chain guard and rear-wheel cover
Remove bolt (1) and expanding rivet (2) and keep them safely aside, will be
reused.
Loosen locator (arrow) and remove chain guard (3).
Remove expanding rivets (1) and (2) keep them safely aside, will be
reused.
(-) M Installing Carbon rear-wheel cover and chain guard
Position Carbon rear-wheel cover (1) and install expanding rivets (2)
and (3).

Clip holder in (1) on brake line (2).

Secure holder (1) together with brake line (2) on Carbon rear-wheel
cover (3).
Clean thread.
Position Carbon chain guard (1) on Carbon rear-wheel cover (2) and rear
wheel swinging arm (3).
Install screw (5) with plastic washer (6).
Tightening torques
encapsulated)
Follow-up work

77 12 019 Installing carbon pinion cover

+ 77 12 514
Core activity
(-) Removing pinion cover
Remove bolt (1).

Slacken detent pins (arrows) evenly and remove pinion cover (2).
(-) Installing carbon pinion cover
Lubricate detent pins (arrows).
Installation tool
Position Carbon pinion cover (3) and let detent pins (arrows) engage.
Follow-up work

77 14 006 Installing the radiator protection

+ 77 14 506
Preparatory work
Removing air guide for radiator
Core activity
(-) Installing protective grille in air duct
Position protective grille for coolant radiator (1) and protective grille for oil
cooler (2) on radiator air duct (3) (arrows).
Install U clamps (4).
Install grommet (5) in mounting of protective grille for coolant radiator (1).
(-) Installing air duct with radiator protection
Fit air duct with radiator grille guards (2) and secure on left and right in
rubber grommets (arrow).
Install screws (3).
Fasten hoses (1) for tank ventilation to air duct (2).
Follow-up work

77 14 099 Installing engine protector

+ 77 14 599
Preparatory work
Removing right engine housing screws
Removing left engine cover screws
Core activity
(-) Installing right engine guard
Pull clutch cable (1) to the side.

Install screws (3).
Tightening torques
M6 x 45 9 Nm
(-) Installing left engine guard

Install bolts (2), do not tighten yet.
Tighten bolts (1) to (3) in specified sequence.
Tightening torques
M6 x 40 Tightening
sequence: see
installation
instructions
7 Nm

Follow-up work

77 21 004 Installing forged wheels

+ 77 21 504
Preparatory work
=> Removing and installing the rear-wheel stand
special tool (motorcycles without centre stand)
(Description in item: 46 52 510, Billed as a separate
item)
Core activity
(-) Releasing front brake calipers
Release cable (1) for the wheel speed sensor from the holder
(arrow).
Remove screws (2).
Remove screws (1).

ATTENTION
Incorrect gap between sensor ring and wheel speed sensor due
to misaligned threaded bush in front suspension
Left clamp locates the threaded bush; do not loosen or remove this
clamp.
Loosen screws (1).


ATTENTION
ATTENTION
Component damage
(-) Removing front sensor ring
Remove screws (1).

Remove screws (1).


Remove screws (1).

(-) Installing angle valve in forged wheel
Check sealing ring (1) for damage, replace if necessary.

Insert angle valve (2), turned by 90° to the direction of travel, with
sealing ring (1) and install nut (3)
Tightening torques
ATTENTION
Component damage

specifications to fit the tyres, and make sure that the direction-of-
rotation arrows on tyre and rim point in the same direction.
Manufacturer-specific tyre mark for imbalance must be toward the
valve.
Check
Technical data
pressure
Result:
Valve is leaking.
Measure:


Result:
Measure:
Technical data
Tyre pressure, with cold 2.5 bar
front tyre; one-up
and two-up
Place new brake disc (2) with labelling facing outward onto the
wheel rim.
Install bolts (1) and tighten alternating between bolts.
Tightening torques
Cylinder-head screw, M8 x 25 Tightening
sequence: tighten
in diagonally
opposite
sequence
24 Nm
Place new brake disc (2) with labelling facing outward onto the
wheel rim.
Install bolts (1) and tighten alternating between bolts.
Tightening torques
Cylinder-head screw, M8 x 25 Tightening
sequence: tighten
in diagonally
opposite
sequence
24 Nm
(-) Installing front sensor ring

Install screws (1).
Tightening torques
M5 x 10 5 Nm


required.
Insert balancing shaft (No. 36 5 571) in front wheel and secure it
with tensioning device (No. 36 5 572), making sure that front-wheel
bearing is lightly preloaded.
Place the front wheel on the balancing jig (No. 36 3 601) and allow it
to come to rest.
Affix new adhesive weights (2) opposite the heaviest point of the
wheel.
Technical data
wheel imbalance
front wheel
Weights have to be
affixed with one
half on the left and
one half on the
right, in other
words centred on
the rim
Lubricant
Optimoly TA 18 21 9 062 599
ATTENTION
Installation of front wheel not in compliance with correct
procedure



Tightening torques
M24 x 1.5 50 Nm
Tighten screws (1).
Tightening torques
M8 x 35 Tightening
sequence:
Tighten screws
six times in
alternate
sequence
19 Nm
(-) Securing front brake calipers

Tightening torques
M10 x 65 38 Nm

Install screws (1).
Tightening torques
M10 x 65 38 Nm
(-) Removing front-wheel stand

ATTENTION
Make sure that the vehicle is secured so that it cannot topple
sideways.
Raise the front-wheel stand uniformly in order to lower the

motorcycle, and remove front-wheel stand.
Release mounting bolt (1) to move the fixtures (No. 36 3 975) or
remove retaining pins (2), so that the removal is facilitated.
Remove basic stand (No. 36 3 971) with adapters (No. 36 3 975).
Remove adapters for front forks (No. 36 3 976).
Push brake caliper (1) against brake disc (2) to push back the brake
piston.


Remove rear wheel (4) and at the same time disengage complete
brake caliper (5) and leave it hanging to the side.

(-) Removing rear sensor ring
Remove screws (1).


Remove screws (1).

ATTENTION
Component damage
(-) Installing angle valve in forged wheel
Check sealing ring (1) for damage, replace if necessary.

Insert angle valve (2), turned by 90° to the direction of travel, with
sealing ring (1) and install nut (3)
Tightening torques
ATTENTION
Component damage

specifications to fit the tyres, and make sure that the direction-of-
rotation arrows on tyre and rim point in the same direction.
Manufacturer-specific tyre mark for imbalance must be toward the
valve.
Check

Technical data
pressure
Result:
Valve is leaking.
Measure:
Result:
Valve is.
Measure:
Technical data
Tyre pressure, rear with cold 2.9 bar
tyre; one-up
and two-up
Check the tyre and make sure the line is at a uniform distance from
the rim flange all the way round.
Position brake disc (2) with labelling facing out.

Install new screws (1).
Tightening torques
Rear brake disc to forged wheel or Carbon wheel
Thread-locking compound (micro sequence: tighten
-encapsulated) in diagonally
opposite
sequence
8 Nm
(-) Installing rear sensor ring

Install screws (1).
Tightening torques
M5 x 10 5 Nm


required.
Insert balancing shaft (No. 36 5 571) into rear wheel and secure it
with tensioner (No. 36 5 572), making sure that the rear-wheel
bearing is lightly preloaded.
Place the rear wheel on the balancing jig (No. 36 3 601) and allow it
to come to rest.
Affix new adhesive weights (2) opposite the heaviest point of the
wheel.
Technical data
wheel imbalance
rear wheel
Weights have to be
affixed with one
half on the left and
one half on the
right, in other
words centred on
the rim
(-) Transferring chain sprocket to new chain-sprocket

carrier
Clamp chain sprocket support (1) in vice with vice jaw protectors.
Remove nuts (2).
Remove chain sprocket support (1) from vice and clamp new chain
sprocket support (1) in vice.

Tightening torques
Thread-locking compound sequence: tighten
(mechanical) in diagonally
opposite
sequence
110 Nm

Lubricate the bearing bushing and radial shaft sealing ring of
sprocket carrier
Remove all dirt and old lubricant from bearing bush (1) and radial
shaft seal (2).
Lubricate bearing bush (1) and radial shaft seal (2) on marked
surfaces (arrows).
Lubricant
Unirex N3 83 19 2 160 349
Check the judder damper elements (4) for damage, deformation and
wear, replace if necessary.
Installation tool

Install rear wheel (1), so that the brake caliper (2) is set completely
with support and ensure that the support is located in guide (arrow).
Lubricant
Optimoly TA 18 21 9 062 599


ATTENTION
Rear wheel skewed at a slight angle because tensioning screws
not adjusted to same setting
Make sure that the rear wheel is aligned to track correctly (same
scale reading on both sides of the rear wheel swinging arm).
Adjust chain tension (A) with tensioning screw (3) on left and right,
making sure the toe adjustment (same scale value (4) on both sides
of the rear wheel swinging arm) is correct.
Technical data
with no
weight
applied,
supported
on its side
stand
Tighten lock nuts (2) on left and right, counter-holding tensioning

screws (3).
Tightening torques

M8 19 Nm
Tightening torques
M24 x 1.5 125 Nm
(mechanical)
(-) Bedding in brake pads
Once the work has been completed, repeatedly operate the brakes
until they are seated against the brake pads and check operation of
the brake system.
Follow-up work

77 21 006 Installing end stoppers for front and rear axles

+ 77 21 505
Preparatory work
Core activity
(-) Installing end stoppers for front axle
NOTICE
It is absolutely essential to install the caps correctly positioned (BMW logo
horizontal), because removal without damaging the caps is not possible.
Installing left front end stopper

Completely insert protector (1) (small diameter) in front axle (2) (if
necessary, slightly loosen clamping bolt (3) before inserting).
Tighten clamping bolt (3).
Tightening torques
M8 x 50 20 Nm
Install cap (4).
Installing right front end stopper
Completely insert protector (1) (large diameter) in front axle (2) (if
necessary, slightly loosen clamping bolt (3) before inserting).
Tightening torques
M8 x 50 20 Nm
Install cap (4).
(-) Installing end stoppers for rear axle
NOTICE
It is absolutely essential to install the caps correctly positioned (BMW logo
horizontal), because removal without damaging the caps is not possible.
Installing left rear end stopper

Completely insert protector (1) (small diameter) in rear axle (2) (if necessary,
slightly loosen clamping bolt (3) before inserting).
Tightening torques
M8 x 50 20 Nm
Install cap (4).
Installing right rear end stopper

Completely insert protector (1) (large diameter) in rear axle (2) (if necessary,
slightly loosen clamping bolt (3) before inserting).
Tightening torques
M8 x 50 20 Nm
Install cap (4).
Follow-up work

77 21 009 Installing carbon wheels

+ 77 21 509
Preparatory work
Core activity
(-) Releasing front brake calipers
Remove screws (2).
Remove screws (1).

ATTENTION
Loosen screws (1).

ATTENTION

ATTENTION
Component damage
ATTENTION
Component damage

Check
Technical data
pressure
Result:
Valve is leaking.
Measure:
Result:

Measure:
Technical data
one-up and
two-up

required.
lightly preloaded.
come to rest.

Technical data
wheel imbalance
front wheel
Weights have to be
on the left and one
other words centred
on the rim
Lubricant
Optimoly TA 18 21 9 062 599
ATTENTION

Tightening torques
M24 x 1.5 50 Nm
Tighten screws (1).
Tightening torques
M8 x 35 Tightening
sequence: Tighten
screws six times in
alternate sequence
19 Nm
(-) Securing front brake calipers

Tightening torques
M10 x 65 38 Nm

Install screws (1).
Tightening torques
M10 x 65 38 Nm
(-) Removing front-wheel stand
ATTENTION
Make sure that the vehicle is secured so that it cannot topple sideways.
Raise the front-wheel stand uniformly in order to lower the motorcycle, and
remove front-wheel stand.
Release mounting bolt (1) to move the fixtures (No. 36 3 975) or remove
retaining pins (2), so that the removal is facilitated.
Remove basic stand (No. 36 3 971) with adapters (No. 36 3 975).
Remove adapters for front forks (No. 36 3 976).



ATTENTION
Component damage

ATTENTION
Component damage

Check
Technical data
pressure
Result:
Valve is leaking.
Measure:
Result:
Valve is.
Measure:
Technical data
one-up and
two-up

required.
preloaded.
to rest.
Technical data

wheel imbalance
rear wheel
Weights have to be
on the left and one
other words centred
on the rim
(-) Transferring chain sprocket to new chain-sprocket carrier
Clamp chain sprocket support (1) in vice with vice jaw protectors.
Remove nuts (2).
Remove chain sprocket support (1) from vice and clamp new chain sprocket
support (1) in vice.
Tightening torques
sequence
110 Nm

carrier
(2).
(arrows).
Lubricant
Unirex N3 83 19 2 160 349
Installation tool

Lubricant
Optimoly TA 18 21 9 062 599

ATTENTION
Technical data
with no
weight
applied,
supported on
its side stand
Tightening torques
M8 19 Nm
Tightening torques
M24 x 1.5 125 Nm
(mechanical)
Once the work has been completed, repeatedly operate the brakes until they
are seated against the brake pads and check operation of the brake system.
Follow-up work

77 22 001 Installing hinged clutch lever

+ 77 22 503
Preparatory work
Core activity
(-) Removing clutch lever
Insert adjusting screw (1) and lock nut (2) as far as possible and align in
such a way that all the recesses align with clutch lever fitting (arrow) .
Use suitable tool to push release lever (3) to the front while working clutch
cable (4) out of adjusting screw (1), clutch lever fitting (arrow) and clutch
lever (5) and detach.
Remove nut (1) and bolt (2).

Remove screw (2) and store, subsequently needed for reassembly.
Remove clutch lever (3), checking switching elements of clutch switch (4).
(-) Transferring intermediate lever to clutch lever, hinged
Remove bush (1).

Remove intermediate lever (2) and spring (3) from clutch lever (4).
Clean and lubricate bush (1).

Lubricant
Unirex N3 83 19 2 160 349
Clean marked area (arrow) on intermediate lever (2) and lubricate.
Lubricant
Unirex N3 83 19 2 160 349
Position intermediate lever (2) with spring (3) on clutch lever (4) ensuring the
correct fit of the spring (3).
Install bush (1).
(-) Install folding clutch lever
Lubricate sliding surfaces of clutch lever (1) and shank of bolt (2).
Lubricant
Unirex N3 83 19 2 160 349
Insert clutch lever (1), checking switching elements (3) of clutch switch.
Install bolt (2) and new nut (4).
Tightening torques
holding the bolt
6 Nm
Use suitable tool to push release lever (1) forward attaching clutch cable (2)
in clutch lever (3), clutch lever fitting (arrow) and adjusting screw (4) and
feed in.
Turn back lock nut (5) and adjusting screw (5) again.
(-) Adjusting clutch play
NOTICE
Adjust distance (A) by turning adjusting screw (2).
Technical data

handlebar fitting
lever (1).
Technical data
outer clutch
lever,
handlebars in
straight-
ahead
position, with
cold engine

(-) Adjusting hinged clutch lever
WARNING
Adjusting the clutch lever while riding
Risk of accident
Adjust the clutch lever only when the motorcycle is at a standstill.
At adjustment lever (1), the distance between clutch lever (2) and handlebar
grip (3) can be adjusted.

Follow-up work

77 22 002 Installing hinged brake lever

+ 77 22 504
Preparatory work
Core activity
(-) Removing lever for front brake
Remove nut (1), counter-holding screw (2).

Remove bolt (2).
Remove lever (3).
(-) Install folding brake lever

Lubricating hinged clutch lever and installing thrust piece
Lubricate both faces (arrows) and the hole.
Lubricant
Unirex N3 83 19 2 160 349
Lubricate and install thrust piece (1). Make sure that the thrust piece does
not drop out during installation.
Lubricant
Unirex N3 83 19 2 160 349
Lubricate shank of bolt (2).
Lubricant
Unirex N3 83 19 2 160 349
Install brake lever (3). Make sure that pushrod (4) is seated in deflection
(arrow).
Install bolt (2) with new nut (5).
Tightening torques
M6, Screw 1 Nm

holding the bolt
6 Nm
(-) Adjusting hinged brake lever
WARNING
Adjusting the handbrake lever while riding
Risk of accident
Do not attempt to adjust the handbrake lever unless the motorcycle is at a
standstill.
At adjustment lever (1), the distance between brake lever (2) and handlebar
grip (3) can be adjusted.
Follow-up work

77 22 007 Installing brake lever protector for brake lever

+ 77 22 613
Preparatory work
Core activity
(-) Installing the brake lever protector
WARNING
Impaired operation of brake lever and throttle twistgrip due to
installation of brake-lever protector not in compliance with correct
procedure
Risk of falling
When installing, make sure that the brake lever can be operated correctly
and that nothing obstructs the action of the throttle twistgrip.
Install brake lever protector (1) with bolt (2) and handlebar weight (3) in
handlebar (4) hand-tight.
Tightening torques
M8 x 40 20 Nm
Follow-up work

77 22 025 Installing hand brake level with remote adjustment

+ 77 22 525
Preparatory work
Removing lever for front brake
Core activity
(-) Installing remote front wheel brake adjuster
Lubricate the contact surfaces (arrows).
Lubricant
Unirex N3 83 19 2 160 349
Insert and align thrust piece (1), making sure that thrust piece (1) does not
drop out.
Lubricate shank of bolt (1).
Lubricant
Unirex N3 83 19 2 160 349
Install handbrake lever (2) making sure that the pushrod (3) is centred in the
thrust piece (arrow).
Install bolt (1) with new nut (4).
Tightening torques
M6, Screw 1 Nm
holding the bolt
6 Nm
Remove bolt (1).

Position bracket for remote adjuster (1) on clamp (2), align clamp (2) with
the mark indicated and secure with screw (3).
Tightening torques
Remove adjuster to clamp
M6 x 40 12 Nm
Position Bowden cable (1) for remote adjuster against clutch cable (2) and
secure with cable ties (arrows).
Follow-up work

77 22 026 Installing fork bracket for stub handlebars

+ 77 22 512
NOTICE
These installation instructions serve to prepare for the installation of accessory
stub handlebars. Please note: only the installation of the fork clamps is
described without stub handlebars.
Preparatory work
Releasing left handlebar half
Removing left handlebar
Removing right handlebar
Core activity
(-) Installing M fork clamps
Position left M fork clamp (1).

Tightening torques
Position right M fork clamp (1).

Tightening torques

Follow-up work

77 22 027 Installing clutch lever protector for clutch lever

+ 77 22 527
Preparatory work
Core activity
(-) Installing clutch lever protector
Install clutch lever protector (1) with bolt (2) and handlebar weight (3) in
handlebar (4) hand-tight.
Align clutch lever protector (1) with position of clutch lever (2).
Tightening torques
M8 x 40 20 Nm
(-) Installing screw for grip unit
Fold down rubber grip (1) and install bolt (2).
Tightening torques
M3.5 x 30 2 Nm
Follow-up work


77 22 185 Installing heated handlebar grips

+ 77 22 795
Preparatory work
Core activity
throttle grip.
Remove bolt (1).


Remove bolt (3).
(-) Disengaging throttle twistgrip
Remove bolt (1).

Release throttle grip (2) and slide to the side.


(-) Install throttle grip with heat function
Install new throttle grip (1).


Tightening torques
M8 x 35 19 Nm
(-) Securing throttle twistgrip
Position throttle grip (2).

Install bolt (1).
Tightening torques
M3.5 x 30 2 Nm
(-) Installing right multifunction switch for heated grips
Fit new multifunction switch (4).

ATTENTION
Component damage
Install bolt (3).
Tightening torques

Connect connector (1) for the heated grip and clip it into position.
ATTENTION
Component damage
Install bolt (3).

Tightening torques

Follow-up work
Removing passenger seat
Performing software update with BMW motorcycle diagnostic system
Installing passenger seat

77 23 012 Install front sport brake

+ 77 23 512
NOTICE
instructions.
Preparatory work
Core activity
(-) Remove both front brake callipers
ATTENTION
Material damage
rubber components.
Remove reset tool (No. 34 1 531) from both brake callipers.
Position left brake calliper (1) and install screws (2) hand-tight.
Loosen holder (3).
Position right brake calliper (1) and install screws (2) hand-tight.
(-) Removing brake pads from M brake callipers
Remove circlips (1), locking pins (2) and brake pads (3) from both M brake
callipers (4).
If necessary, remove sealing cap from bore hole (arrow).
(-) M Installing the front brake calliper
M Position right brake calliper (1) and install screws (2) hand-tight.
Tightening torques
M10 x 1 24 Nm
M Position left brake calliper (1) and install screws (2) hand-tight.
Tightening torques
M10 x 1 24 Nm
Secure holder (3).

Insert reset tool (No. 34 1 531) in brake callipers on the left and right.

Follow-up work
Filling/bleeding front brake system

77 23 013 Install rear sport brake

+ 77 23 513
NOTICE
instructions.
Preparatory work
Core activity
(-) Removing rear brake calliper

Remove bolt (3) and release wheel speed sensor (4).
Remove brake calliper (5) complete with carrier.
(-) M Installing rear brake calliper
Position M brake calliper (1) complete with support on vehicle.

Position wheel speed sensor (2) and install screw (3).
Tightening torques
encapsulated)
Route cable of wheel speed sensor (2).

Position holder (4) noting the anti-twist lock (arrow) and install screw (5).
Tightening torques
encapsulated)
Follow-up work
Filling/bleeding rear brake system
Adjusting chain sag

77 23 014 Replace brake pads

+ 77 23 514
NOTICE
Only approved for use on the race track.
Preparatory work
Core activity
(-) Removing front brake pads
Use a suitable tool to push back brake pads (3).

Remove circlips (1).
Remove (2) locking pins.
Check locking pins (2) for wear/damage and replace, if necessary.
Clean brake calliper .
(-) Installing front brake pads

Install new brake pads (3).

Wear
Corrosion
Tightening torques
Locking pin for front brake pads
Steel locking pin 8 Nm

Replace the brake pads in the right brake calliper in the same way.
Follow-up work

77 25 004 Installing rear footrests

+ 77 25 504
0413 - Two-up riding packageOE
Preparatory work
Core activity
(-) Removing left rear footrest

Remove bolts (2).
Keep components, will be reused.
Remove footrest (3) with guide plate (4).
Detach guide plate (1) from footrest (2) checking ball (3) and spring (4).
Store guide plate (1), ball (3) and spring (4), subsequently needed for
reassembly.
(-) M Install left rear footrest
Clean and lubricate spring (1), ball (2) and sliding surfaces of guide plate
(3).
Lubricant
Insert spring (1) and ball (2) in new rear footrest (4).
Install rear footrest (4) in guide plate (3) making sure the ball (2) engages in
bore hole (arrow).
Install rear footrest (1) completely with guide plate (2) in footrest bracket (3).
Install bolts (4).

(-) Removing rear right footrest

Remove bolts (2).
Keep components, will be reused.
Remove footrest (3) with guide plate (4).
Detach guide plate (1) from footrest (2) checking ball (3) and spring (4).
Store guide plate (1), ball (3) and spring (4), subsequently needed for
reassembly.
(-) M Install right rear footrest
Clean and lubricate spring (1), ball (2) and sliding surfaces of guide plate
(3).
Lubricant
Insert spring (1) and ball (2) in new rear footrest (4).
Install rear footrest (4) in guide plate (3) making sure the ball (2) engages in
bore hole (arrow).
Install rear footrest (1) completely with guide plate (2) in footrest bracket (3).
Install bolts (4).

Follow-up work

77 25 011 Installing front footrests

+ 77 25 777
Preparatory work
Core activity
(-) Removing left footrest

Remove bolts (2).
(-) Installing M Rider footrest, left
Lubricant
Position rider footrest (3) with spring (4).

Install bolts (2).
(-) Remove the right footrest

Remove bolts (2).
(-) Installing M Rider footrest, right

Lubricant
Position rider footrest (3) with spring (4).

Install bolts (2).
Follow-up work

77 25 022 Installing chain tensioner

+ 77 25 521
Preparatory work
Core activity
(-) Removing adjusting screw for chain tensioner, left
Remove adjusting screw (1) from rear wheel swinging arm (2).
(-) Removing adjusting screw for chain tensioner, right
Remove adjusting screw (1) from rear wheel swinging arm (2).
(-) Transferring nuts for chain tensioners on both sides
Remove the nut (1).

Install nut (1) on adjusting screw (2).

(-) Installing quick-release axle with chain tensioners until hand-
tight
Requirement
Contact surfaces for the chain tensioners have been cleaned.
Slip quick-release axle (1) with right chain tensioner (2) through elongated
holes (3) onto rear wheel swinging arm (4).
Slip left chain tensioner (5) onto quick-release axle (1) and install hand-tight
with shim (6) and nut (7).
Push quick-release axle (1) fully forward in the elongated holes (3).
(-) Cutting scale for adjustment to size
Cut both scales for adjustment to size so that the No. 4 line can still be seen.
(-) Affixing left scale for adjustment
NOTICE
Peel off the backing paper.

Slip scale for adjustment (1) into the groove provided (arrow) on chain
tensioner (2) until it is at start position 0 and affix it to rear wheel swinging
arm (3).
(-) Affixing right scale for adjustment
NOTICE

Peel off the backing paper.

Slip scale for adjustment (1) into the groove provided (arrow) on chain
tensioner (2) until it is at start position 0 and affix it to rear wheel swinging
arm (3).
(-) Removing quick-release axle with chain tensioners
Remove nut (1) with shim (2) and take off left chain tensioner (3).
Remove quick-release axle (4) and remove right chain tensioner (5).
(-) Inserting adjusting screw into chain tensioner, left
Insert adjusting screw (1) with the plastic washer into left chain tensioner (2).
(-) Inserting adjusting screw into chain tensioner, right
Insert adjusting screw (1) with the plastic washer into right chain tensioner
(2).

(-) Installing left chain tensioner
Requirement
Fully tighten lock nut (1) on adjusting screw (2).

Screw adjusting screw (2) of chain tensioner(3) into rear wheel swinging arm
(4) until drive chain can be engaged; use provided tool (5) if necessary.
(-) Installing right chain tensioner
Requirement
Fully tighten lock nut (1) on adjusting screw (2).

Screw adjusting screw (2) of chain tensioner(3) into rear wheel swinging arm
(4) until drive chain can be engaged; use provided tool (5) if necessary.
As applicable, clean the areas indicated (arrows) and lubricate.
Lubricant
Optimoly TA 18 21 9 062 599
Insert brake calliper (1) in guide (2).
ATTENTION
Installation of rear wheel not in accordance with correct procedure
Note the wheel-speed sensor when rolling in the rear wheel.
Install rear wheel (1), noting spacer bush (2) and brake calliper (3).
Loop chain (4) over chain sprocket (5).
Clean and lubricate quick-release axle (1).
Lubricant
Optimoly TA 18 21 9 062 599
Align rear wheel (2), raise it where necessary and install quick-release axle
(1) through the hole in right chain tensioner (3).
Slip quick-release axle (1) through the bore hole in left chain tensioner (4).
Install nut (5) with washer (6) hand-tight.
Make sure that brake line (1) and wheel-speed sensor cable (2) are seated
in the holders (arrows); secure if necessary.
Follow-up work
Adjusting chain sag

77 25 149 Installing retrofit kit, footrest system

+ 77 25 901
Preparatory work
Replacing bracket for rear silencer with spacer bush
Core activity
(-) Removing gearshift lever

Remove bolt (1).

Take off gearshift lever (2) and mount (3).
(-) Removing left footrest system
Remove screws (1).

Remove complete footrest system (2).
(-) M Installing left footrest system
Fit gearshift lever (1) and mounting (2) with shouldered side (arrow) to
gearshift lever (1).
Install bolt (3).
Tightening torques
M8 x 65 19 Nm
Clean thread.
Install bolt (2).
Tightening torques
encapsulated)

Fit footrest system (2).
Install screws (1).
Tightening torques
M8 x 25 19 Nm
(-) Removing right footrest system
Remove bolts (1) and shaped washer (2).

CAUTION

Detach spring (1) and remove.

Unclip locking clip (2) from pushrod (3) and remove it from pushrod (3) and
footbrake lever (4).
Remove bolts (1) and retaining plate (2).

Remove footrest plate (3) and heel guard (4) from footbrake cylinder (5).
(-) M Installing right footrest system
Fit footbrake cylinder (1).

Install screws (2).
Tightening torques
Footbrake cylinder to footrest plate
M6 x 20 10 Nm
Align footbrake lever (1) with pushrod (2) and install locking clip (3).
Clip in locking clip (3) on pushrod (2).
Fit complete footrest plate (4) and install bolts (3).
Tightening torques

M8 x 25 19 Nm
Install screw (1) and shaped washer (2).
Tightening torques
M8 x 40 19 Nm
(-) Adjusting play of footbrake lever
Insert feeler gauge (1) transverse to the direction of travel between

footbrake lever (2) and stop (arrow).
Technical data
Blow-by clearance of between the 2...3 mm
the footbrake lever footbrake
lever and
footrest plate
Slacken nut (3) on pushrod (4).

Turn pushrod (4) until all play on the pushrod (4) is taken up.
Lock nut (3) on pushrod (4).
Tightening torques
Pushrod, footbrake cylinder
M6, Locknut 6 Nm
Secure nut (3) with thread-locking sealant.
(-) Blocking folding mechanism of footrests (for racetrack)
NOTICE
footrests.
position.

Follow-up work
77 31 002 Installing front-wheel cover

+ 77 31 502
Preparatory work
Core activity
(-) Removing front-wheel cover
Remove bolts (1) and remove front wheel cover (2).
(-) Affixing rear reflector on front-wheel cover
Fit supplied template (1) on front-wheel cover (2) and fix with adhesive tape.
NOTICE
The surfaces to be labelled must be clean and dry.
Remove protective film from rear reflector.

Affixing rear reflector (3) on front-wheel cover (2).
Repeat installation on the other side of the front-wheel cover.
(-) Installing front-wheel cover
Insert front-wheel cover (2) and install screws (1).
Tightening torques
encapsulated)
Follow-up work

77 31 003 Installing rear-wheel cover

+ 77 31 503
NOTICE
The two Carbon parts rear wheel cover and chain guard can be installed only
together.
Installation of only one or other of these parts is not possible.
Preparatory work
Core activity
(-) Remove chain guard and rear-wheel cover
Remove bolt (1) and expanding rivet (2) and keep them safely aside, will be
reused.
Loosen locator (arrow) and remove chain guard (3).
Remove expanding rivets (1) and (2) keep them safely aside, will be
reused.
(-) M Installing Carbon rear-wheel cover and chain guard
Position Carbon rear-wheel cover (1) and install expanding rivets (2)
and (3).

Clip holder in (1) on brake line (2).

Secure holder (1) together with brake line (2) on Carbon rear-wheel
cover (3).
Clean thread.
Position Carbon chain guard (1) on Carbon rear-wheel cover (2) and rear
wheel swinging arm (3).
Tightening torques
encapsulated)
Follow-up work

77 31 005 Installing tank cover

+ 77 31 624
Preparatory work
Removing trims from tank trims
Core activity
(-) Installing trim in left carbon tank trim
Install trim (1) with clamps (2) on left tank trim (3).
(-) Installing trim in right carbon tank trim
Install trim (1) with clamps (2) on right tank trim (3).
(-) Installing clip clamps in airbox cover
Attach clip clamps (1) on retaining lugs (arrows) of airbox cover (2).

(-) Assembling tank trim with airbox cover
Attach left tank trim (1) and right tank trim (2) in holder (4) of airbox cover (3)
and clip in detent pins (arrows).
(-) Installing complete cover of fuel tank
Fit complete cover of fuel tank (1), attach locators (arrows) and install.
Install bolts (short collar) (2) together with plastic washers (3).
Install bolt (long collar) (1) together with plastic washers (3)
Secure locators (arrows) on rear carrier.
Follow-up work


77 31 031 Installing cover kit

+ 77 31 514
Preparatory work
Core activity
(-) Installing M mirror cover
Removing windscreen
Remove screws (1).

inlet.

Release air inlet cover (1) from mounting clips (2), detach in front (arrows)
and remove.

Disconnect plug connection (1) for left turn indicator.
Remove nuts (1).

Remove mirror (2).

Disconnect plug connection (1) for right turn indicator.
Remove nuts (1).

Remove mirror (2).
Installing M mirror cover

Position the left cover (1) and install bolt (2) with nut (3).
Tightening torques
M6 x 25 3 Nm
Position the right cover (1) and install bolt (2) with nut (3).

Tightening torques
M6 x 25 3 Nm

Fit air inlet cover (1), attach in front (arrow) and secure in mounting clips (2).
Install screws (1).
Tightening torques
M5 x 16 1 Nm
(-) Installing M cover for number plate carrier

Using an ignition key (1) unlock the lock for tail-hump cover (2).
Remove tail-hump cover (2), to unhook the fixture (arrow).


Remove bolt (1).
Remove bolt (1).




Disconnect plug connection (1) for number plate light and feed out cable (2)
to the rear.

(2).

Remove screws (1).

Release number plate carrier (2), detach lugs (arrows) for this purpose.
Thread out cable (3) from rear end (4) and remove number plate carrier (2).

Installing M Cover for number plate carrier

Position cover (1) while paying attention to the lugs (arrows).
Install screws (2).
Affix badge (3).
Install bolt (5).

Install bolt (5).


Position tail-hump cover (2) while hooking fixture (arrow).
Press tail-hump cover (2) down and lock with ignition key (1).
Follow-up work

77 31 035 Installing carbon fairing side panel at the top, left and right
+ 77 31 525
Preparatory work
Core activity
Remove screws (1).

Remove screws (2).
(arrow) and remove.
(-) Replacing left top side panel
Remove bolt (1).

Transfer small parts to the new top fairing side panel (1), change as
needed:
1 x flat nut

retainers (arrows).
Install bolt (1).
holder (arrow).
(4).


Remove screws (1).

Remove screws (2).
(arrow) and remove.
(-) Replace fairing side panel, top right
Remove bolt (1).

1 x flat nut

retainers (arrows).
Install bolt (1).
holder (arrow).
(4).


Follow-up work

77 33 024 Installing windscreen

+ 77 33 621
Preparatory work
Core activity
Remove screws (1).

inlet.
Transfer small parts to the new windscreen (1), change as needed:

4 x rubber nuts
(-) Install the windscreen
Install screws (1).
Tightening torques
M5 x 16 1 Nm
Follow-up work

77 33 025 Installing high windscreen

+ 77 33 525
Preparatory work
Core activity
Remove screws (1).

inlet.
Transfer 4 x M5 rubber nuts (2) to new windscreen (1), renew as needed:
(-) Installing high windscreen
Fit windscreen (2) and insert rubber nuts (3) in air inlet.
Install screws (1).
Tightening torques
M5 x 16 1 Nm
Follow-up work

77 34 009 Installing tail-hump cover

+ 77 34 511
Core activity
(-) Assemble tail-hump cover
Install flat nuts (1) in tail-hump cover (2).
Install supports (1) in support for tail-hump cover (2).
Attach the tail-hump cover (1) in the rear in support (2) (arrow).
Position tail-hump cover (1) in front and install bolts (3).
Tightening torques
Trim panels
M5 2 Nm
(-) Removing passenger seat
Use ignition key (1) to unlock lock for passenger seat (2).
Remove passenger seat (2) by unhooking fastener (arrow).

(-) Installing tail-hump cover

Follow-up work

77 44 031 Install spacer for saddlebag

+ 77 44 531
SaddlebagOA
Preparatory work
Attach protective film for rear trim panel
Core activity
(-) Removing rear footrest extension cover
Remove cover for left rear footrest extension (arrows).
Remove cover for right rear footrest extension (arrows).
(-) Installing left spacer for saddlebag
Position spacer (1) on rear frame (2) and install screws (3).
Tightening torques
M8 x 30 19 Nm
Loctite 243, Medium strength 83 19 2 210 339

(-) Installing right spacer for saddlebag
Position spacer (1) on rear frame (2) and install screws (3).
Tightening torques
M8 x 30 19 Nm
Loctite 243, Medium strength 83 19 2 210 339
Follow-up work

77 52 015 Installing data logger

+ 77 52 508
NOTICE
Ignition must be switched off for the installation of the data logger.
Preparatory work
Ordering enabling code for software update with ISTA/P
Programming vehicle control unit
Core activity
(-) Disconnecting diagnostic socket
Press locks (arrows) and disconnect diagnostic socket (1).
(-) Exposing connector for power supply
Disconnect connector (1) from blind cap (2).
(-) Preparing storage compartment

NOTICE
Clean bonding points on storage compartment (1).

Attach holder for USB port (2).
Attach hook and loop tape (3).
(-) Preparing data logger
NOTICE
Clean rear side of data logger (1) and GPS receiver (2).
Attach hook and loop tape (3) on data logger (1) and GPS receiver (2).
Insert connector (4) of GPS receiver (2) in data logger (1).
(-) Installing data logger
Secure data logger (1) on glued in hook and loop tape.

Connect plug connection (2) for power supply.
Secure USB port (1) in glued in holder (2).

Connect plug connection (3) to diagnostic socket (4) and position in storage
compartment.

Store GPS receiver (1) temporarily in the storage compartment.
(-) Installing centre rear trim panel
Place centre rear trim panel (2) in position and hook in lug (arrow).
Bend tabs (1) of cover of fuel tank slightly to the outside and install centre
rear trim panel (2).
Clip in tabs (1) of cover of fuel tank.

(-) Installing right rear trim panel
Install bolt (5).

(-) Installing left rear trim panel
Install bolt (5).
(-) Securing GPS receiver
NOTICE
Clean bonding surface on tail section (1).

Attach hook and loop tape (2).
Secure GPS receiver (3).
Position tail-hump cover (1) and attach fixture (arrow).

Push tail-hump cover (1) down, noting cable (2) of GPS receiver.
Lock with ignition key (3).

(-) Installing rider’s seat
Insert driver's seat (1) at front and position.

Press driver's seat (1) to the front at the seat cushion surface (arrow).
Position bolt (2) and install.
Follow-up work

77 53 005 Installing RDC

+ 77 53 910
Preparatory work
Core activity
ATTENTION
Loosen screws (1).

ATTENTION
ATTENTION
Component damage
(-) Remove rubber valve
ATTENTION
Component damage
(-) Installing RDC sensor in front wheel rim

Observe the distance to the rim flange (arrows) and tighten nut (3).
Tightening torques
M8, Renew nut 6 Nm
encapsulated)
Attach sign (1) for sensor position at the height of the valve (2).
NOTICE
Hold the tyre in position, noting the RDC sensor.
ATTENTION
Component damage

Check
Technical data
pressure
Result:
Valve is leaking.
Measure:
Result:
Valve is leak-tight.
Measure:

Technical data
one-up and
two-up

required.
lightly preloaded.
come to rest.
Technical data
wheel imbalance
front wheel
Weights have to be
on the left and one
other words centred
on the rim
Lubricant
Optimoly TA 18 21 9 062 599
ATTENTION

Tightening torques
M24 x 1.5 50 Nm
Tighten screws (1).

Tightening torques
M8 x 35 Tightening
sequence: Tighten
screws six times in
alternate sequence
19 Nm



ATTENTION
Component damage
(-) Remove rubber valve
ATTENTION
Component damage
(-) Installing RDC sensor in rear wheel rim

Insert valve (1), RDC sensor (2) and nut (3).
Observe the distance to the rim flange (arrows) and tighten nut (3).
Tightening torques
M8, Renew nut 6 Nm
encapsulated)
Attach sign (1) for sensor position at the height of the valve (2).
NOTICE
Hold the tyre in position, noting the RDC sensor.
ATTENTION
Component damage

Check
Technical data
pressure
Result:
Valve is leaking.
Measure:
Result:
Valve is leak-tight
Measure:
Technical data
one-up and
two-up

required.
preloaded.
to rest.
Technical data
wheel imbalance
rear wheel
Weights have to be
on the left and one
other words centred
on the rim

carrier
(2).
(arrows).
Lubricant
Unirex N3 83 19 2 160 349

Installation tool

Lubricant
Optimoly TA 18 21 9 062 599

ATTENTION
Technical data
with no
weight
applied,
supported on
its side stand
Tightening torques
M8 19 Nm
Tightening torques
M24 x 1.5 125 Nm
(mechanical)
Once the work has been completed, repeatedly operate the brakes until they
are seated against the brake pads and check operation of the brake system.
(-) Removing chain guard
Remove bolt (1) and expanding rivet (2).

Loosen locator (arrow) and remove chain cover (3).
(-) Exposing tire pressure control connector (RDC)
Remove the cable strap (arrow).

Remove protective cap (2) from connector (1).
(-) Installing RDC control unit
Fit RDC control unit (1).

Install screws (2).
Connect connector (3) with control unit and secure with cable strap (arrow).

(-) Installing chain guard
Fit chain guard (3) and secure in mounting (arrow).

Install bolt (1) and expanding rivet (2).
Tightening torques
encapsulated)
(-) Removing tail-hump cover
(-) Removing rider’s seat
Push driver's seat (1) on the seat cushion surface (arrow) forwards.
Loosen bolt (2).
Raise the driver's seat (1) at the rear and remove.

NOTICE
13 V.

NOTICE
instructions.
(-) Performing software update with BMW motorcycle diagnostic

system
Requirement
Engine is off.
Battery is fully charged and battery charger is connected.
NOTICE
Do not attempt to perform work of any other kind on the motorcycle while
programming/coding is in progress.
Switch off all electrical consumers.

Start BMW motorcycle diagnosis system.
Identify the vehicle.

Select the retrofit.
Create a measures plan and perform the retrofit.
(-) Teaching in RDC sensor at control unit
Start the diagnosis system.

Go to "Service functions" and select "Tyre pressure monitoring (RDC)".
NOTICE
Only one wheelset can be registered with the RDC control unit.
Call up the "Teach wheel sensors" function and follow the instructions
issued by the system.




Follow-up work

77 53 006 Installing cruise control

+ 77 53 911
Preparatory work
Core activity
(-) Removing screw for grip unit
Fold down rubber grip (1) and remove bolt (2).
(-) Remove the left handlebar weight

(-) Loosen handlebar on left

Disconnect plug (2) from clutch switch (3) and loosen wiring harness (4).

Completely remove handlebar (3) with grip unit (4) and clutch lever fitting
(5).
(-) removing left grip unit
Loosen handlebars (1) from grip unit (2).

Remove cover (1).



(-) Installing left multifunction grip with speed control
heated grip.
Installation tool


(-) Securing left grip unit
Slide grip unit (1) on handlebars (2) while taking care of the damper rubber
(arrow).

(-) Secure left handlebar
Completely position the handlebar(3) with grip unit (4) and clutch lever fitting
(5).
Install threaded bolts (2), then install clamping bolts (1).
Tightening torques
Route wiring harness (4) and connect plug (2) with clutch switch(3).
Install the tensioning strap(1).
If required, lay excess cable length in loops. Secure the cable strap (arrow).
(-) Installing left handlebar weight

Tightening torques
M8 x 35 19 Nm
(-) Installing screw for grip unit
Fold down rubber grip (1) and install bolt (2).

Tightening torques
M3.5 x 30 2 Nm

throttle grip.
Remove bolt (1).


Remove bolt (3).
(-) Disengaging throttle twistgrip
Remove bolt (1).

Release throttle grip (2) and slide to the side.

(-) Installing throttle grip with speed control
Install new throttle grip (1).


Tightening torques
M8 x 35 19 Nm
(-) Securing throttle twistgrip
Position throttle grip (2).

Install bolt (1).
Tightening torques
M3.5 x 30 2 Nm

ATTENTION
Component damage
Install bolt (3).
Tightening torques

ATTENTION
Component damage
Install bolt (3).

Tightening torques

Follow-up work
Performing software update with BMW motorcycle diagnostic system

77 53 007 Installing riding mode

+ 77 53 912
Core activity
(-) Ordering enabling code for software update with ISTA/P
Order the requisite enabling code through BMW Parts Sales.
(-) Removing rider’s seat
Push driver's seat (1) on the seat cushion surface (arrow) forwards.
Loosen bolt (2).
Raise the driver's seat (1) at the rear and remove.
(-) Removing tail-hump cover
NOTICE
13 V.

NOTICE
instructions.





Follow-up work

77 53 009 Installing battery

+ 77 53 509
Preparatory work
Core activity
(-) Removing battery
ATTENTION
Battery not disconnected in accordance with correct procedure
Always proceed in compliance with the specified disconnection sequence.
Remove bolt (1) and remove wiring harness negative terminal (2) and push
to the front.
Remove screw (3) and wiring harness positive terminal (4).
Remove the battery (5).

characteristic.
Workshop equipment
(-) Installing lithium ion battery
Install adapter (1).
Install the battery (1).

ATTENTION

Battery not connected in accordance with correct procedure

Always proceed in compliance with specified installation sequence.
Position wiring harness positive terminal (2) and install bolt (3).
Position wiring harness negative terminal (4) and install bolt (5).
Follow-up work

77 53 100 Installing anti-theft alarm

+ 77 53 501
Preparatory work
Core activity
(-) Installing bracket for anti-theft alarm
Install flat nuts (1) in tabs (2) of rear carrier.
Fit holder for anti-theft alarm (1).

Install screws (2).
(-) Exposing connector for anti-theft alarm
Remove the cable strap (arrow).

Remove connector (1) and remove protective cap (2).

(-) Installing anti-theft alarm
Fit anti-theft alarm (2) and connect connector (1).
Work in anti-theft alarm (3) and attach in holders (4).

Push anti-theft alarm (3) down and let locks (2) engage.
NOTICE
13 V.

NOTICE
instructions.


Follow-up work

BMW-S1000 RR K67 Service Manual

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Technical data - S 1000 RR

Designation Precondition Value Valid

Running-in speed Odometer <7000 min-1

Engine design Oil-/water-cooled four-stroke inline

052021 BMW Motorrad, UX-VA-4 1/4

Identification of main bearing and BMW part number / 1234567 12

052021 BMW Motorrad, UX-VA-4 2/4

Mark for classification of the Coloured dots on the yellow/green/violet

11 24 - Conrod with bearings

Conrod bearing, bore diameter Identification/colour A/red or B/blue

Overview of conrod marks A Correlation, conrod bearing cap to

11 25 - Piston with rings and bolts

052021 BMW Motorrad, UX-VA-4 3/4

052021 BMW Motorrad, UX-VA-4 4/4

Technical data - S 1000 RR

Designation Precondition Value Valid

Spark plugs, manufacturer and NGK LMAR9FI-10G

052021 BMW Motorrad, UX-VA-4 1/1

Technical data - S 1000 RR

Designation Precondition Value Valid

052021 BMW Motorrad, UX-VA-4 1/1

Technical data - S 1000 RR

Designation Precondition Value Valid

052021 BMW Motorrad, UX-VA-4 1/1

Technical data - S 1000 RR

Designation Precondition Value Valid

Coolant, total capacity 2.95 l

052021 BMW Motorrad, UX-VA-4 1/1

Technical data - S 1000 RR

Designation Precondition Value Valid

052021 BMW Motorrad, UX-VA-4 1/1

Technical data - S 1000 RR

Designation Precondition Value Valid

052021 BMW Motorrad, UX-VA-4 1/1

Technical data - S 1000 RR

Designation Precondition Value Valid

Negative spring displacement of front

052021 BMW Motorrad, UX-VA-4 1/1

Technical data - S 1000 RR

Designation Precondition Value Valid

052021 BMW Motorrad, UX-VA-4 1/1

Technical data - S 1000 RR

Designation Precondition Value Valid

Suspension compression at rear Racing use with 30+2 mm

052021 BMW Motorrad, UX-VA-4 1/1

Technical data - S 1000 RR

Designation Precondition Value Valid

34 11 - Front wheel brakes

Brake-pad wear limit, front Friction pad only, min 1 mm

34 21 - Rear wheel brakes

052021 BMW Motorrad, UX-VA-4 1/2

052021 BMW Motorrad, UX-VA-4 2/2

Technical data - S 1000 RR

Designation Precondition Value Valid

052021 BMW Motorrad, UX-VA-4 1/1

Technical data - S 1000 RR

Designation Precondition Value Valid

052021 BMW Motorrad, UX-VA-4 1/1

Technical data - S 1000 RR

Designation Precondition Value Valid

052021 BMW Motorrad, UX-VA-4 1/1

Technical data - S 1000 RR

Designation Precondition Value Valid