BMW-Motorrad - 0B54 - F 800 R, K73 12

11 11 514 Replace engine block (engine removed)

NOTICE
Pistons and piton pins have to be renewed if the engine block is
replaced.

Preparatory work
Removing oil filter
Removing starter
Removing flange for heat exchanger with coolant lines
Securing engine to assembly stand
Removing direct ignition coils
Removing spark plugs
Remove the cylinder head cover
Removing crankshaft sensor
Removing right crankcase cover
Setting engine to firing TDC
Checking valve clearance
Locking engine at firing TDC
Removing chain tensioner
Removing camshaft bearing cap unit
Removing both camshafts
Removing timing chain slide rail
Remove the cylinder head
Operating and removing gear lever
Removing pinion
Removing left crankcase cover
Removing selector shaft
Removing clutch pressure plate
Remove the lined plates
Removing clutch hub
Removing clutch cage
Removing oil pan
Remove the swing-arm shaft cover and oil pressure control
valve
Releasing TDC locator
Removing bottom crankcase half
Removing oil-pump drive gear
Removing cover of oil delivery pump
Removing oil delivery pump
Removing cover of oil suction pump

092017 BMW Motorrad, UX-VA-4 1/9

BMW-Motorrad - 0B54 - F 800 R, K73 12

Removing oil suction pump

Removing gearbox potentiometer
Removing oil-pump shaft
Removing shaft sealing ring for gearbox output shaft
Removing transmission output shaft and transmission input
shaft
Removing shift forks for 1st/3rd and 2nd/4th gears
Removing shift fork, 5th/6th gear
Removing locking lever
Removing selector drum with star-shaped locking element
Removing conrod bearing caps

Core activity
(-) Removing piston with conrod

Mark the conrods to ensure that they remain matched with their
original cylinders.
Mark the exhaust side on the crown.
Push both conrods with pistons (1) down, taking care not to damage
the crankpins and the bearing shells.
Check

Check bearing shells for wear (scoring, damage).

Result:

Bearing shells show scoring or other signs of damage.

Measure:

Replace the bearing shells.

(-) Removing piston

Clamp conrod (1) in a vice fitted with protective jaws.

Remove circlip (2).
Remove piston pin (3).
Remove piston (4).

(-) Installing piston (conrod removed)

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BMW-Motorrad - 0B54 - F 800 R, K73 12

Lubricate the piston pin with engine oil.

Heat the piston.

Technical data
Mating 50 °C
temperature, piston
pin in piston

Install conrod and piston pin (2), making sure that the installed
position is correct.
The dot on the base of the conrod (arrow) must face toward the
exhaust (note the mark on the piston crown).
ATTENTION
Loose circlips or gudgeon pin
Damage to cylinder barrel
Make sure that the circlips are correctly seated on the gudgeon pin.

Install new circlips (1).

Seat the tab of the circlip in the recess and work round the
circumference, pressing the circlip into the groove; the circlip must
engage with an audible click.

(-) Removing crankshaft main bearing caps

Mark both main bearing caps prior to removal to ensure that they
can be reinstalled in their original positions.
Do not mix up the two main bearing caps.
Remove screws (1) and remove both main bearing caps (2).

(-) Removing crankshaft

Mark the direction of rotation on timing chain (1).

Remove timing chain (1) and crankshaft (2).

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BMW-Motorrad - 0B54 - F 800 R, K73 12

(-) Removing layshaft for starter

Remove washer (1).

Remove gears (2) and (3) from axles (4).

(-) Removing timing-chain tensioning rail

Remove screw (1) and remove timing chain tensioning rail (2).

(-) Replacing engine block

Install new main bearing shells.

Clean and check the components after removal; replace defective or

worn components as necessary.

(-) Installing timing-chain tensioner rail

Clean the threads.

Install timing chain tensioning rail (2) and install screw (1).

Tightening torques
Chain tensioner rail to engine block
M6, Replace screw 10 Nm
Thread-locking compound (Micro
-encapsulated)

(-) Installing crankshaft bearing shells

Clean the bearing shells and the bearing-shell seats.

092017 BMW Motorrad, UX-VA-4 4/9

BMW-Motorrad - 0B54 - F 800 R, K73 12

ATTENTION
Incorrect positioning of the bearing shells
Engine damage
Position the lubrication holes in the bearing shells over the oil ducts.

Install all the bearing shells (arrows) in pairs, with the projections
engaged in the bearing-shell seats.
NOTICE
Replace the crankshaft bearing shells if the crankshaft is replaced.

(-) Installing layshaft for starter

ATTENTION
Installation of the gears not in compliance with correct procedure
Component damage
Install double gear on bottom axle.

Lubricate axles (4).

Lubricant
Klüberpaste 46 MR 401 11 00 7 660 831

Install gearwheels (3) and (2).

Install washer (1).

(-) Installing crankshaft

Requirement
Bearing shells are installed in the engine block.

Clean the sealing faces.

Before installing crankshaft (2), lubricate all bearing seats with
engine oil.
Install crankshaft (2), while at the same time looping timing chain (1)
over the bearing stub.
Engage timing chain (1).
Make sure that the timing chain is installed right way round, i.e.in its
original direction of rotation.

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BMW-Motorrad - 0B54 - F 800 R, K73 12

(-) Installing crankshaft main bearing caps

Clean the mating faces.

Install main bearing caps (2), making sure that the reamed pins
(arrows) are correctly positioned.
Make sure that the marks indicating the correct installed position
match.
Use an electronic torque wrench/angle-of-rotation tightening tool
when tightening.
Workshop equipment
Electronic torque wrench/angle-of-rotation tightening tool

Tightening sequence for main bearing caps

Tighten screws (1) to (8) in the appropriate tightening sequence.

Tightening torques
Main bearing cap
M8 x 77 - 10.9, Replace screw Tightening
Collar flat of screw lightly oiled sequence: See
repair manual
Tightening torque,
15 Nm
Additional angle of
rotation, 45+5°
−5

(-) Installing piston (conrod removed)

Lubricate the piston pin with engine oil.

Heat the piston.

Technical data
Mating 50 °C
temperature, piston
pin in piston

Install conrod and piston pin (2), making sure that the installed
position is correct.
The dot on the base of the conrod (arrow) must face toward the
exhaust (note the mark on the piston crown).
ATTENTION
Loose circlips or gudgeon pin
Damage to cylinder barrel
Make sure that the circlips are correctly seated on the gudgeon pin.

Install new circlips (1).

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BMW-Motorrad - 0B54 - F 800 R, K73 12

Seat the tab of the circlip in the recess and work round the
circumference, pressing the circlip into the groove; the circlip must
engage with an audible click.

(-) Installing piston with conrod

Turn the engine to its normal position.

Make sure that the gaps of the piston rings are not in line with the
piston's axis of tilt.
Position the gaps of oil wiper ring (3) so that they are offset approx.
30° from each other (detail).
Position the other piston rings (2), (1) so that the gaps are each
offset 120° from the top gap of the oil wiper ring.

Lubricate the friction face of the cylinder and the friction face of the
piston skirt with engine oil.
Introduce the conrod and piston into the cylinder bore, making sure
that the assembly is installed right way round (arrows).

Technical data
Piston, installed Arrow on piston
direction crown pointing to
exhaust side

Turn the crankshaft until the crankpins are at the bottom.

Slip piston-ring compressor (No. 11 5 731) around the piston in such
a way that it just encloses all the piston rings.
Tighten piston-ring compressor (No. 11 5 731) and carefully ease
the piston into the cylinder, taking care not to allow the conrods to
contact the crankshaft.

(-) Installing conrod bearing caps

ATTENTION
Cracked conrods mismatched or installed wrong way round.
Component damage
Mark both conrod and conrod cap prior to disassembly and use
these marks to ensure that the components are reinstalled in their
original positions.

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BMW-Motorrad - 0B54 - F 800 R, K73 12

Clean the mating faces of the conrod.

Lubricate the friction faces with engine oil.
Set conrod bearing cap (2) on the conrod, making sure that the
marks (arrows) are matched.
ATTENTION
Re-tightening of reduced-shaft bolts
Stretching or failure of the reduced-shaft bolts
Tighten reduced-shaft bolts only once.

Oil the threads and collar seats of new conrod bolts (1).
Engage conrod bolts (1).

Use an electronic torque wrench/angle-of-rotation tightening tool

when tightening.
Workshop equipment
Electronic torque wrench/angle-of-rotation tightening tool
Tighten conrod bolts (1).

Tightening torques
Conrod bolt
M9 x 1 x 49, Replace screws 1st tightening
Thread and seating face of the torque, 10 Nm
screw oiled 2nd tightening
torque, 20 Nm
Additional angle of
rotation, 70°

Follow-up work
Installing selector drum with star-shaped locking element
Installing shaft sealing ring of selector drum
Installing locking lever
Installing shift fork, 5th/6th gear
Installing shift forks for 1st/3rd and 2nd/4th gears
Installing oil-pump shaft
Installing gearbox potentiometer
Installing oil delivery pump
Installing cover of oil delivery pump
Installing oil-pump drive gear
Installing oil suction pump
Installing cover of oil suction pump
Installing transmission output shaft and transmission input shaft
Installing bottom half of crankcase
Locking crankshaft in TDC position
Installing clutch cage
Installing clutch hub

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BMW-Motorrad - 0B54 - F 800 R, K73 12

Installing lined plates

Installing clutch pressure plate
Installing selector shaft
Install the cover for swing-arm shaft
Installing oil pan
Installing left crankcase cover
Installing shift lever
Installing shaft sealing ring, gearbox output shaft
Installing pinion
Operating gearshift lever
Installing cylinder head
Installing timing-chain slide rail
Installing both camshafts
Securing camshaft bearing cap unit
Installing camshaft bearing cap unit
Install the chain tensioner
Checking engine timing
Releasing TDC locator
Checking engine timing
Rechecking valve clearance
Installing cylinder head cover
Installing spark plugs
Installing direct ignition coils
Installing right crankcase cover
Installing crankshaft sensor
Removing engine from assembly stand
Installing flange for heat exchanger with coolant lines
Installing starter
Installing screw (in hole for TDC locating screw)
Installing oil filter

092017 BMW Motorrad, UX-VA-4 9/9