BMW-Motorrad - 0A05 - R 1200 RS, K54

31 42 005 Oil change in telescopic front forks

+ 31 42 899
Equipment trim-level variant:
OE
0191 - Dynamic ESA

Additional billing items

46 52 512 Additional work for vehicle without centre stand

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 cover from left fork leg
Disengaging cable for left fork leg
Installing engine lifter
Removing front-wheel cover
Removing left brake caliper
Remove the right brake caliper
Removing front wheel
Removing left fork leg
Removing right fork leg

Core activity
(-) Oil change in telescopic forks
Draining oil from left fork leg

Remove screws (1).

ATTENTION
Hard or sharp-edged objects.
Component damage
Take care not to scratch components; cover or mask as necessary.

Fully unscrew cap (1) from fixed fork tube (2) and carefully lower fixed
fork tube (2) on to the slider tube.
Drain the oil from the fork leg into a suitable container until flow is
reduced to a slow drip.

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BMW-Motorrad - 0A05 - R 1200 RS, K54

Removing spring

Prepare pretensioning tool (No. 31 3 712) with extensions (No. 31 3

717).
Seat fork leg (1) in pretensioning tool (No. 31 3 712), with fork base on
locking pin (A).
Secure fork leg (1) with rubber retainer (2).

Insert dog (No. 31 3 718) into fork spring (1).

Set hold-down tool (B) in position and push extensions (No. 31 3 717)
into dog (No. 31 3 718).
Pretension compression spring (1) with hold-down tool (B) and spindle
(C).

Remove fork cap (1), while counter-holding at double sleeve (2).

Remove locknut (3).
Remove backup washer (4).

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BMW-Motorrad - 0A05 - R 1200 RS, K54

Back off hold-down tool (B) with spindle (C).

Remove dog (No. 31 3 718) from extensions (No. 31 3 717) and
compression spring (1).

Remove compression spring (1) and backup washer (2)

Remove the damper unit

Remove screw (1) with sealing ring (2).

Remove complete damper unit (3).

Drain off the rest of the oil.

Pouring oil into left fork leg

Installing damper unit

Note the fits (arrows) on damper unit (1) and fork base (2) on
installation and make sure that they are seated inside each other.
Damper unit and fork base are not damaged.

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BMW-Motorrad - 0A05 - R 1200 RS, K54

Install damper unit (1). Make sure that the damper unit is firmly
seated in the recess in the fork base (arrows) and cannot be
twisted out of position.
Carefully engage screw (1) with new sealing ring (2) and install. In this
process hold damper unit (3) securely to keep it from slipping out of
the recess (arrows).

Tightening torques
Damper unit to fork base
left fork leg, M10 x 1.25 x 40 - 30 Nm
10.9
Thread-locking compound (Loctite
243, Medium strength)
right fork leg, M10 x 1.25 x 60 - 30 Nm
10.9
Thread-locking compound (Loctite
243, Medium strength)

Carefully lower the fixed fork tube all the way onto the slider tube.
Pour the correct quantity of oil into the slider tube.

Technical data
Fork oil, capacity of initial filling approx. 304 ml
left fork leg
Telescopic fork oil (Telescopic fork oil SAE 7.5)

Allow the oil to settle for a few minutes.

Adjusting oil level

Set the correct oil level on dipstick (No. 31 6 551), insert the dipstick
into the telescopic fork and draw off the excess fork oil.

Technical data
Level of fork oil in Forks and 65 mm
left fork leg (air damper unit
chamber) fully
compressed,
compression

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BMW-Motorrad - 0A05 - R 1200 RS, K54

spring and
spacer
removed
Telescopic fork oil (Telescopic fork oil SAE 7.5)

Install backup washer (2) and fork spring (1)

Insert dog (No. 31 3 718) into fork spring (1).

Set hold-down tool (B) in position and push extensions (No. 31 3 717)
into dog (No. 31 3 718).
Pretension fork spring (1) with hold-down tool (B) and spindle (C).

Clean fork cap (1).

Check sealing ring (2) for damage; replace if necessary.

Install backup washer (4).

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BMW-Motorrad - 0A05 - R 1200 RS, K54

Install locknut (3).

Install fork cap (1) until firmly seated, while counter-holding at double
sleeve (2).

Tightening torques
Fork-leg cap, left to double sleeve
20 Nm

Lock fork cap (1) with locknut (3).

Tightening torques
Locknut (double threaded sleeve) to fork cap, left (Dynamic ESA)
20 Nm

Relieve the strain on fork spring (1) with hold-down tool (B) and spindle
(C), positioning fork spring (1) and backup washer (2) at fork cap (3).

Remove dog (No. 31 3 718) from extensions (No. 31 3 717) and fork
spring (1).
Back off hold-down tool (B) with spindle (C).

Disengage rubber retainer (B).

Remove fork leg (1) from pretensioning tool (No. 31 3 712), noting
locking pin (A).

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BMW-Motorrad - 0A05 - R 1200 RS, K54

Check sealing ring (3) for damage; replace if necessary.

ATTENTION
Hard or sharp-edged objects.
Component damage
Take care not to scratch components; cover or mask as necessary.

Push fixed fork tube (2) up and install cap (1).

Tightening torques
Cover to fixed fork tube
M52 x 1.5 20 Nm

Install screws (1), but do not tighten.

Drain the oil from right fork leg

Remove screws (1).

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BMW-Motorrad - 0A05 - R 1200 RS, K54

Firmly and repeatedly compress the fork leg to free any dirt that may
be inside.
ATTENTION
Hard or sharp-edged objects.
Component damage
Take care not to scratch components; cover or mask as necessary.

Fully unscrew cap (1) from fixed fork tube (2) and carefully lower fixed
fork tube (2).
Drain the oil from the fork leg into a suitable container.

Prepare pretensioning tool (No. 31 3 712) with extensions (No. 31 3

717).
Seat fork leg (1) in pretensioning tool (No. 31 3 712), with fork base on
locking pin (A).
Secure fork leg (1) with rubber retainer (B).

Position hold-down tool (C) from pretensioning tool (No. 31 3 712).

Position extension (No. 31 3 717) with knurled screws (D) in the holes
(arrows) of bushing (1), making sure that bushing (2) is not trapped.

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BMW-Motorrad - 0A05 - R 1200 RS, K54

Take care not to allow pretensioning tool (No. 31 3 712) and extension
(No. 31 3 717) to damage thread (1) in the fixed fork tube.

Press down bushing (1) with hold-down tool (C) and spindle (E) from
pretensioning tool (No. 31 3 712).
Pull cap (2) up.

ATTENTION
Hard or sharp-edged objects.
Component damage
Take care not to scratch components; cover or mask as necessary.

Slacken cap (1), while counter-holding at locknut (2).

Remove cap (1) and bushing (3).

Back off hold-down tool (C) with spindle (E) from pretensioning tool
(No. 31 3 712).
Disengage extension (No. 31 3 717) with knurled screws (D) from
bushing (1).

Remove bushing (1) with adapter (2) and backup washer (3).

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BMW-Motorrad - 0A05 - R 1200 RS, K54

Remove fork spring (4), backup washer (5) and plate (6).

Remove the damper unit

Remove screw (1) with sealing ring (2).

Remove damper unit (3).
Pump damper unit (3) to drain it fully.

Drain off the rest of the oil.

Pouring oil into right fork leg

Installing right damper unit

Note the fits (arrows) on damper unit (1) and fork base (2) on
installation and make sure that they are seated inside each other.
Damper unit and fork base are not damaged.

Install damper unit (1). Make sure that the damper unit is firmly
seated in the recess in the fork base (arrows) and cannot be
twisted out of position.

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BMW-Motorrad - 0A05 - R 1200 RS, K54

Checking installation of damper unit

Requirement
The damper unit must be firmly seated in the fork base and the piston
rod must be fully retracted.

Position depth gauge (1) on fixed fork tube (2).

Check

Measure distance (A) between fixed tube (2) and piston rod (3).

Technical data
Reference distance, 4.9 mm
projection of
damper unit

Result:

Distance is not to specification.

Measure:

Reinstall damper unit.

Carefully engage screw (1) with new sealing ring (2) and install. In this
process hold damper unit (3) securely to keep it from slipping out of
the recess (arrows).

Tightening torques
Damper unit to fork base
left fork leg, M10 x 1.25 x 40 - 30 Nm
10.9
Thread-locking compound (Loctite
243, Medium strength)
right fork leg, M10 x 1.25 x 60 - 30 Nm
10.9

Thread-locking compound (Loctite

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BMW-Motorrad - 0A05 - R 1200 RS, K54

243, Medium strength)

Carefully lower the fixed fork tube all the way onto the slider tube.
Pour the correct quantity of oil into the slider tube.

Technical data
Fork oil, capacity of initial filling approx. 682 ml
right fork leg
Telescopic fork oil (Telescopic fork oil SAE 7.5)

Repeatedly move piston rod (1) of the damper unit up and down.
Air is expelled from the damper unit.
Allow the oil to settle for a few minutes.
Repeat the procedure until the oil is free of bubbles and the oil level no
longer changes.
Adjusting oil level

Set the correct oil level on dipstick (No. 31 6 551), insert the dipstick
into the telescopic fork and draw off the excess fork oil.

Technical data
Level of fork oil in Forks and 82 mm
right fork leg (air damper unit
chamber) fully
compressed,
compression
spring and
spacer
removed
Telescopic fork oil (Telescopic fork oil SAE 7.5)

Install plate (6) backup washer (5) and fork spring (4).
Install backup washer (3) and bushing (1) with adapter (2).

Take care not to allow pretensioning tool (No. 31 3 712) and extension
(No. 31 3 717) to damage thread (1) in the fixed fork tube.

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BMW-Motorrad - 0A05 - R 1200 RS, K54

Position hold-down tool (C) from pretensioning tool (No. 31 3 712).

Position extension (No. 31 3 717) with knurled screws (D) in the holes
(arrows) of bushing (1).
Press down bushing (1) with hold-down tool (C) and spindle (E) from
pretensioning tool (No. 31 3 712).

Check the O-ring (arrow) for damage; replace if necessary.

Install bushing (1).
Slowly tighten cap (2) until it is lightly seated.
Secure cap (1) with locknut (3).

Tightening torques
Locknut to fork-leg cap
M13 x 1.25 20 Nm

Slowly relieve pressure on bushing (1) by backing off hold-down tool

(C) and spindle (E) from pretensioning tool (No. 31 3 712).
Make sure that bushing (2) is correctly seated in bushing (1).

Back off extension (No. 31 3 717) with knurled screws (D) from
bushing (1).

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BMW-Motorrad - 0A05 - R 1200 RS, K54

Push back hold-down tool (C) from pretensioning tool (No. 31 3 712).

Disengage rubber retainer (B).

Remove fork leg (1) from pretensioning tool (No. 31 3 712), noting
locking pin (A).

Push fixed fork tube (2) up and install cap (1).

Tightening torques
Cover to fixed fork tube
M52 x 1.5 20 Nm

Install screws (1), but do not tighten.

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BMW-Motorrad - 0A05 - R 1200 RS, K54

Finishing work
Install the right fork leg
Installing left fork leg
Install the front wheel
Securing right brake caliper
Securing left brake caliper
Bedding in brake pads
Installing front-wheel cover
Removing engine lifter
Securing cable for left fork leg
Installing cover on left fork leg
Final check of work performed

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