BMW F 650 GS, K72 0218

BMW-Motorrad - 0218 - F 650 GS, K72
Technical data 0218 - F 650 GS

Equipment trim-level variant:
0774 - Seat, lowOE
0499 - Lowered suspensionOE
0703 - Power reductionOE
00 - Maintenance and general notes
Designation Precondition Value Valid

Acceleration From 0...100 km/h 4.3 s
Rider's inside-leg arc, heel to heel Without rider at unladen 1710 mm
weight
Front-seat height Without rider at unladen 765 mm
weight
Width of motorcycle across mirrors without 845 mm
mirrors
Height of motorcycle Without rider at unladen 1240 mm
weight
Length of motorcycle across front wheel to 2280 mm
number-plate carrier
Top speed max 147 km/h
Vehicle kerb weight DIN unladen weight, 199 kg
ready for road, 90 %
load of fuel
Maximum payload 150 kg
Permissible gross weight 349 kg
092017 BMW Motorrad, UX-VA-4 1/1


0703 - Power reductionOE
11 - Engine

Running-in speed <5000 min-1
Displacement 798 cm3
Piston stroke 75.6 mm
Compression test pressure Poor <11 bar
Normal 11...15 bar
Good >15 bar
Direction of crankshaft rotation Crankshaft viewed from Clockwise
right in forward
direction of travel
Idle speed vehicle at standstill 1250+50 min-1
Torque - at engine 57 Nm
speed 3000 min-1
Press loss Engine at regular max 25 %
through valves or cylinder operating temperature
Engine design Two-cylinder four-stroke, DOHC with

chain-and-sprocket drive, 4 valves
operated by cam followers,
balancing conrod, liquid-cooled
cylinders and heads, integral water
pump, 6-speed gearbox and dry
sump lubrication
Location of engine number Crankcase, bottom right
Nominal output - at engine 25 kW
speed 5000 min-1
Compression ratio 12 : 1
Maximum engine speed max 9000 min-1
Cylinder bore 82 mm
Engine oil, capacity with filter change approx. 2.9 l
Fluids and lubricants
Viscosity class
Engine oil, quantity for topping up Difference between max 0.4 l
MIN and MAX
Viscosity class
additional quantity of engine oil after 0.3 l
removal of swing-arm shaft cover Fluids and lubricants
Viscosity class
Engine oil, specified level between MIN and MAX marks

11 11 - Engine block
Total wear clearance between max 0.10 mm
piston and cylinder
Cylinder bore When new, from top 82+0.007 mm
edge 31...36 mm −0.007
Wear, from top max 82.03 mm

edge 31...36 mm
11 12 - Cylinder head with cover
Exhaust valve seat width When new 1.4+0.15 mm
−0.15
Wear limit max 2.5 mm

Inlet valve seat width When new 1.2+0.15 mm
−0.15

Radial play of exhaust-valve guide When new 0.03...0.056 mm
Radial play of inlet-valve guide When new 0.02...0.046 mm
permissible distortion of cylinder- 0.03...0.06 mm
head sealing face
11 21 - Crankshaft with bearings
Radial play of crankshaft main When new 0.03...0.06 mm
bearing Wear limit max 0.08 mm
Endplay of crankshaft When new 0.15...0.30 mm
Wear limit min 0.45 mm
Crankshaft bearings Plain bearing
11 24 - Conrod with bearings
Radial play of small-end bore of When new 0.001...0.018 mm
balancing conrod Wear no noticeable play, no rough
limit max 0.03 mm operation permissible
Piston-pin radial play in conrod New condition (version 0.01...0.024 mm
with bushing)
New condition (version 0.015...0.034 mm
without bushing)
Wear limit (both max 0.04 mm
versions)
Conrod endplay When new 0.10...0.35 mm
Radial play of bearing pin in When new 0.005...0.022 mm
balancing swing arm Wear limit max 0.04 mm

Radial play of big-end bore of When new 0.044...0.08 mm

balancing conrod Wear limit max 0.09 mm
Radial play of big-end bearing bore When new 0.026...0.062 mm
11 25 - Piston with rings and bolts
Piston, installed direction the arrow on the piston crown points
toward the exhaust side, the
projection on the underside of the
piton is opposite the timing-chain
cavity
Piston type Cast light-alloy piston with three
rings
Piston diameter When new (until 81.97+0.02 mm
02/2012), at right −0.02
angles to piston-pin
axis, across bottom
edge of piston 6 mm
When new (02/2012 81.975+0.02 mm
onward), at right angles −0.02
to piston-pin axis,
across bottom edge of
piston 6 mm
Wear limit, at right min 81.94 mm
angles to piston-pin
axis, across bottom
edge of piston 6 mm
Piston installation clearance New condition (until 0.04...0.056 mm
02/2012)
New condition (02/2012 max 0.051 mm
onward)
Piston-ring direction of installation "Top" marking uppermost
Piston ring shape Type, rectangular-section ring
1st groove
Piston ring shape Type, taper-face oil-control ring
2nd groove
Piston ring shape Type, oil wiper ring
3rd groove
11 31 - Camshaft
Track depth in timing-chain Wear limit max 0.8 mm
tensioner rail and slide rail
Endplay of camshaft When new 0.07...0.17 mm
Radial play of camshaft When new 0.02...0.05 mm
11 34 - Valves with springs
Valve spring length When new, no load 50.85 mm
Wear limit, no load min 49.50 mm

Exhaust valve stem diameter When new 4.963 mm

Inlet valve stem diameter When new 4.973 mm
Valve stem runout At stem; wear limit max 0.02 mm
At head; wear limit max 0.04 mm
Exhaust valve clearance Engine cold max 35 °C 0.27...0.35 mm
Inlet valve clearance Engine cold max 35 °C 0.18...0.26 mm
11 40 - Oil supply
Oil pressure at idle speed approx. 1.5...2.0 bar
Engine oil is at normal operating - at engine approx. 4.5...6.5 bar
temperature (fan has started) speed 5000 min-1
Lubrication system type Dry-sump lubrication
11 41 - Oil pump with strainer and drive
Oil pump type 2 trochoid pumps, driven off primary
drive


12 - Engine electrical system

12 12 - Ignition lead, spark plugs
Electrode gap of spark plug when new 0.8...0.9 mm
Spark plugs, manufacturer and NGK DCPR 8 E
designation


13 - Fuel preparation and control

Recommended fuel grade Regular, unleaded max. 10 %
ethanol, E10
91 ROZ/RON
87 AKI
13 53 - Injection nozzles and lines
Fuel pressure of the injection 2.5...5 bar
system


16 - Fuel supply

Usable fuel capacity approx. 16 l
Reserve fuel approx. 4 l
16 14 - Delivery, preparation and measurement, control unit, fuel pump
Operating pressure of fuel pump 3.5+0.5 bar
−0.5


17 - Cooling

Cut-in temperature for coolant 115.5 °C
temperature warning
Cooling system test pressure Test pressure must 1.5 bar
remain
unchanged: 5 min
Coolant, specified level between MIN and MAX marks on
the expansion tank
General consumable (Antifreeze and corrosion inhibitor)
Coolant, total capacity 1.65 l

Coolant, capacity of expansion tank 0.15 l
Coolant, frost protection min -25 °C
17 12 - Coolant lines
Opening temperature for coolant 85 °C
thermostat


21 - Clutch

Clutch type Multiplate clutch running in oil bath
Number of clutch plates 9 steel plates
9 friction plates
21 21 - Clutch with driver plate
Clutch spring length When new, no load on 63 mm
spring
Wear limit, no load on min 60 mm
spring
Thickness of one lined plate When new 3.5+0.08 mm
−0.08

Distortion of one lined plate Wear limit max 0.15 mm
Distortion of one steel plate Wear limit max 0.15 mm


23 - Gearbox

Gearbox type Claw-shift 6-speed transmission,
integrated into engine block
23 22 - Gears
Gearbox transmission ratios Primary transmission 1.943 (35/68 teeth)
ratio
1st gear 1:2.462 (13/32 teeth)
2nd gear 1:1.750 (16/28 teeth)
3rd gear 1:1.381 (21/29 teeth)
4th gear 1:1.174 (23/27 teeth)
5th gear 1:1.042 (24/25 teeth)
6th gear 1:0.960 (25/24 teeth)
23 31 - Internal gearshift components
Shift-fork web width, thickness at When new 5.825...5.9 mm
contact faces Wear limit min 5.6 mm
Gear shift wheel groove width When new 6.1...6.2 mm


31 - Front axle, front-wheel steering

Spring travel, front At wheel 180 mm
Type of front suspension telescopic forks
Fork oil, capacity per fork leg 530 ml
Telescopic fork oil (Telescope fork oil type 2)
Level of fork oil in fork leg (air Forks fully compressed, 100 mm
chamber) spring removed, spacer
installed
31 42 - Telescopic forks
Fixed fork tube outside diameter 41 mm
Fixed fork tube surface Hard chrome plated
Fixed fork tube runout max 0.1 mm


32 - Steering and wheel alignment

Steering lock angle To each side 40°
32 71 - Motorcycle handlebars
Handlebars, type Tubular steel handlebars
Width of handlebars With handlebar weights 845 mm
Handlebar tube diameter 22 mm
32 73 - Bowden cables
Setting, throttle-cable play at outermost diameter 1...2 mm
of rubber grip, engine
cold max 35 °C
Clutch play Handlebars turned fully 3 mm
left, between handlebar
fitting and clutch cable


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

Type of final drive Chain drive
Type of rear suspension Two-arm cast-aluminium swinging
arm
33 54 - Spring strut, mounting parts
Basic setting of spring preload, rear Full load of fuel, with Turn adjusting screw as far as it will
rider 85 kg go counter-clockwise, then preload
the spring 5 clicks.
Spring travel at rear wheel At wheel 135 mm
Basic setting of rear-suspension full load of fuel, with Turn adjusting screw as far as it will
damping characteristic rider 85 kg go clockwise, then back it off 2
turns.
Type of rear suspension Direct-pivot central spring strut with
steplessly adjustable rebound-stage
damping
33 82 - Traction drive, chain pinion, belt pinion
Final drive, number of teeth 17 / 41
Pinion / sprocket
Secondary transmission ratio 2.412
33 83 - Traction drive, chain, belt
Final-drive chain type and O-ring chain 525 x 5/8 x 5/16
designation
Number of links in final-drive chain 116
Chain deflection Motorcycle with no 20...30 mm
weight applied,
supported on its side
stand
Chain-link width after press-fitting 19.90+0.1 mm
−0.05
Measured across outer flats of outer
plates
Permissible chain length measured centre to max 144.30 mm
centre over 10 pins,
chain pulled taut


34 - Brakes

Brake fluid level, front (for repair) Brake-fluid reservoir MAX mark on reservoir; with new
horizontal brake pads
Hydraulic fluid (Brake fluid, DOT4)
Brake fluid level, front (visual It is impermissible for the brake fluid
inspection) level to drop below the MIN mark.
Brake fluid level, rear (for repair) Brake-fluid reservoir MAX mark on reservoir; with new
horizontal brake pads
Brake fluid level, rear (visual It is impermissible for the brake fluid
34 11 - Front wheel brakes

Type of front brake Hydraulically operated disc brake
with 2-piston floating caliper and
fixed disc
Brake-pad material, front Sintered metal
Brake-pad wear limit, front Friction pad only, min 1.0 mm
without backing plate.
The wear indicators
(grooves) must be
clearly visible.
Brake disc diameter, front 300 mm

Brake disc lateral runout, front At circumference max 0.15 mm
Brake disc thickness, front When new 5.0 mm
34 21 - Rear wheel brakes
Type of rear brake Hydraulically actuated disc brake
with 1-piston floating caliper and
fixed disc
Brake-pad material, rear Organic material
Brake-pad wear limit, rear Friction pad only, min 1.0 mm
The wear
indicators must be
clearly visible.

Brake disc diameter, rear 265 mm

Brake disc lateral runout, rear At circumference max 0.15 mm
Brake disc thickness, rear When new 5.0 mm


35 - Foot operation

35 21 - Footbrake lever, connecting linkage
Blow-by clearance of the footbrake between footbrake 2.5+0.5 mm
lever lever and stop −0.5


36 - Wheels and tyres

36 30 - Motorcycle wheels
Balance weight for the rear wheel max 80 g
One half of the weights must be
attached to the left and the other
half to the right of the wheel rim
Balance weight for front wheel max 80 g
Permissible rear-wheel imbalance max 45 g
Permissible front-wheel imbalance max 5 g
36 31 - Wheels with bearings
Rear-wheel type Cast aluminium, MT H2
Rear wheel rim size 3.50" x 17"
Vertical runout, rear wheel max 1.5 mm
Lateral runout, rear wheel max 1.5 mm
Front wheel type Cast aluminium, MT H2
Front wheel rim size 2.50" x 19"
Vertical runout, front wheel max 1.5 mm
Lateral runout, front wheel max 1.5 mm
36 32 - Tyres
Wheel valve test pressure 4 bar
Tyre designation, rear 140 / 80 R 17
Tyre designation, front 110 / 80 R 19
Tyre pressure, rear one-up, at tyre 2.4 bar
temperature 20 °C
two-up and/or with 2.8 bar
luggage, at tyre
temperature 20 °C
Tyre pressure, front one-up, at tyre 2.2 bar
temperature 20 °C
luggage, at tyre
temperature 20 °C
Tyre tread depth, front and rear Wear limit, for Germany min 1.6 mm
only
Wear limit, outside Country-specific legal requirements
Germany


46 - Frame and mounted components

46 51 - Motorcycle frame
Position of the Vehicle Identification Frame, front right, on steering head
Number
Frame type Tubular spaceframe
Type plate location Steering head, front top


0369 - Deviation from standard for authority vehiclesBU
0524 - BMW MotorradABSOE
61 - General vehicle electrics

61 13 - Plug, terminal
Electrical rating of on-board sockets 5A
Fuse 1 10 A
Marker strobe
Fuse 2 7.5 A
360° marker strobe
Fuse 3 10 A
Hailing system
Fuse 4 10 A
Two-way radio
Fuse 5 4A
Switch for hailing system
Fuse 6 Not used
Fuse 7 4A
Accessories socket
Fuse 8 Not used
61 21 - Battery with holder
Battery type AGM (Absorbent Glass Mat) battery
Battery rated capacity 12 Ah
Battery rated voltage 12 V
61 31 - Switch, sensor
Microswitch trip point 5...9 mm
Travel of handlebar lever
Gap between rear wheel speed 0.2...1.4 mm

sensor and sensor ring
Gap between front wheel speed 0.2...1.4 mm
sensor and sensor ring


62 - Instruments

62 14 - Display and instrument indicator lights
Bulbs for warning lights and LED
instrument lighting


0588 - Flashing turn indicators, whiteOE
LED flashing turn indicatorsOA
63 - Lights

63 10 - Front lights, position lights and side lights
Bulb for parking light W5W / 12 V / 5 W
63 12 - Headlight
Distance between light/dark cut-off Suspension set to basic 7.5 cm
and mark at height of centre of setting and vehicle
headlight loaded with 85 kg
Distance between headlight and 5m
vertical surface
For headlight adjustment
Bulbs for the low-beam headlight H7 / 12 V / 55 W
Bulb for high-beam headlight H7 / 12 V / 55 W
63 13 - Flashing turn indicators, front
Bulbs for flashing turn indicators, RY10W / 12 V / 10 W
– with white turn indicatorOE
front (0588)
LED / 12 V – with LED flashing turn

indicatorsOA
63 21 - Rear light cluster

Bulb for tail light/brake light LED
Maximum number of defective LEDs Brake light/rear light 6
in rear-light unit
63 23 - Flashing turn indicators, rear
Bulbs for flashing turn indicators, RY10W / 12 V / 10 W
– with white turn indicatorOE
rear (0588)
LED / 12 V – with LED flashing turn

indicatorsOA
63 26 - Number-plate light
Light source for the number plate W5W / 12 V / 5 W
light


0603 - Anti-theft alarm (DWA)OE
Anti-theft alarm (DWA)OA
65 - Audio, navigation, information systems

65 61 - Two-way radios
Payload of two-way radio box max 10 kg
65 75 - Anti-theft alarm
Battery type CR123A lithium
3V


Rear softbagOA
CasesOA
Tank rucksackOA
TopcaseOA
71 - Parts and accessories for engine and frame and suspension

71 54 - Accessories for luggage carrier
Maximum permissible speed for max 130 km/h
riding with the rear softbag fitted to
the motorcycle
Maximum permissible speed for see label in case
riding with cases fitted to the
motorcycle
Maximum permissible speed for max 130 km/h
riding with the tank bag fitted to the
motorcycle
Maximum permissible speed for see label in topcase
riding with topcase fitted to the
motorcycle
Payload of rear softbag max 1.5 kg
Payload of cases see label in case
Payload of tank rucksack max 5 kg
Payload of topcase see label in topcase

Tightening torques 0218 - F 650 GS

00 - Maintenance and general notes Value Valid
General tightening torques as per BMW GS 90003-2 (as issued, August 2011) unless other torques are specified.
Screw connection class III +/- 15 %. Does not apply to G models (K15).
M3 x 0.5 - 8.8 1 Nm
M3 x 0.5 - 10.9 1.4 Nm
M4 x 0.7 - 8.8 2.3 Nm
M4 x 0.7 - 10.9 3.3 Nm
M5 x 0.8 - 8.8 4.5 Nm
M5 x 0.8 - 10.9 6.8 Nm
M5 x 0.8 - 12.9 7.6 Nm
M6 x 1 - 8.8 8 Nm
M6 x 1 - 10.9 11.8 Nm
M6 x 1 - 12.9 13 Nm
M7 x 1 - 8.8 13 Nm
M7 x 1 - 10.9 19 Nm
M7 x 1 - 12.9 21 Nm
M8 x 1.25 - 8.8 19 Nm
M8 x 1.25 - 10.9 28 Nm
M8 x 1.25 - 12.9 31.5 Nm
M8 x 1 - 8.8 20.5 Nm
M8 x 1 - 10.9 30 Nm
M8 x 1 - 12.9 33 Nm
M10 x 1.5 - 8.8 38 Nm
M10 x 1.5 - 10.9 56 Nm
M10 x 1.5 - 12.9 62 Nm
M10 x 1 - 8.8 41 Nm
M10 x 1 - 10.9 60 Nm
M10 x 1 - 12.9 67 Nm
M12 x 1.75 - 8.8 66 Nm
M12 x 1,75 - 10.9 96 Nm
M12 x 1.75 - 12.9 108 Nm
M12 x 1.5 - 8.8 68 Nm
M12 x 1.5 - 10.9 100 Nm
M12 x 1.5 - 12.9 110 Nm


11 - Engine Value Valid

Engine block
Engine block, bottom, to engine block, top, M6 x 35 Tightening sequence: See repair
manual
12 Nm
Engine block, bottom, to engine block, top, M6 x 65 12 Nm
Engine block, bottom, to engine block, top, M8 x 70 30 Nm
Threaded fasteners for crankshaft main bearings, M8 x 130 Tightening torque, 15 Nm
10.9, Replace screw
Additional angle of rotation, 80+5°
Thread and seating face of the screw oiled −5
Oil filter adapter to crankcase

M18 x 1.5 5.8 30 Nm
Coolant drain plug
M6 x 16 10 Nm
Socket-head screw (hole for TDC locating pin)
M8 x 16 25 Nm
Vent connector to cylinder head cover
self-tapping screw, M6 x 16 10 Nm
Thread-locking compound (Loctite 243, Medium strength)
Threaded stud, manifold
M7 x 30 Projection, 17+1 mm
−1
Threaded stud, camshaft bearing cap

M6 x 45 Projection, 30.5+1 mm
−1
Camshaft bearing cap to cylinder head

M6 Tightening sequence: See repair
manual
1st tightening torque, tightened
uniformly by hand
2nd tightening torque, 10 Nm
Cylinder head to crankcase
M10 x 1.25 - 10.9 Tightening sequence: See repair
manual
1st tightening torque, 10 Nm
Additional angle of rotation, 130°

M6 x 65 10 Nm
Cylinder head cover to cylinder head
M6 Tightening sequence: tighten in
diagonally opposite sequence
10 Nm
11 13 - Oil sump
Cover of swing-arm shaft
M6 x 25 Tightening sequence: See repair
Thread-locking compound (Loctite 243, Medium strength) manual
12 Nm
Engine guard to engine-guard adapter
M8 8 Nm
Engine guard to oil pan
M8 x 115 8 Nm
Engine-guard adapter to oil pan
Silentblock, M8 19 Nm
Oil drain plug
M24 x 2 40 Nm
Oil pan to crankcase
Hexagon Torx screw with collar, M6 x 35 - 8.8, in the event of Tightening sequence: See repair
repair, replace with collar bolt with imprint 10.9 manual
12 Nm
Collar bolt, M6 x 35 - 10.9 Tightening sequence: See repair
manual
14 Nm
11 14 - Housing cover
Engine-block cover, left, to engine block
manual
12 Nm
Line holder to crankcase cover, right
Taptite screw M4 x 8 4 Nm
Pinion cover to engine
M5 x 25 4 Nm
Pinion cover to frame
M5 x 12 4 Nm
Engine housing cover, right, to crankcase
manual
12 Nm

11 15 - Crankcase breather
M6 x 16, use thread-locking compound for repair 10 Nm
11 21 - Crankshaft with bearings
Main bearing cap
M8 x 77 10.9, Replace screw Tightening sequence: See repair
Collar flat of screw lightly oiled manual
Tightening torque, 15 Nm
Additional angle of rotation, 45+5°
−5
11 24 - Conrod with bearings

Balancing conrod
M12 x 1.25 - 12.9, Replace screws 1st tightening torque, 10 Nm
Threads and underside of head lightly oiled 2nd tightening torque, 50 Nm
Conrod bolt
M9 x 1 - 12.9, Replace screws 1st tightening torque, 10 Nm
Thread and seating face of the screw oiled 2nd tightening torque, 20 Nm
11 31 - Camshaft
Chain tensioner rail to engine block
M6 10 Nm
Sprockets to camshafts
M18 x 1.5 - 10.9 50 Nm
Chain tensioner to cylinder head
M18 x 1.5 40 Nm
11 41 - Oil pump with strainer and drive
Oil-pump cover (suction pump) to crankcase
M6 x 16 12 Nm
Thread-locking compound (Micro-encapsulated)
or, Thread-locking compound (Loctite 243, Medium strength)
Oil-pump cover (pressure pump) to crankcase
M6 x 16 10 Nm
11 42 - Oil filter and lines
Oil filter to crankcase 11 Nm
11 51 - Coolant pump with drive

Priming screw to coolant pump

M6 x 25 12 Nm
Pump impeller to pump shaft
M8 5 Nm
Coolant pump housing to cylinder head
manual
12 Nm
Coolant pump to cylinder head
M6 x 16 10 Nm
Coolant-pump drive gear to camshaft
M8 x 25 - 10.9, left-hand thread 30 Nm
11 78 - CO adjustment, oxygen sensor
Oxygen sensor to exhaust manifold
M18 x 1.5 45 Nm
Lubricate thread, Lubricant (Optimoly TA)
11 84 - Engine and powerplant protection parts
Crash bar to engine
Front, M10 x 30 38 Nm
Left, M8 x 20 19 Nm
Right, M8 x 50 19 Nm
Crash bar, left, to crash bar, right
M6 8 Nm


12 - Engine electrical system Value Valid
Spark plugs
M12 x 1.25 20 Nm
12 31 - Alternator with drive and fasteners
Freewheel housing to magnetic gear
M8 x 16 - 12.9 35 Nm
Adhesive (Loctite 648)
Stator to housing cover
M6 x 35 10 Nm
Magnetic wheel to crankshaft
M16 x 35 140 Nm
12 32 - Regulator
Bracket for voltage regulator to frame
M6 x 12 7 Nm
Voltage regulator to bracket
M6 x 35 7 Nm
12 41 - Starter with fastener
Starter to engine block
M6 x 30 10 Nm
Starter housing screw
M5 - 6.8, chrome plated 5 Nm
Positive contact to starter
M6 6 Nm
12 61 - Oil pressure, oil temperature, oil-level indicators
Oil-pressure switch to cylinder head
M12 x 1.5 20 Nm
12 62 - Coolant temperature
Temperature sensor to cylinder head
M12 x 1.5 16 Nm
12 72 - Transmitter for control unit
Crankshaft sensor to engine block
M6 x 16 10 Nm


Speed sensor, camshaft, to cylinder head
M6 x 16 10 Nm


13 - Fuel preparation and control Value Valid
13 54 - Throttle valve and actuation
Injection rail to throttle-valve stub
M5 x 12 2 Nm
Throttle-valve potentiometer to throttle-valve stub
M4 x 25 3 Nm
Bracket for throttle cable to throttle valve stub assembly
M5 x 14 5 Nm
13 61 - Control unit electronic
Bracket for control unit to rear frame
M5 x 22 6 Nm
13 71 - Intake air silencer
Intake air silencer to frame
M6 x 25 6 Nm
Idle actuator to intake air silencer
PT screw 3 Nm
Secondary air system changeover valve to intake air silencer
Screw for plastic, 4 x 15 2 Nm


16 - Fuel supply Value Valid
16 11 - Fuel tank with filler neck
Safety valve to fuel tank
M5 x 20 1.5 Nm
Fuel tank to rear frame
M6 x 35, Replace screw 8 Nm
Thread-locking compound (mechanical)
Fuel filler cap to fuel tank
M5 x 20 2.5 Nm
M5 x 16 2.5 Nm
16 14 - Delivery, preparation and measurement, control unit, fuel pump
Fuel pump to fuel tank
Union nut 35 Nm
Electronics unit/fuel line to pump unit
Screw for plastic, 3.5 x 14 0.7 Nm
Lever-type sensor to fuel-pump flange
Self-tapping screw, 4.2 x 13 0.7 Nm


17 - Cooling Value Valid
17 11 - Radiator with fasteners
Radiator to holder
M6 x 20 5 Nm
Holder for radiator at bottom to main frame
M6 x 16 8 Nm
17 12 - Coolant lines
Coolant line to heat exchanger
M6 x 16 10 Nm
17 13 - Expansion tank
Expansion tank to front panel carrier
M6 x 16 2.5 Nm
17 21 - Oil cooler
Heat exchanger to engine
M6 x 16 10 Nm


Case carrierOA
18 - Exhaust system Value Valid

18 51 - Exhaust system parts with mountings
Exhaust manifold to frame
M8 x 50 19 Nm
Exhaust header to cylinder head
M7 14 Nm
Case carrier with silencer to rear frame
M8 x 75 19 Nm
Silencer to rear frame
M8 x 50 19 Nm


21 - Clutch Value Valid
21 21 - Clutch with driver plate
Pressure plate to clutch hub
M6 x 45 Tightening sequence: tighten in
10 Nm
Clutch hub to gearbox input shaft
M24 x 1.5 180 Nm


23 - Gearbox Value Valid
23 00 - Gearbox
Pinion to gearbox output shaft
M10 x 35 50 Nm
23 12 - Bearing in housing, sealing rings
Selector-drum bearing to engine block
M6 x 13 10 Nm
23 14 - Electrical components
Gearbox potentiometer to engine block
23 31 - Internal gearshift components
Locking lever to bottom casing
with washer, M6 x 16, Replace screw 10 Nm
without washer, M6 x 13, Replace screw 10 Nm
Star-shaped locking element to selector drum
M6 x 25 10 Nm
23 41 - External gearshift components
Shift lever to selector shaft
M6 x 25 8 Nm


31 - Front axle, front-wheel steering Value Valid
Damper unit to slider tube
M10 x 30 50 Nm
Adjustment specification, steering-head bearing
M18 x 1 Tightening torque, 25 Nm
Swing the forks 3x to left/right
through full arc of travel
Loosen, 60°
Fork stabiliser to slider tube
M8 x 25 -10.9 19 Nm
Clamp of quick-release axle
M8 x 25 19 Nm
Pinch bolt, steering head
M8 x 40 19 Nm
Handlebar clamping block to top fork bridge
M10 x 70 - 10.9, Replace nut 25 Nm
Fixed fork tube to fork bridge, top
M8 x 25 19 Nm
Fixed fork tube to fork bridge, bottom
M8 x 25 Tightening sequence: Tighten

screws six times in alternate
sequence
19 Nm


32 - Steering and wheel alignment Value Valid
Handlebar weight to handlebar
M12 x 1.5 21 Nm
Handlebar grip, left, to handlebar
M3.5 x 32 2 Nm
Handlebars to clamping block
M8 x 30 - 10.9 Tightening sequence: in the
forward direction of travel, tighten
until seated
28 Nm
32 72 - Handlebar lever
Adapter to handlebar fitting
Screw for plastic, 3.5 x 20, Replace screw 1.7 Nm
Expansion tank to bracket
Plastic screw, 3 x 20 1 Nm
Handlebar fitting to handlebar
M5 x 35 Tightening sequence: tighten
alternately, at front on block
5 Nm
Clutch handlebar fitting to handlebar
M5 x 20 Tightening sequence: tighten
alternately, at front on block
5 Nm
Lever to handlebar fitting
M5, Replace nut Tightening sequence: Tighten the
Thread-locking compound (mechanical) nut, counter-holding the bolt
7 Nm
Suppressor weight to holder
M5 x 10 5 Nm
32 73 - Bowden cables
Retainer to fork bridge, top
M5 x 12 5 Nm
Locknut, clutch cable at engine cover
M8 2 Nm


33 - Rear axle, rear-wheel drive and rear-wheel guidance Value Valid
33 35 - Rear wheel swinging arm with pivot mount, link
Rear wheel swinging arm to frame
M14 x 1.5, Replace nut 100 Nm
Locknut of the final-drive chain tensioning screw
M8 19 Nm
Spring strut to frame
M12 x 120- 10.9 100 Nm
Spring strut to swinging arm
Fitted-head screw, M12 x 1.5 x 60 - 10.9, Replace screw 100 Nm
33 84 - Traction drive, chainwheel, belt wheel
Chain sprocket to chain-sprocket carrier
M10, Replace the nuts and screws Tightening torque, 10 Nm
Thread-locking compound (mechanical) Additional angle of rotation, 90°
33 85 - Mounted parts, traction drivetrain
Chain slide rail to frame
M6 x 40 4 Nm
Chain slide rail to rear wheel swinging arm
M5 x 12 4 Nm


34 - Brakes Value Valid

Brake caliper to fork leg
M10 x 40 38 Nm
Brake disc to front wheel
Bleed screw on handbrake fitting
M5 2 Nm
Bleed screw, brake caliper, front
M10 x 1 - 4.9 14 Nm
Brake disc with sensor ring to rear-wheel hub
M8 x 15.5, Replace screw Tightening sequence: tighten by
Thread-locking compound (Micro-encapsulated) stages in diagonally opposite
sequence
30 Nm
Rear brake caliper bleed screw
M10 x 1 - 4.9 14 Nm
Locknut, fork end to pushrod
M6 8 Nm
34 31 - Footbrake cylinder, tandem brake master cylinder
Brake-fluid reservoir to frame
M6 x 16, Replace screw 2.5 Nm
Footbrake cylinder to frame
34 32 - Brake lines
Brake pipe with union screw to components
M10/M12 14 Nm
Brake hose with banjo bolt to components
M10 x 1 24 Nm
Brake hose to bottom fork bridge
M6 x 16 8 Nm

Brake-hose guide to rear swinging arm

Brake-hose guide to swinging arm, front
Distributor to frame, rear left
M6 8 Nm
Distributor to frame, front right
M6 x 12 8 Nm
34 51 - Mechanical, hydraulic components
Pressure modulator to bracket
M6, Replace nut 8 Nm
Bracket for pressure modulator to engine block
M6 x 40 8 Nm
34 52 - Electronic components
Wheel-speed sensor, rear
M6 x 16 8 Nm
Wheel-speed sensor, front
M6 x 16 8 Nm


35 - Foot operation Value Valid
35 21 - Footbrake lever, connecting linkage
Brake lever to footrest plate
M8, Replace screw 19 Nm


0530 - Tyre pressure monitoring (RDC)OE
36 - Wheels and tyres Value Valid

RDC sensor, front, to wheel rim
Thread-locking compound (Micro-encapsulated) Tightening torque, 12 Nm
or, Thread-locking compound (Loctite 243, Medium strength) Slacken the nut
Quick-release axle, front, in axle holder
M16 x 1.5 30 Nm
Rear quick-release axle in swinging arm
M16 x 1.5 100 Nm


0636 - Centre standOE
Centre standOA
0130 - CasesOE
46 - Frame and mounted components Value Valid

46 51 - Motorcycle frame
Rear frame to main frame, top
Rear frame to main frame, bottom
Frame, rear left, to cylinder head
M10 x 40 40 Nm
Frame, rear right, to cylinder head
M10 x 65 40 Nm
Frame, bottom, to engine
M10 x 40 38 Nm
Frame, front, to cylinder head
M12 x 50 66 Nm
46 53 - Side stand
Side-stand pivot mount/footrest plate, left, to frame
M10 x 20 - 10.9, Replace screw 50 Nm
Side stand to pivot mount
M10 - 10.9, Replace screw 38 Nm
Side-stand switch to side-stand screw
46 54 - Luggage system
Cover to bottom of case 1 Nm
Locknut on case locating stud 16 Nm
Luggage carrier to grab handle and number-plate carrier
M8 x 55 19 Nm

Grab handle to rear frame at rear

M8 x 35 19 Nm
Grab handle to rear frame at front
M8 19 Nm
Lever to adjuster unit 1.5 Nm
Case carrier to rear frame at rear
M8 x 25 19 Nm
Case carrier to rear frame at front
M8 x 25 19 Nm
Lock strip to case lid 1.5 Nm
Locking mechanism to bottom of case 4 Nm
Adjuster unit to adjuster frame 3 Nm
Adjuster unit to bottom of case 3 Nm
46 61 - Front-wheel cover
Cover to fork bridge, bottom
M6 x 16 3.5 Nm
Front-wheel cover to forks
46 62 - Rear-wheel cover, number-plate carrier
Spray-guard extension to number-plate carrier
M5 x 16 2.5 Nm
Cover to rear-wheel cover
M5 x 12 6 Nm
Rear-wheel cover to rear frame
M5 x 12 6 Nm
M5 x 12 2.5 Nm
with flat nut
Number-plate carrier to rear-wheel cover
M5 x 16 2.5 Nm
Number-plate carrier to rear frame
M8 x 25 10 Nm
46 63 - Motorcycle fairing, windscreen
Bracket, cover, to main frame

M5 x 16 2.5 Nm
Bracket, radiator, to fairing
M5 x 16 2.5 Nm
Heel guard to main frame
M6 x 20 4 Nm
Front panel carrier (side) to frame
M6 x 50 8 Nm
Front panel carrier (middle) to frame
Chain guard to swinging arm
Air guide to side panel
M5 x 16 2.5 Nm
Air guide to side panel
M5 x 16 2.5 Nm
Trim panels
M5 2.5 Nm
Centre trim panel to side panel
M5 x 25 2 Nm
Heat shield to main frame
M5 x 12 2.5 Nm
Windscreen to front panel carrier/bracket
M5 x 18 2.5 Nm
Windscreen and strobe marker light carrier to holder
M5 x 20 2 Nm
M5 x 35 4 Nm
46 71 - Engine fasteners, footrests
Spacers for front footrest, right, to frame
M6 x 30 8 Nm


51 - Trim panels Value Valid
51 16 - Mirrors, covers, ashtrays, stowage compartments
Clamping piece (mirror) to clamping block
M10 30 Nm
Locknut (mirror) to clamping piece
M10 x 1.5 20 Nm
General consumable (Multi-wax spray)
51 25 - Other fasteners
Ignition switch/steering lock to frame
M8 x 40 19 Nm


52 - Seats and seat bench Value Valid
52 53 - Seat
Intake air silencer to seat bridge
M5 2.5 Nm
Seat bridge, top, to bottom
M5 x 10 4 Nm
Seat retainer bridge to rubber mount
M5 2.5 Nm
Rubber mount (seat retainer bridge) to rear frame
M5 2.5 Nm


0493 - Electronic hailing systemOE
61 - General vehicle electrics Value Valid

61 11 - Wiring harness
Wiring harness to starter
M6 5 Nm
Wiring harness to engine
M6 x 12 8 Nm
61 13 - Plug, terminal
Starter relay to bracket
M6 x 16 7 Nm
Bracket, starter relay, to front panel carrier
M6 x 30 7 Nm
Earthing strap to starter and cylinder head
M6 x 12 8 Nm
On-board socket to bracket
M18 x 1 3.5 Nm
Battery holder to intake air silencer
M6 x 12 3.5 Nm
Wiring harness to battery
M6 5 Nm
61 31 - Switch, sensor
Brake-light switch to footrest plate
M6 x 10 5 Nm
Cover to throttle twistgrip
Clamp, multifunction switch to handlebar
M5 x 20 5 Nm
Multifunction switch, handlebar fitting to handlebar
KA30 x 10 - 3.6 1 Nm
Clutch switch to handlebar fitting
Handlebar grip to handlebar

M3.5 x 30 1 Nm
Extra switches to bracket
M4 x 8 2 Nm
Brake-light switch to handlebar fitting
Locking element, brake-light switch to footrest plate
M6 x 12, Replace screw Threaded pin screws in until
Thread-locking compound (Micro-encapsulated) projecting 3 mm, but at least 8 mm
61 33 - Emergency power siren, horn

Horn to fastener, front panel carrier, left
M6 x 50 20 Nm
Horn to crash bar
M6 x 20 8 Nm
61 35 - Control units, module
Control-unit bracket to frame
M6 x 30 8 Nm


63 - Lights Value Valid

63 12 - Headlight
Headlight to front panel carrier
M8 x 16, Replace screws 8 Nm
63 13 - Flashing turn indicators, front
Flashing turn indicator to side panel, front
M6 x 20 2.5 Nm
Glass to turn indicator housing
PT screw, 2.9 x 25 - 3.6 1 Nm
63 17 - Foglights, additional lights
Strobe marker light holder to front panel carrier
M5 x 35 4 Nm
360° marker light to bracket
M6 x 35 5 Nm
63 21 - Rear light cluster
Rear light to number-plate carrier
M5 x 12 3 Nm
63 23 - Flashing turn indicators, rear
Flashing turn indicator to rear side panel
M6 x 20 2.5 Nm
Glass to turn indicator housing 0.6 Nm
63 26 - Number-plate light
Number-plate light to tail section
M5 2 Nm


65 - Audio, navigation, information systems Value Valid

65 61 - Two-way radios
Cover to backing plate (radio-equipment case)
TS5 x 12 4 Nm
Lock/hinge/backing plate to two-way radio box carrier
M5 x 12 4 Nm
65 75 - Anti-theft alarm
Anti-theft alarm to holder


Bow-shaped hand guardOA
0170 - Special modelOE
Spray guardOA
Case carrierOA
Rear softbagOA
Topcase carrierOA
Holder for BMW MotorradNavigatorOA
Smartphone CradleOA
headlight guardOA
Crash barsOA
71 - Parts and accessories for engine and frame and Value Valid
suspension
71 32 - Accessory to handlebar
Spoiler to hand protector, large
M5 x 14 3 Nm
Hand protector to bow
M5 x 12 3 Nm
Screw to clamp
M5 x 16 5 Nm
M12 x 1.5 x 65, Replace screw 21 Nm
Screw, clamp in bow
M8 x 25 12 Nm
71 46 - Accessory for frame
Spray guard to rear-wheel cover
M5 x 16 2.5 Nm
71 54 - Accessories for luggage carrier
Mushroom head to grab handle
M8 x 25 19 Nm
Rear softbag to luggage carrier with number-plate carrier on rear frame
M8 x 60 4.0 Nm
Rear softbag to number-plate carrier and rear frame
M8 x 35 4.0 Nm
M8 x 25 19 Nm


M8 x 25 19 Nm
Screw in anchorage
M6 8 Nm
Topcase carrier plate to rear frame
M8 x 65 19 Nm
71 60 - Miscellaneous accessories
Advanced Mount Cradle to holder
M4 x 25 2 Nm
Securing screw to handlebar clamping block
M8 x 30 - 10.9 Tightening sequence: tighten the
Lubricate screw, Lubricant (Optimoly TA) front screw (as viewed in the
forward direction of travel) first,
then the rear screw.
25 Nm
Screws for holder to securing screws
M5 x 16 5 Nm
Lubricate screw, Lubricant (MP 3 paste) forward direction of travel, tighten
until seated
25 Nm
71 63 - Accessory for lights
Bracket to front panel carrier
M8 x 16 8 Nm
71 71 - Accessory crash bars
Lug, crash bar
M8 x 25 19 Nm
Crash bar, left, to engine
M8 x 16 19 Nm
Crash bar, right, to engine
M8 x 40 19 Nm
M8 x 55 19 Nm
Crash bar, front, to engine
M10 x 20 19 Nm
Connection of crash bars
M5 x 16 6 Nm


Topcase carrierOA
Smartphone CradleOA
77 - Optional accessories, motorcycle Value Valid

77 02 - Maintenance and Technology
M6 x 50 8 Nm
Holder for oil tank to bracket
M6 x 40, when carrying out repairs, replace nut 8 Nm
Bracket for supply tube nozzle to swinging arm
M6, when carrying out repairs, replace nut 8 Nm
77 44 - Mounted parts, topcase, luggage carrier
Luggage carrier for topcase to grab handle and number-plate carrier
M8 x 55 19 Nm
77 52 - Audio, navigation, information system
Cross-member to bracket top section
M5 x 12 5 Nm
Mount Cradle to holder
M4 x 30 2 Nm
Bracket to screws for handlebar clamps
Lubricate screw, Lubricant (MP 3 paste) forward direction of travel, tighten
until seated
25 Nm
Smartphone Cradle to bracket
M4 x 30 2 Nm

Service data 0218 - F 650 GS

Centre standOA

11 - Engine
Running-in speed <5000 min-1
Engine oil, capacity with filter change approx. 2.9 l
Viscosity class
Engine oil, quantity for topping up Difference between max 0.4 l
MIN and MAX
Viscosity class
additional quantity of engine oil after 0.3 l
removal of swing-arm shaft cover Fluids and lubricants
Viscosity class
Engine oil, specified level between MIN and MAX marks
1134 - Valves with springs

Inlet valve clearance Engine cold max 35 °C 0.18...0.26 mm
Exhaust valve clearance Engine cold max 35 °C 0.27...0.35 mm
1212 - Ignition lead, spark plugs
Spark plugs, manufacturer and NGK DCPR 8 E
designation
13 - Fuel preparation and control
Recommended fuel grade Regular, unleaded max. 10 %
ethanol, E10
91 ROZ/RON
87 AKI

16 - Fuel supply
Usable fuel capacity approx. 16 l
Reserve fuel approx. 4 l
17 - Cooling
Cooling system test pressure Test pressure must 1.5 bar
remain
unchanged: 5 min
Coolant, specified level between MIN and MAX marks on
the expansion tank
3273 - Bowden cables

Setting, throttle-cable play at outermost diameter 1...2 mm
of rubber grip, engine
cold max 35 °C
Clutch play Handlebars turned fully 3 mm
left, between handlebar
fitting and clutch cable
3383 - Traction drive, chain, belt
Permissible chain length measured centre to max 144.30 mm
centre over 10 pins,
chain pulled taut
Chain-link width after press-fitting 19.90+0.1 mm

−0.05
Measured across outer flats of outer
plates
Chain deflection Motorcycle with no 20...30 mm
weight applied,
supported on its side
stand
34 - Brakes
Brake fluid level, front (visual It is impermissible for the brake fluid
Brake fluid level, rear (visual It is impermissible for the brake fluid
3411 - Front wheel brakes

Brake disc thickness, front When new 5.0 mm

Brake-pad wear limit, front Friction pad only, min 1.0 mm

The wear indicators
(grooves) must be
clearly visible.
Brake disc lateral runout, front At circumference max 0.15 mm

3421 - Rear wheel brakes
Brake-pad wear limit, rear Friction pad only, min 1.0 mm
The wear
indicators must be
clearly visible.
Brake disc thickness, rear When new 5.0 mm

Brake disc lateral runout, rear At circumference max 0.15 mm
3630 - Motorcycle wheels
Permissible front-wheel imbalance max 5 g
Permissible rear-wheel imbalance max 45 g
Balance weight for front wheel max 80 g
Balance weight for the rear wheel max 80 g
3632 - Tyres
Tyre pressure, front one-up, at tyre 2.2 bar
temperature 20 °C
luggage, at tyre
temperature 20 °C
temperature 20 °C
luggage, at tyre
temperature 20 °C
Tyre tread depth, front and rear Wear limit, for Germany min 1.6 mm
only
Wear limit, outside Country-specific legal requirements
Germany
Wheel valve test pressure 4 bar
6575 - Anti-theft alarm


3V
M8 x 16 25 Nm
M6 Tightening sequence: tighten in
10 Nm
M6 Tightening sequence: See repair
manual
1st tightening torque, tightened
uniformly by hand
11 13 - Oil sump
Oil drain plug
M24 x 2 40 Nm
M8 8 Nm
M8 x 115 8 Nm
11 15 - Crankcase breather
11 31 - Camshaft
M18 x 1.5 40 Nm
11 42 - Oil filter and lines
Oil filter to crankcase 11 Nm
Spark plugs
M12 x 1.25 20 Nm
13 71 - Intake air silencer

M6 x 25 6 Nm
23 00 - Gearbox
M10 x 35 50 Nm
M8 x 25 19 Nm
M8 x 25 Tightening sequence: Tighten

screws six times in alternate
sequence
19 Nm
M8 x 40 19 Nm
M18 x 1 Tightening torque, 25 Nm
Swing the forks 3x to left/right
through full arc of travel
Loosen, 60°
M8 x 25 19 Nm
forward direction of travel, tighten
until seated
28 Nm
33 35 - Rear wheel swinging arm with pivot mount, link
M8 19 Nm


Fitted-head screw, M12 x 1.5 x 60 - 10.9, Replace screw 100 Nm
33 84 - Traction drive, chainwheel, belt wheel
33 85 - Mounted parts, traction drivetrain
M5 x 12 4 Nm
M6 x 40 4 Nm
M10 x 40 38 Nm
M10 x 1 - 4.9 14 Nm
M5 2 Nm
M8 x 15.5, Replace screw Tightening sequence: tighten by
Thread-locking compound (Micro-encapsulated) stages in diagonally opposite
sequence
30 Nm
M10 x 1 - 4.9 14 Nm
34 32 - Brake lines

M6 x 16 8 Nm
34 52 - Electronic components
M6 x 16 8 Nm
M6 x 16 8 Nm
M16 x 1.5 30 Nm
Thread-locking compound (Micro-encapsulated) Tightening torque, 12 Nm
or, Thread-locking compound (Loctite 243, Medium strength) Slacken the nut
M16 x 1.5 100 Nm
46 53 - Side stand
46 54 - Luggage system
M8 x 35 19 Nm
M8 19 Nm
46 63 - Motorcycle fairing, windscreen
Trim panels
M5 2.5 Nm
M5 x 18 2.5 Nm
Windscreen and strobe marker light carrier to holder
M5 x 20 2 Nm
M5 x 35 4 Nm
Centre trim panel to side panel
M5 x 25 2 Nm


51 16 - Mirrors, covers, ashtrays, stowage compartments
Locknut (mirror) to clamping piece
M10 x 1.5 20 Nm
General consumable (Multi-wax spray)
Clamping piece (mirror) to clamping block
M10 30 Nm
M6 5 Nm
63 17 - Foglights, additional lights
Strobe marker light holder to front panel carrier
M5 x 35 4 Nm
360° marker light to bracket
M6 x 35 5 Nm
71 32 - Accessory to handlebar
Screw, clamp in bow
M8 x 25 12 Nm
Screw to clamp
M5 x 16 5 Nm
M5 x 12 3 Nm

00 60 258 Replacing open-type drive chain, pinion and sprocket (without replacing chain slide
rails)
Preparatory work
Removing pinion cover
Relieving chain tension
Core activity
(-) Removing pinion
Lock the rear wheel.

Remove screw (1).
Remove washer (2) and spring washer (3).
Lift drive chain (4) and remove pinion (5) with puller (No. 00 8 400) and
thrust piece (No. 00 5 015).
(-) Splitting and removing drive chain
Position insert with hole (A) and guide screw (B) from drive-chain
splitting/joining tool (No. 27 1 561) in basic unit (D).
Hold basic unit (D) in position and remove drive-chain pin (1) with
mandrel (C).
Remove drive chain (2).
(-) Removing rear wheel
ATTENTION
Brake actuation with brake pads or brake calipers removed
Brake pistons pushed out
Do not operate brake.
Install brake pads and brake caliper or insert the piston resetting device.

Press the brake caliper against the brake disc in order to force the
piston back.
Releasing rear wheel-speed sensor
Remove screw (1) and disengage wheel-speed sensor (2).
Slacken locknuts (1) on left and right.

Slacken adjusting screws (2) on left and right.
Remove nut (1) with washer (2).

Remove quick-release axle (3).
NOTICE
There are different construction statuses. The left chain tensioner might
be press-fitted onto the quick-release axle.
Remove bushings (4) and chain tensioner (5).

Work wheel (6) to the rear to remove.
(-) Checking both chain slide rails
Check chain slide rail (1).
Check chain slide rail (1).
Check
Check both chain slide rails for deep scoring and chipping.
Result:
Slide rails are damaged.

Measure:
=> 33 85 504, Replacing chain slide rails (chain removed) (Billed as a
separate item)

(-) Removing sprocket carrier
Remove sprocket carrier (1), noting judder-damper rubber elements (2).
(-) Removing sprocket
Remove nuts (1) and screws (2).

Remove sprocket (3) from sprocket carrier (4).
(-) Installing sprocket
Hold sprocket (3) in position on sprocket carrier (4) and install screws
(2) and nuts (1).
Tightening torques
M8, Replace the nuts and screws Tightening torque,
Thread-locking compound 10 Nm
(mechanical) Additional angle of
rotation, 90°
(-) Installing sprocket carrier in rear wheel
Make sure that judder-damper rubber elements (1) are correctly

positioned and install sprocket carrier (2).

(-) Installing rear wheel
NOTICE
Insert brake caliper (1) into the guide of the swinging arm (arrow).
Clean and lubricate the friction faces of the shaft sealing rings (arrows).
Lubricant
Staburags NBU 30 PTM 07 55 9 056 992
Insert bushings (1) into rear wheel (2).

Install and align rear wheel (2).
Clean chain tensioner (3) and insert it into position.
Clean and lubricate quick-release axle (4) and install.
Lubricant
Optimoly TA 18 21 9 062 599
Install nut (6) with washer (5), leaving the nut loose.

Install wheel-speed sensor (2).

Install screw (1).
Tightening torques
M6 x 16 8 Nm
(-) Installing drive chain and pinion
Clean the threads.

Lubricate internal splines of pinion (1).
Lubricant
MP 3 paste 07 55 9 062 476
Install pinion (1) with the wording facing out.

Hold washer (2) (with large diameter toward pinion) and washer (3) in
position.
Apply thread-locking compound to screw (4).
Thread-locking compound
Loctite 243, Medium strength 83 19 2 210 339
Fit the bolt (4) and tighten by hand.

Work chain (1) into position and loop it over pinion (2).
Block the rear wheel and tighten screw (1).
Tightening torques


M10 x 35 50 Nm
Thread-locking compound (Loctite
243, Medium strength)
(-) Joining drive chain
Make sure that the sealing beads (arrow) at the O-rings face out.
Fit the ends of drive chain (1) together.

Fit inside chain link plate (3) with O-rings (2) and slip it into the ends of
the drive chain.
Fit O-rings (2) and lay outside chain link plate in position.
Press inside chain link plate (3) and outside chain link plate (4) together.
Install insert without hole in basic unit (No. 27 1 561).

Install screw (No. 27 1 562) in basic unit (No. 27 1 561) and seat insert
(No. 27 1 563) in screw (No. 27 1 562).
Lubricate insert (No. 27 1 563).
Lubricant
Acid-free friction-bearing grease 81 22 9 407 174

Position basic unit (No. 27 1 561) on chain link plates (1) and (2).
Tighten screw (No. 27 1 562) and alternately press-fit chain link (1)
onto the two pins until seated.
Checking width of chain after joining
Check
Check chain width (A) at press-fitted links with pins (3) and chain link (4)
at front and rear.
Technical data
Chain-link width 19.90+0.1 mm
after press-fitting −0.05
Measured across
outer flats of outer
plates
Result:
Chain width exceeds specification.
Measure:
Repeat the press-fitting process.

Result:
Chain width is less than specification.

Measure:
Remove the chain links and re-join the chain, using a new removable
link.

Position insert without hole (E) and guide screw (F) in basic unit (D) of
drive-chain splitting/joining tool (No. 27 1 561).
Position correctly assembled basic unit (D) on pin (1).
Hold mandrel (G) in position and use a hammer to drive in pin (1).
Turn mandrel (G) through 90 degrees and again rivet the plate to the
pin.
Repeat this procedure with the other pin.
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 removable
link.
Follow-up work
Installing pinion cover
Adjust chain sag
Final check of work performed

00 60 654 Replacing air filter element (if applicable with installing/removing special tool,
centre stand)
NOTICE
Remove loose parts from the intake air silencer.
Preparatory work
Removing seat
Remove the centre trim panel
Disengaging both side panels
Core activity
(-) Removing air filter
Disengage cable (1) for the air-temperature sensor (arrow).
Remove screws (1).

Remove cover (2) noting the sealing faces (arrows).
Remove air-filter element (3).
(-) Replacing air filter and cleaning intake air silencer
Remove loose parts from the intake air silencer.

Examine the intake air silencer with a worklight or close the intake
funnels and blow in compressed air.

Replace the air filter element.
(-) Installing air filter
Insert air-filter element (3).

Install cover (2) noting the sealing faces (arrows).
Install screws (1).
Secure cable (1) for the air-temperature sensor (arrow).
Follow-up work
Securing both side panels
Install the centre trim panel
Installing seat

00 98 000 Vehicle transport/recovery
Core activity
(-) Securing motorcycle for transportation
Use masking tape or soft cloths suitably positioned to prevent scratches.
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.
Push the motorcycle onto the transportation flat and hold it in position:
do not place it on the centre stand.
ATTENTION
Trapping of components
Component damage
Do not trap components such as brake lines or cable legs.
At the front, secure the straps to the bottom fork bridge on both sides
and tighten the straps.
At the rear, secure the straps to the rear frame on both sides and tighten
the straps.

Tighten all the straps uniformly; the motorcycle's suspension should be

compressed as tightly as possible front and rear.

11 00 040 Testing compression with BMW Motorrad diagnostic system

+ 11 00 567
Preparatory work
Removing seat
Remove the centre trim panel and side panels
Remove the battery
Removing intake air silencer
Core activity
(-) Removing spark plugs
Disconnect plug (1).

Remove direct ignition coil (2) with puller tool (No. 12 3 561).
Remove spark plugs (3) with socket (No. 12 3 510).
(-) Installing battery
Requirement
Ignition is switched OFF.
Install the battery in the motorcycle and secure it, for example with a
rubber strap.
Connect the leads to battery terminals (1).
Tightening torques
M6 5 Nm

(-) 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.
Disengage diagnosis socket (1) from holder (2) and remove protective
cap (3).
Connect diagnosis socket (1) to the BMW Motorrad diagnostic system.
Follow the instructions issued by the BMW Motorrad diagnostic system.
(-) Testing compression with MBOX
Connect diagnosis adapter M12 with non-return valve (No. 11 7 847)

to hose, tightening until (No. 11 7 842) hand-tight.
Select the following functions in MBOX:
Preset measurements
Print
Compression
Connect 0-25 bar pressure sensor and calibrate.
Check
Switch on the ignition and crank the engine on the starter with the
throttle valve open until the pressure reading stops rising.
Read the compression shown by the MBOX.
Technical data
Compression test Poor <11 bar
pressure Normal 11...15 bar
Good >15 bar
Result:
Compression below wear limit.
Measure:
Pinpoint the cause of the fault.

Possible causes:
Valves leaking
Piston and cylinder leaking
Cylinder-head gasket defective
Adopt the same procedure to check the compression of the other

cylinder.
Remove the tools.
(-) Disconnecting BMW Motorrad diagnostic system from

vehicle
Close all diagnostic programs and switch off the ignition.

Disconnect the BMW Motorrad diagnostic system from diagnosis
socket (1) and install cap (3).
Secure diagnostic socket (1) in bracket (2).
Disconnect the BMW Motorrad battery charger from the vehicle.
(-) Removing battery
Requirement
ATTENTION
Battery not disconnected in accordance with correct procedure
Risk of short-circuit
Always proceed in compliance with the specified disconnection
sequence.
Disconnect negative terminal (1).

Disconnect positive terminal (2).
Remove battery (3).
(-) Installing spark plugs
Install spark plug (3) with spark-plug wrench (No. 12 3 510).

Tightening torques
Spark plugs
M12 x 1.25 20 Nm
Install direct ignition coil (2).

Connect plugs (1), making sure the plugs are not mixed up (note the
cable lengths).
Follow-up work
Installing intake air silencer
Installing battery
Checking, if necessary correcting date
Connecting BMW Motorrad diagnostic system to vehicle
Performing vehicle test with BMW Motorrad diagnostic system
Disconnecting BMW Motorrad diagnostic system from vehicle
Installing side panels and centre trim panel
Installing seat

11 00 050 Removing/installing engine

+ 11 00 541
NOTICE
The adaptation values have to be reset after engine or gearbox
replacement.
Preparatory work
Removing engine guard
Removing seat
Removing both frame covers
Remove the battery
Removing ignition coils
Disconnecting engine-electrics plug
Release the throttle-valve stub assembly
Disengaging clutch cable
Removing silencer
Removing voltage regulator with bracket
Disconnecting plugs of alternator and gearbox potentiometer
Remove the camshaft sensor
Releasing wiring harness from engine
Draining coolant
Removing fan shroud
Remove the radiator with expansion tank
Removing exhaust manifold
Installing engine lifter
Removing both radiator holders
Removing heat shield
Removing complete front left footrest plate assembly
ABSReleasing pressure modulator

Removing footbrake lever
Core activity
(-) Removing engine
Remove the chain from the pinion.

Protect the engine against scratches at the points indicated, for example
by affixing masking tape.
Protect the frame against scratches at the strut indicated (arrow), for
example by affixing masking tape.
Use straps to secure the vehicle to crane (No. 46 5 670).

Raise the frame and engine at the rear until the middle strut (arrow) is
horizontal.

Remove axle (3) with washer (4).

Remove cap (1).

Remove screws (2), (3) and (4).
Remove cap (7).

Remove screws (2) and (4).
Remove screw (6).
Remove spacing sleeves (1), (3) and (5).
Carefully lower the engine, paying particular attention to the region of

the swinging-arm pivot bearing.
Carefully lift the frame.
(-) Removing engine lifter
Lower the scissor-type lifter.

Unlock the split pins and the retaining pin and remove the engine from
engine adapter (No. 00 1 576).
Remove the engine adapter from scissor-type lifter (No. 00 1 571) and
extensions (No. 00 1 575).

Remove pin (No. 00 1 578) and pins of engine adapter (No. 00 1 576).
(-) Removing ABS pressure-modulator bracket
Remove screws (1) and remove holder (2).
(-) Installing engine lifter
Install pins (No. 00 1 578) and pin of engine adapter (No. 00 1 576).

Install engine adapter (No. 00 1 576) in the rear pins and install the
retaining pin to secure.
Seat the pins in the engine adapter and secure with split pins.
Secure extension (No. 00 1 575) to scissor-type lifter (No. 00 1 571).
Push the lifter with the extension into the engine adapter.
(-) Installing ABS pressure modulator bracket
Clean the threads.

Secure bracket (2) with screws (1) to the engine.
Tightening torques
Bracket for pressure modulator to engine block
Thread-locking compound (Micro-
encapsulated)
M6 x 40 8 Nm
(-) Installing engine

Use straps to secure the vehicle to crane (No. 46 5 670).

Bring the vehicle to a position in which the middle strut (arrow) is
horizontal.
Carefully lower the vehicle onto the engine, taking particular care in the
region of the swinging-arm pivot bearing.
Carefully raise the engine, paying particular attention to the left cylinder
head.
Install screws (2), (3) and (4).
Tightening torques
M10 x 40 38 Nm
M10 x 40 40 Nm
M12 x 50 66 Nm

Install cap (1).
Install spacing sleeve (1) with screw (2).
Tightening torques
M10 x 65 40 Nm
ATTENTION
Incorrect shimming of the frame
Frame damage
On replacement of cylinder head, engine block or frame, the frame has
to be correctly shimmed with two of the spacer sleeves.
Establish the requisite size of spacing sleeves (3) and (5); the sleeves
installed should be as large as possible. The remaining gap is taken up
by the frame's elasticity.
Install spacing sleeves (3) and (5) with screws (4) and (6).
Tightening torques
M12 x 50 66 Nm
M10 x 40 38 Nm
Install cap (7).

Remove masking tape from the frame and engine.
Clean and thinly lubricate axle (3).
Lubricant
Install axle (3) with washer (4).

Install nut (1) with washer (2).

Tightening torques
(mechanical)
Loop the chain onto the pinion.
Follow-up work
Installing both radiator holders
Installing footbrake lever
ABS Securing pressure modulator
Connecting engine-electrics plug
Securing clutch cable
Securing throttle-valve stub assembly
Securing ignition coils
Installing complete front left footrest plate assembly
Installing heat shield
Remove the engine lifter
Installing exhaust manifold
Installing radiator with expansion tank
Installing fan shroud
Refilling with coolant and bleeding system
Securing engine wiring harness at front
Install the camshaft sensor
Adjust chain sag
Connect the plugs of alternator and gearbox potentiometer
Securing voltage regulator with bracket
Checking/adjusting throttle cable
Installing battery
Reading fault memory with BMW Motorrad diagnostic system and
resetting adaptation values

Setting date with BMW Motorrad diagnostic system

Installing both frame covers
Installing silencer
Installing seat
Installing engine guard

11 00 209 Oil change, engine, with filter

+ 11 00 611
Core activity
(-) Engine-oil change, with filter
NOTICE
Change oil, warmed to normal operating temperature.
Draining engine oil
Remove oil drain plug (1) and drain the oil.

Remove sealing ring (2).
Removing oil filter

Remove oil filter (1) with oil-filter wrench (No. 11 4 650) and catch the
escaping oil in a suitable container.
Installing oil filter

Clean the sealing face (arrow) and lubricate it with engine oil.
Install new oil filter (1), using oil filter wrench (No. 11 4 650).

Tightening torques
Oil filter to crankcase
Lubricate sealing ring with engine 11 Nm
oil
Pouring engine oil into engine

Install oil drain plug (1) with new sealing ring (2).
Tightening torques
Oil drain plug
M24 x 2 40 Nm
Remove oil dipstick (1).

Fill the engine with engine oil.
Technical data
Engine oil, capacity with filter approx. 2.9 l
change
Viscosity class
additional quantity of 0.3 l
engine oil after
removal of swing-
arm shaft cover Viscosity class
Install oil dipstick (1).
(-) Checking engine oil level
Park the motorcycle upright.
Allow the engine to idle until the fan starts up, then allow it to idle one
minute longer.

Wipe the area around the oil filler neck clean.
Remove oil dipstick (1) and wipe it with a clean, dry cloth.
Check
Insert the oil dipstick into the oil filler neck until the head rests on the
crankcase, and turn it backward through one full turn to make the level
easier to read.
Remove the oil dipstick and check the oil level.
Technical data
Engine oil, specified level between MIN and
MAX marks
Result:
If the oil level is below the MIN mark:
Measure:
Top up the engine oil.
Technical data
Engine oil, quantity Difference max 0.4 l
for topping up between MIN
and MAX
Viscosity class
Result:
If the oil level is above the MAX mark:
Measure:
Correct the oil level.
Follow-up work

11 00 609 Oil change in engine with filter (for maintenance)
Core activity
(-) Engine-oil change, with filter
NOTICE
Change oil, warmed to normal operating temperature.
Draining engine oil
Remove oil drain plug (1) and drain the oil.

Removing oil filter

Remove oil filter (1) with oil-filter wrench (No. 11 4 650) and catch the
escaping oil in a suitable container.

Clean the sealing face (arrow) and lubricate it with engine oil.
Install new oil filter (1), using oil filter wrench (No. 11 4 650).
Tightening torques
Oil filter to crankcase
Lubricate sealing ring with engine 11 Nm
oil


Install oil drain plug (1) with new sealing ring (2).
Tightening torques
Oil drain plug
M24 x 2 40 Nm

Fill the engine with engine oil.
Technical data
Engine oil, capacity with filter approx. 2.9 l
change
Viscosity class
additional quantity of 0.3 l
engine oil after
removal of swing-
arm shaft cover Viscosity class
(-) Checking engine oil level
Park the motorcycle upright.
Allow the engine to idle until the fan starts up, then allow it to idle one
minute longer.

Wipe the area around the oil filler neck clean.
Remove oil dipstick (1) and wipe it with a clean, dry cloth.
Check
Insert the oil dipstick into the oil filler neck until the head rests on the
crankcase, and turn it backward through one full turn to make the level
easier to read.
Remove the oil dipstick and check the oil level.
Technical data
Engine oil, specified level between MIN and
MAX marks
Result:
If the oil level is below the MIN mark:
Measure:
Top up the engine oil.
Technical data
Engine oil, quantity Difference max 0.4 l
for topping up between MIN
and MAX
Viscosity class
Result:
If the oil level is above the MAX mark:
Measure:
Correct the oil level.

11 00 646 Checking pressure loss with BMW diagnostic system (spark plug removed)
Core activity
(-) Locking crankshaft in TDC position
Remove screw (1) with sealing ring (2).
Turn the rear wheel to turn the engine in its normal direction of rotation
and find the TDC position.
Check that the notch (arrow) in the front crank web is visible through the
bore; if necessary, turn the engine through a complete revolution in its
normal direction of rotation.
Install locating screw (No. 11 6 570) and tighten until hand-tight.

The locating screw engages in the notch in the crankshaft.

Requirement
Install the battery in the motorcycle and secure it, for example with a
rubber strap.
Connect the leads to battery terminals (1).
Tightening torques
M6 5 Nm
(-) Checking pressure loss with MBOX
NOTICE
On completion of the work it is essential to run a vehicle test and delete
fault memory.
Select the following functions in MBOX:

Preset measurements
Print
Press loss
Connect 0-25 bar pressure sensor to MBOX.
Connect adapter for pressure loss (No. 11 7 841) to the MBOX.
Connect the compressor adapter for pressure loss (No. 11 7 841) and
set to the reference pressure.
Secure diagnosis adapter M12 without non-return valve (No. 11 7
844) and hose (No. 11 7 842) in the spark-plug bore, tightening the
adapter until hand-tight.
Connect adapter for pressure loss (No. 11 7 841) to hose (No. 11 7
842).
Check
Open the shut-off cock on adapter for pressure loss (No. 11 7 841) and
check pressure loss with the MBOX.
Technical data
Press loss Engine at max 25 %
through valves or regular
cylinder operating
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
Disconnect the compressor from the adapter for pressure loss (No. 11 7
841) and remove the tools.
Remove the locating pin and turn cylinder 2 to ignition TDC.
Insert locating pin to lock the engine in position.

Check cylinder 2 for pressure loss in the same way.
(-) Removing battery
Requirement
ATTENTION
sequence.
Disconnect negative terminal (1).

Disconnect positive terminal (2).
Remove battery (3).
(-) Releasing crankshaft
Remove locating screw (No. 11 6 570).

Install screw (1) with new sealing ring (2).
Tightening torques
M8 x 16 25 Nm
Follow-up work

11 11 514 Replace engine block (engine removed)
Preparatory work
Determining construction status of engine and gearbox
Removing oil filter
Removing starter
Removing heat exchanger
Removing coolant lines
Securing engine to assembly stand
Draining engine oil
Removing direct ignition coil
Remove the cylinder head cover
Checking valve clearances and noting down measured results
Locking engine at firing TDC
Removing camshaft bearing cap unit
Removing chain tensioner
Removing both camshafts
Removing timing chain slide rail
Remove the cylinder head
Removing oil pan
Removing cover for swing-arm shaft
Removing crankshaft sensor
Removing right crankcase cover
Removing magnetic wheel
Removing freewheel gear
Removing layshaft for starter
Removing pinion
Removing gearshift lever
Removing left crankcase cover
Removing selector shaft
Removing complete clutch
Releasing TDC locator
Removing bottom half of crankcase
Removing oil-pump drive gear
Removing cover of oil delivery pump
Removing oil delivery pump
Removing cover of oil suction pump

Removing oil suction pump

Removing gearbox potentiometer
Removing oil-pump shaft
Removing shaft sealing ring for gearbox output shaft
Removing shift forks for 1st/3rd and 2nd/4th gears
Removing shift fork, 5th/6th gear
Remove the locking lever
Removing selector drum with star-shaped locking element
Removing conrod bearing caps
Core activity
(+) Removing piston with conrod
(+) Checking pistons for wear
(+) Removing transmission output shaft and transmission input
shaft
(+) Removing crankshaft main bearing caps
(+) Removing crankshaft
(+) Removing timing-chain tensioning rail
(+) Replacing engine block
(+) Installing timing-chain tensioner rail
(+) Installing crankshaft bearing shells
(+) Installing crankshaft
(+) Installing crankshaft main bearing caps
(+) Installing piston with conrod
(+) Installing conrod bearing caps
(+) Changing gearbox bearing when replacing engine block
(+) Installing transmission output shaft and transmission input shaft
Follow-up work
Installing oil-pump shaft
Installing selector drum with star-shaped locking element
Installing shaft sealing ring of selector drum
Installing gearbox potentiometer
Installing locking lever
Installing shift fork, 5th/6th gear
Installing oil delivery pump
Installing cover of oil delivery pump
Installing oil-pump drive gear
Installing shift forks for 1st/3rd and 2nd/4th gears
Installing bottom crankcase half
Locking crankshaft in TDC position

Installing shaft sealing ring, gearbox output shaft

Installing pinion
Installing entire clutch assembly
Changing oil-pressure control device when replacing engine block
Installing swing-arm shaft cover
Installing oil pan
Installing cylinder head
Installing timing-chain slide rail
Install all oil sinks
Installing exhaust camshaft
Installing inlet camshaft
Securing camshaft bearing cap unit
Installing chain tensioner
Tightening camshaft bearing cap unit
Checking engine timing
Installing screw (in hole for TDC locating screw)
Installing cylinder head cover
Installing direct ignition coils
Installing selector shaft
Install the left crankcase cover
Installing gearshift lever
Installing layshaft for starter
Installing magnetic gear with freewheel gear and thrust washer
Installing right crankcase cover
Installing crankshaft sensor
Installing oil suction pump
Installing cover of oil suction pump
Removing engine from assembly stand
Installing starter
Installing coolant lines
Installing heat exchanger

11 12 081 Replacing sealing rings for camshaft bearing cap

+ 11 12 823
Preparatory work
Removing seat
Remove the battery
Disengaging throttle cable from throttle-valve stub assembly
Removing cylinder head cover
Core activity
(-) Checking valve clearance
Check
Set the engine to firing TDC
Crank the engine by turning exhaust camshaft (1) by means of the

hexagon (arrow).
Turn the engine in its normal direction of rotation until the marks on the
camshaft gears are in line with each other and parallel with the sealing
face.
The inlet and exhaust valves of the left cylinder are closed; the valves of
the right cylinder are at overlap.

Measuring valve clearance

At each valve, measure valve clearance with feeler gauge (1) between
camshaft (2) and cam follower (3).
Noting measured results

Note down the measured results on a record sheet.
Continue turning the engine until the right cylinder is at firing TDC;
measure vale clearance in the same way and note down the values.
Technical data
Inlet valve clearance Engine 0.18...0.26 mm
cold max 35 °
C
Exhaust valve Engine 0.27...0.35 mm
clearance cold max 35 °
C
Result:
Valve clearance is out of tolerance.
Measure:
=> 11 34 504, Adjusting valve clearance (cylinder-head cover removed)
(Billed as a separate item)
(-) Removing camshaft bearing cap unit

Working in diagonally opposite sequence, uniformly slacken all nuts (1)

and remove.
Remove slider (2) with holder (3).
Remove bearing cap (4).
Remove sealing rings (5).
(-) Securing camshaft bearing cap unit
Check slider (1) for signs of wear; replace if necessary.

Clean the sealing faces.
Lubricate new sealing rings (2) and (3) with engine oil and install.
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.
Lubricate the friction faces of camshaft bearing cap unit (4) with engine
oil and install, noting the axial guides (arrows).
Place slider holder (5) in position.
Engage all nuts (6) on their threads and tighten them until hand-tight
(do not use tools).
Make sure that bearing cap (4) is seated flat on the timing-chain side; if
necessary adjust the camshafts and the bearing cap until the bearing
cap is seated flat.
(-) Remove the screw (in hole for TDC locating pin)
Remove screw (1) and washer (2).

(-) Checking engine timing
ATTENTION
Barring of the engine not in compliance with correct procedure
Component damage
Bar the engine carefully. Stop the rotational movement if resistance is
perceptible.
Carefully turn the engine through two full revolutions of the crankshaft
and set the crankshaft to the TDC position.
Check the TDC position of the crankshaft by means of the notch (arrow)
on the front crank web.
Check
Check the positions of the marks (arrows) on the camshaft sprockets.
Result:
The marks are not in line with each other and parallel with the sealing
face. Possibility of collisions between pistons and valves.
Measure:
Remove the timing-chain tensioner and correctly install the camshafts.
(-) Tightening camshaft bearing cap unit
Tighten all nuts, taking care to tighten the nuts in the specified tightening
sequence.
Tightening sequence for camshaft bearing cap unit
Tightening sequence for fasteners of camshaft bearing cap unit, see (1)
to (12).
Tightening torques
M6 Tightening
sequence: See
repair manual

1st tightening
torque, tightened
uniformly by hand
2nd tightening
torque, 10 Nm
(-) Installing screw (in hole for TDC locating screw)
Tightening torques
M8 x 16 25 Nm
Follow-up work
Securing throttle cable to throttle-valve stub assembly
Installing battery
Installing seat

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 seat
Remove the battery
Removing silencer
Remove the camshaft sensor
Draining coolant
Removing fan shroud
Removing exhaust manifold
Release the throttle-valve stub assembly
Disconnecting engine-electrics plug

Core activity
(-) Removing coolant-pump housing
Open hose clips (1) with pliers(No. 17 5 571).

Disconnect hoses (2).
Remove screws (1).

Remove coolant-pump housing (2) with gasket (3).
(-) Releasing brake lines from frame
Remove screw (1).

Remove brake lines (3) from holder (2).
(-) Lowering engine for cylinder-head removal

Remove cap (1).

Remove screw (4).
Remove cap (7).

Remove bushings (1) and (3).
Remove screw (6) with washer (5).

Carefully lower engine (1) until it is sitting in the region of the swinging
arm.
(-) Removing cylinder head
If required, pull off drainage hose (1).
Remove screws (1).

Starting at the outside, remove screws (2) in diagonally opposite
sequence.
Remove cylinder head (3), if gasket (4) adheres to mating face tap
lightly to release.

Lift cylinder head at the control side.

Ease the right engine mount (arrow) into the frame triangle.
Turn the control side a little to the rear.

Turn the left engine mounting (Arrow) to the rear over the frame flange.
Lift the control side and feed the side of the coolant pump out of the
frame.

Tip the cylinder head to the bottom and remove to the rear.
(-) Installing cylinder head
ATTENTION
Use of adhesive tape
Adhesive residues, component damage
Do not leave adhesive tape applied to the areas requiring protection for
longer than absolutely necessary.
Use only a suitable cleanser to remove residual traces of adhesive.
by affixing fibre-reinforced masking tape.

Remove all sealing residues from sealing faces (1) and clean the
sealing faces.
CAUTION
Scattering of splinters if compressed air is used
Danger of injury
Wear safety goggles.
Clean the tapped holes (arrows) with compressed air, keeping a cloth
wrapped round the tip of the compressed-air gun.
Carefully blow out cylinder bores (2) with compressed air.
Install a new cylinder-head gasket.
Install the cylinder head.
Ease the right engine mount (arrow) into the frame triangle.

Turn the cylinder head toward the front, noting the left engine mount
(arrow).
Check that the installed position of cylinder-head gasket (1) is correct,

noting reamed pins (2).
Carefully install cylinder head (3), noting reamed pins (2).
Engage threads of screws (4) and (5).
Tightening sequence for cylinder head

Use an electronic torque wrench/angle-of-rotation tightening tool when
tightening.
Workshop equipment
Electronic torque wrench/angle-of-rotation tightening tool
Tighten screws (1) to (8) in the appropriate tightening sequence.
Tightening torques
Cylinder head to crankcase

M10 x 1.25 - 10.9 Tightening

sequence: See
repair manual
1st tightening
torque, 10 Nm
2nd tightening
torque, 30 Nm
Additional angle of
rotation, 130°
M6 x 65 10 Nm
Carefully pivot engine (1) to its correct installed position.
Tightening torques
M12 x 50 66 Nm
M10 x 40 40 Nm

M10 x 40 38 Nm
Install cap (1).
ATTENTION
Frame damage
Install screws (2) and (4) with sleeves (1) and (3).
Tightening torques
M10 x 65 40 Nm
M12 x 50 66 Nm
Install screw (6) with washer (5).
Tightening torques
M10 x 40 38 Nm
Install cap (7).

Remove the masking tape from the cylinder head and frame.
(-) Installing coolant-pump housing
Position new seal (4) in housing (3).

Install screws (1) and washers (2), noting the specified tightening
sequence.

Tightening sequence, fasteners for coolant-pump housing
Tighten the screws in the sequence (1) to (5).
Tightening torques
M6 x 25 Tightening
sequence: See
repair manual
12 Nm
Connect hoses (2) and close hose clips (1) with pliers (No. 17 5 571).
(-) Securing brake lines to frame
Secure the brake-pipe distributor with screw (1).
Tightening torques
Distributor to frame, front right
M6 x 12 8 Nm

Secure brake lines (3) in holder (2).
Follow-up work
=> Oil change, engine, with filter (Description in item: 11
00 611, Billed as a separate item)
Checking valve clearance
Connecting engine-electrics plug
Securing throttle-valve stub assembly
Installing exhaust manifold
Install the camshaft sensor

Installing frame cover

Installing silencer
Installing battery
Installing seat

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

+ 11 12 821
Preparatory work
Removing seat
Remove the battery
Core activity
(-) Removing cylinder head cover
Remove securing strap (1) from the clutch cable.
Open the cable ties (arrows).

Remove screws (1).
Remove cylinder-head cover (2) with gasket (3), noting the sealing face
(arrow).
Remove gaskets (4) and (5).
(-) Installing cylinder head cover
Seal the new gasket (1) in the area shown (arrows).

Sealant
3 - Bond 1209 07 58 9 062 376
Replace rubber bushes (1) and screws (2).
Clean all sealing faces and seals.

Install new gasket (4) in cylinder-head cover (2).
Check sealing ring (5); replace if necessary.
Install sealing ring (5).
Install new gasket (3).
Place cylinder-head cover (2) complete with gasket (4) in position,
noting the breather adapter (arrow).
The breather adapter (arrow) is seated against sealing ring (5).
Install screws (1).
Tightening torques
M6 Tightening
sequence: tighten
in diagonally
opposite sequence
10 Nm
Secure the wiring harness with cable ties (arrows).

Secure the clutch cable with retaining strap (1).

Follow-up work
Installing battery
Installing seat

11 12 641 Replacing cylinder head (cylinder head removed)
ATTENTION
Installation of a camshaft bearing cap that has already been run-in a
new cylinder head
Component damage
Install a correct, new camshaft bearing cap.
Preparatory work
Removing coolant-pump impeller
Removing coolant pump with drive gear
Core activity
(-) Removing cylinder-head externals
Open clips (1) and remove air intake stubs (2).

Remove temperature sensor (3) and oil-pressure switch (4).
(-) Removing cam followers
Remove circlips (1) with pliers (No. 11 1 911).

Remove cam followers (2).
(-) Removing cam-follower shafts
Remove cam-follower shafts (1).

(-) Removing valve
Secure mount (No. 11 0 853) to valve spring compressor (No. 11 0

851).
Adjust thrust cage (No. 11 0 852) for spring retainer (1).
Secure thrust cage (No. 11 0 852) to valve spring compressor (No. 11 0
851).
Position valve spring compressor on spring retainer (1) and valve (2),
press down spring retainer (1).
Remove valve collets (3) and remove the clamp.
Remove valve (2), spring retainer (1) and valve spring (4).
(-) Replacing cylinder head
Use a suitable tool to install spacing sleeves (1) until seated.
(-) Installing valve
Lubricate the valve stem (arrow) with engine oil.

Insert valve (1) into cylinder head (2).

Install the valve stem seal
Clean valve stem (1).

Fit a length of shrink-on hose (2) to valve stem (1) and shrink tight.
The groove for the valve collets (arrow) is covered and cannot damage
valve-stem seal (3).
Slip valve-stem seal (3) into position and remove length of shrink-on
hose (2).
Drive in valve stem sealing ring (3) until seated with drift (No. 11 5 602).
Install bottom valve-spring retainers (1).

Install valve springs (2).
Install top valve-spring retainers (3).

851).
Adjust thrust cage (No. 11 0 852) for spring retainer (1) and secure on
valve-spring compressor (No. 11 0 851).
Align valve spring (4) and spring retainer (1).
Position clamp on spring retainer (1), press down spring retainer (1).
ATTENTION

Loose valves because installation of valve collets not in compliance

with correct procedure.
Engine damage
Make sure that the valve collets are correctly seated in the valve stem
grooves.
Insert valve collets (3) and slowly relieve valve spring (4).
Valve collets (3) locate valve (2).
Install the other valves in the same way.
Remove the special tool.

Lubricate all components with engine oil.
(-) Installing cam-follower shafts
Lubricate cam-follower shafts (1) with engine oil and install.
(-) Installing cam followers
Lubricate cam-follower shaft (1) with engine oil.

Install cam followers (2).
ATTENTION
Re-use of retaining clips.
Engine damage due to loosened retaining clip, security of rocker arms not
ensured
Always replace the retaining clips.
Install circlips (3) with pliers (No. 11 1 911).
(-) Installing cylinder-head externals
Secure clips (1) and air intake stubs (2) with pliers (No. 13 1 500).

The openings of the clips face down.

Install temperature sensor (3) and oil-pressure switch (4).
Tightening torques
M12 x 1.5 20 Nm
M12 x 1.5 16 Nm
Follow-up work
Installing coolant pump with drive gear
Installing coolant-pump impeller

11 13 000 Removing/installing or sealing oil pan

+ 11 13 531
Preparatory work
Draining engine oil
Core activity
(-) Removing oil pan
Remove screws (1) and remove oil pan (2).
(-) Removing oil-pan gasket
Remove screws (2) and remove gasket (1).
(-) Installing oil-pan gasket
Clean threads and sealing faces.

Place gasket (1) in position and tighten screws (2) with thread-locking
compound until hand-tight.

(-) Tightening sequence, fasteners for cover for swing-arm

shaft
Tighten the screws in the sequence as numbered (1) to (11).
Tightening torques
M6 x 25 Tightening
Thread-locking compound (Loctite sequence: See
243, Medium strength) repair manual
12 Nm
(-) Installing oil pan
Check the seal; replace if necessary.

Place oil pan (2) in position, noting the reamed pins.
Install screws (1).
Tightening sequence for oil-pan fasteners

Tightening torques
Oil pan to crankcase

Hexagon Torx screw with collar, Tightening

M6 x 35 - 8.8, in the event of sequence: See
repair, replace with collar bolt with repair manual
imprint 10.9 12 Nm
Collar bolt, M6 x 35 - 10.9 Tightening
sequence: See
repair manual
14 Nm
Follow-up work
Checking engine oil level

11 14 075 Replacing engine-block cover, left

+ 11 14 858
NOTICE
If the crankcase cover you are installing is new, the bearing and seals are
already installed.
Preparatory work
Core activity
(-) Removing left crankcase cover
Removing oil dipstick
Remove screws (1).

Remove gasket (2) and cover (3), noting the sealing ring of the selector
shaft.
Note the thrust washer (arrow); it can remain fixed to the crankcase
cover.
(-) Removing release shaft

Remove circlip (1).

Pull out release shaft (2).
Remove spring (3).
(-) Installing release shaft
Lubricate the release shaft with engine oil.

Slip release shaft (2) into position, taking care not to damage the sealing
ring.
Push spring (3) onto the release shaft and push the shaft all the way
down; note the installed position of the spring.
Install circlip (1).
Turn the release shaft and check that the spring is engaged.
(-) Installing left crankcase cover
Align the chamfer of release head (1) in the installed position shown
here between the holes (arrows).
Spacer (2) must be in position on the selector shaft.
Make sure that main oil galleries (3) are not dirty or clogged.
Secure sliding sleeve (No. 21 4 620).

Hold crankcase cover (1) in position with new gasket (2), noting reamed
pins (3) and sealing ring (4).
Hand-tighten screws (5).
Remove sliding sleeve (No. 21 4 620).

Tightening sequence for crankcase cover, left
Tightening torques
M6 x 25 Tightening
sequence: See
repair manual
12 Nm
Installing oil dipstick

Follow-up work


11 14 085 Replacing right engine-block cover

+ 11 14 859
Preparatory work
Removing right frame cover
Core activity
(-) Removing right crankcase cover
Disconnect alternator plug (1) and disengage the cable (arrows).

Work plug (1) down to remove.
Remove screws (1).

Remove cover (2) with gasket (3), using a cloth or other suitable means
to catch dripping oil.
(-) Removing stator
Remove screws (4).

Remove cable holder (3).
Remove screws (1).
Disengage the rubber grommet from the cover and remove stator (2)
complete with the cable.

(-) Installing stator
Clean the threads in the cover.

Install the stator in the cover, making sure that cable holder (1) is sated
in the recess (arrow).
Turn stator (2) to bring the screw holes into alignment.

Install screws (1).
Tightening torques
M6 x 35 10 Nm
encapsulated)
or, Thread-locking compound
(Loctite 243, Medium strength)
Seat the rubber grommet in the cover.

Install cable holder (3) and install screws (4).
NOTICE
There are no threads in the new cover: the screw cuts the threads as it is
tightened. Under these circumstances, do not use thread-locking
compound.
Tightening torques


(-) Installing right crankcase cover
Lubricate the end faces (arrows) of the shaft bores.
Lubricant
Klüberpaste 46 MR 401 11 00 7 660 831
Apply sealant to the sealing faces of rubber grommet (1).
Sealant
3 - Bond 1209 07 58 9 062 376
Make sure that thrust washer (1) or (2) is installed.

Place new gasket (3) and crankcase cover (2) in position.
Install screws (1).

Tightening sequence for crankcase cover, right
Tightening torques
M6 x 30 Tightening
sequence: See
repair manual
12 Nm
Work alternator connector (1) into position and connect the connector.
Secure the cable (arrows).
Follow-up work
Install the right frame cover

11 15 051 Replacing sealing ring for crankcase breather at drive gear of coolant pump
+ 11 15 551
Preparatory work
Removing seat
Remove the battery
Core activity

Remove screws (1).
(arrow).

Sealant
3 - Bond 1209 07 58 9 062 376

Install screws (1).
Tightening torques
M6 Tightening
sequence: tighten
in diagonally
opposite sequence
10 Nm


Follow-up work
Installing battery
Installing seat

11 15 138 Replace the crankcase ventilation hose

+ 11 15 507
Preparatory work
Removing seat
Remove the battery
Core activity
(-) Removing engine breather hose (intake air silencer
removed)
Open hose clip (1) with pliers (No. 17 5 500) and disconnect breather
adapter (2).
Open hose clip (3) with pliers (No. 17 5 571).
Remove hose (4).
(-) Installing engine breather hose (intake air silencer

removed)
Connect hose (4).

Secure hose clip (3) with pliers (No. 17 5 500).
Install breather adapter (2) and close hose clip (1) with pliers (No. 17 5
571).
Follow-up work


Installing battery
Installing seat

11 21 511 Renewing crankshaft (engine removed)
Preparatory work
Draining engine oil
Removing oil filter
Removing starter
Removing inlet camshaft
Removing exhaust camshaft
Removing all oil sinks
Removing pinion
Removing oil pan
Removing magnetic wheel
Removing freewheel gear
Core activity
(-) Removing balancing conrod
Swing the balancing conrod forward and remove screw (1).

Swing the balancing conrod to the rear and remove screw (1).
Remove conrod bearing cap (2) and balancing conrod (4).
NOTICE
Do not attempt to separate the balancing conrod and the balancing swing
arm.

Remove bearing shells (3).
(-) Removing conrod bearings

Mark the conrod bearing caps to ensure that they remain matched with
their original cylinders.
Marks (arrows) face in the forward direction of travel.
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.
Remove conrod bearing cap screws (1) and remove both conrod
bearing caps (2).
ATTENTION
Installation of parts that have not worn in together
Scoring of the bearing because running in is repeated
Do not mix up components.
Mark installed positions.
Remove bearing shells (2) from both bearing caps (1).

Push both conrods (3) down and remove bearing shells (2).
(-) 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).

Disengage timing chain (1) and secure it so that it cannot drop.
Remove crankshaft (2).
(-) Removing bearing shells for crankshaft
Mark the installed positions of the bearing shells.

Remove all bearing shells (arrows).
(-) Installing crankshaft bearing shells
Clean the bearing shells and the bearing-shell seats.

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 crankshaft
Requirement
Bearing shells are installed in the engine block.

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.
(-) 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.
tightening.
Workshop equipment
Tightening sequence for main bearing caps


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 conrod bearings
ATTENTION
Lubricate bearing shell (1) with engine oil.

Install bearing shell (1) flush in conrod (2). In this process, note the
installed position of the crescent-shaped groove in the conrod (arrows).
Press bearing shell (1) flush in conrod (2) and install.

Install bearing shell (1) in conrod bearing cap (2). In this process, note
the correlation of shell to cap and also note the installed position of the
crescent-shaped groove in the bearing cap (arrows).
Press bearing shell (1) into conrod bearing cap (2) and install.
Installing conrod bearing caps

ATTENTION
Old conrod bearing shells not matched to new crankshaft
Engine damage
Renew the conrod bearing shells when replacing the crankshaft.
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).
tightening.
Workshop equipment
Tighten conrod bolts (1).
Tightening torques
Conrod bolt
M9 x 1 - 12.9, 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°
(-) Installing balancing conrod
Lubricate bearing shells (1) with engine oil.

ATTENTION
Component damage
positions.
Insert bearing shells (1) with projection (arrow) in conrod bearing cap (2)
and balancing conrod (3).

Lubricate bearing shells (1) with engine oil on the inside.

Clean the mating faces (arrows) of conrod bearing cap (2) and
balancing conrod (3).
Insert conrod bearing cap (2) and balancing conrod (3), noting marks
(4).
Dots (4) face in the forward direction of travel.
ATTENTION
Swivel balancing conrod (3) forward and back to enable screws (5) to be
inserted.
Lay cloths on the gearbox shafts.
Swing balancing conrod (1) and lower it gently on to the cloth.
tightening.
Workshop equipment
Tighten conrod bolt (2).
Tightening torques
Balancing conrod
M12 x 1.25 - 12.9, Replace screws 1st tightening
Threads and underside of head torque, 10 Nm
lightly oiled 2nd tightening
torque, 50 Nm
Additional angle of
rotation, 70°

Pivot balancing conrod (1).

tightening.
Workshop equipment
Tightening torques
Balancing conrod
torque, 50 Nm
Additional angle of
rotation, 70°
Follow-up work
Installing TDC locator
Installing oil pan
Installing pinion


Installing starter

11 24 548 Replacing balancing conrod with follower (engine removed)
Preparatory work
Draining engine oil
Removing oil filter
Removing starter
Removing pinion
Removing oil pan
Core activity

NOTICE
arm.

ATTENTION
Component damage

positions.

(4).
ATTENTION
inserted.
tightening.
Workshop equipment
Tightening torques
Balancing conrod
torque, 50 Nm
Additional angle of
rotation, 70°


tightening.
Workshop equipment
Tightening torques
Balancing conrod
torque, 50 Nm
Additional angle of
rotation, 70°
Follow-up work
Installing oil pan
Installing pinion
Releasing crankshaft
Installing starter

11 24 549 Replacing all conrod bearings (engine removed)
Preparatory work
Draining engine oil
Removing oil filter
Removing starter
Removing pinion
Removing oil pan
Core activity

NOTICE
arm.
(-) Removing conrod bearings

Mark the conrod bearing caps to ensure that they remain matched with
their original cylinders.
Marks (arrows) face in the forward direction of travel.
ATTENTION

Component damage
positions.
Remove conrod bearing cap screws (1) and remove both conrod
bearing caps (2).
ATTENTION
Remove bearing shells (2) from both bearing caps (1).

Push both conrods (3) down and remove bearing shells (2).
(-) Installing conrod bearings
ATTENTION
Check
Check crankpin for wear (scoring, damage).

Result:
Crankpin shows scoring or other signs of damage.
Measure:
Replace the crankshaft.

Install bearing shell (1) flush in conrod (2). In this process, note the
installed position of the crescent-shaped groove in the conrod (arrows).
Press bearing shell (1) flush in conrod (2) and install.


Install bearing shell (1) in conrod bearing cap (2). In this process, note
the correlation of shell to cap and also note the installed position of the
crescent-shaped groove in the bearing cap (arrows).
Press bearing shell (1) into conrod bearing cap (2) and install.
ATTENTION
Old conrod bearing shells not matched to new crankshaft
Engine damage
Renew the conrod bearing shells when replacing the crankshaft.
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
tightening.
Workshop equipment


Tighten conrod bolts (1).
Tightening torques
Conrod bolt
M9 x 1 - 12.9, 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°

ATTENTION
Component damage
positions.

(4).
ATTENTION
inserted.


tightening.
Workshop equipment
Tightening torques
Balancing conrod
torque, 50 Nm
Additional angle of
rotation, 70°

tightening.
Workshop equipment
Tightening torques
Balancing conrod
torque, 50 Nm
Additional angle of
rotation, 70°
Follow-up work
Installing oil pan
Installing pinion


Installing starter

11 25 510 Replacing all pistons (engine removed)
Preparatory work
Draining engine oil
Removing oil filter
Removing starter
Remove the cylinder head
Removing pinion
Removing oil pan
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 (conrod removed)
Clamp conrod (1) in a vice fitted with protective jaws.

Remove circlips (2).
Remove piston pin (3).
Remove piston (4).
Check
Check piston pin (3) for wear (scoring, damage).
Result:
Piston pins show scoring or other signs of damage.
Measure:
Replace piston pin (3).
(-) Installing piston (conrod removed)
When installing the piston pin check the construction status; pin and
conrod must be of the same construction status.
ATTENTION
Mixed installation of components with different construction-status
versions
Component damage
Mixed installation is not possible.

The features distinguishing one construction status from the other are
as follows:
Piston pin (1) polished and shining
Bearing bushing (2) in conrod
Lubricate the piston pin with engine oil.

Heat the piston.
Technical data
Mating temperature, 50 °C
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.
(-) Provisionally installing bottom half of crankcase
Before lowering the crankcase half into position, make sure that selector
star (1) is in the neutral position (arrow).
Retaining pin (2) must be installed.

Position the gear wheels as shown in the illustration.

Make sure that each individual gear wheel of the gearbox output shaft is
free to rotate (gearbox is in neutral).
Before lowering the crankcase half into position, check that the bearing
shells (1) for the crankshaft are installed.
When seating the crankcase half, note the reamed pins (arrows).
Check that the gearbox bearings are correctly positioned.

The locking elements (arrow) must be located in the notch in the
crankcase half.
Turn the gaps of the bearing locating rings (arrow) up; make sure the
gaps are not between the sealing faces.

Pivot the balancing conrod up and set crankcase half (1) in position.
Install 2 screws of appropriate length in the corresponding holes on
opposite sides of the crankcase half and tighten the screws until hand-
tight.
(-) 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 the arrow on the
direction piston crown points
toward the exhaust

side, the projection

on the underside of
the piton is opposite
the timing-chain
cavity
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.
Follow-up work
Removing provisionally installed bottom half of crankcase
Installing pinion
Installing oil pan
Installing cylinder head


Installing starter

11 25 671 Replacing piston rings for one piston (piston removed)
Core activity
(-) Removing piston rings
Remove the piston rings and the oil wiper ring with piston ring pliers.
Visually inspect the grooves for the piston rings.
(-) Installing piston rings
Pass wire (3) through both eyes of wavy spring (2); make sure that the
wire extends to an equal distance at each side and do not shorten the
wire.
Install spring (2) with wire (3).
Use piston-ring pliers to install support ring (4) at the bottom of the 3rd
ring groove.
Use piston-ring pliers to install support ring (1) at the top of the 3rd ring
groove.
Technical data
Piston ring shape Type, oil wiper ring
3rd groove
Use piston-ring pliers to install piston ring (2).
Technical data
Piston ring shape Type, taper-face oil-
2nd groove control ring
Piston-ring direction "Top" marking

of installation uppermost
Use piston-ring pliers to install piston ring (1).
Technical data
Piston ring shape Type, rectangular-
section ring

1st groove
Piston-ring direction "Top" marking
of installation uppermost

11 26 001 Replace reduction gear for starter motor

+ 11 26 608
Preparatory work
Removing magnetic wheel with freewheel gear
Core activity
(-) Removing layshaft for starter
Remove gears (1) and (2).

Check bearing axles for wear.
Use Emery paper to remove scoring from bearing axles.
Check
Check starter pinion (3) for wear.
Result:
Starter pinion is damaged.
Measure:
Replace starter pinion (3).

=> 12 41 528, Replacing starter (Billed as a separate item)
(-) Installing layshaft for starter
Lubricant
Klüberpaste 46 MR 401 11 00 7 660 831

Lubricate starter pinion (3).
Lubricant
Lubricate bearing seats of gearwheels (1) and (2).
Lubricant
Klüberpaste 46 MR 401 11 00 7 660 831
Install gearwheels (1) and (2).
Follow-up work
Securing right crankcase cover
Removing TDC locating screw

11 26 002 Replacing freewheel for starter motor

+ 11 26 609
NOTICE
Always replace the freewheel together with the freewheel housing as a
complete unit.
Preparatory work
Core activity
(-) Removing magnetic wheel with freewheel gear
NOTICE
If the freewheel housing is to be removed, slacken the screws with the
magnetic wheel installed.

Heat magnet wheel (3).
Technical data
Release 100 °C
temperature,
magnetic gear hub
Use puller (No. 12 5 521) to release magnet wheel (3) and remove with
washer (4).
Check the Woodruff key and replace if necessary.
(-) Removing freewheel
Remove screws (3).

Remove freewheel housing (1) and freewheel (2).

(-) Installing freewheel
Prior to assembly, lightly lubricate the freewheel and the freewheel

housing with engine oil.
Install freewheel (2) in freewheel housing (1), making sure that the collar
(arrow) faces toward the magnetic gear.
Clean the threads.
Install screws (3).
NOTICE
Always make sure that six screws are installed.
Tightening torques
Freewheel housing to magnetic gear
M8 x 16 - 12.9 35 Nm
(-) Installing magnetic gear with freewheel gear and thrust

washer
NOTICE
There are different construction statuses.
Select the appropriate repair path.
Either a large thrust washer (1) or a small thrust washer (2) can be
installed.
Large thrust washer (1) must be installed with the magnet wheel.

Clean and degrease the taper of magnetic wheel (2).

Apply a thin coat of adhesive to the taper of the magnetic wheel.
Adhesive
Loctite 648 07 58 9 067 732
Clean the collar and inner bearing of freewheel gear (1) and coat them
with engine oil.
ATTENTION
Freewheel bearing in contact with adhesive
Adhesive affecting freewheel bearing
Install the freewheel bearing in the magnet wheel without permitting
contact with adhesive surfaces.
Install the freewheel gear in the magnetic wheel, turning it gently back
and forth to ease it into position, taking care not to allow oil to make its
way onto the taper of the magnetic wheel.
Clean and degrease the taper of the crankshaft.
Clean and degrease the threads of the crankshaft and the screw.
Install the Woodruff key (arrow) in the crankshaft.
Slip magnet wheel (2) with freewheel gear (1) and thrust washer (5) on
to the crankshaft.
NOTICE
Do not install the magnet wheel without the thrust washer; it is not
possible to subsequently retrofit the thrust washer with large outside
diameter. The alternative thrust washer with small outside diameter, by
contrast, can be retrofitted.
Make sure that the Woodruff key (arrow) is in line with the groove
(arrow).
When slipping the components into position, make sure that the splines
engage the freewheel gear.

Tightening torques
M16 x 35 140 Nm
Follow-up work
Securing right crankcase cover

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

+ 11 31 780
Core activity
(-) Removing chain tensioner

Remove spring (3) and chain tensioner (4) from the bore.
(-) Installing chain tensioner
Insert chain tensioner (4) and spring (3) into the bore.
Replace sealing ring (2) and install screw (1).
Tightening torques
M18 x 1.5 40 Nm
Follow-up work

11 31 101 Replacing timing chain tensioning rail

+ 11 31 783
Preparatory work
Removing seat
Remove the battery
Disengaging radiator
Core activity
(-) Removing inlet camshaft
Using suitable tools, lift first inlet camshaft (2) then exhaust camshaft
(1), taking care not to damage the sealing face.
Disengage timing chain (3) from the sprocket of the inlet camshaft first,
then from the sprocket of the exhaust camshaft, and secure it at a
suitable point so that it cannot fall out of position.
Remove inlet camshaft (2).
(-) Removing timing-chain tensioning rail
Remove screw (1).

Remove timing-chain tensioning rail (2).
(-) Installing timing-chain tensioner rail
Install timing-chain tensioning rail (2).

Clean the threads.
Install screw (1).
Tightening torques
M6 10 Nm
(-) Adjusting valve clearance
ATTENTION
Hemispherical oil sinks dropped in and blocking oil ducts in the
cylinder head
Engine damage
Use closes to seal off the oil ducts.
If valve clearance measured on disassembly was not OK, use suitable

oil sinks to correct valve clearance.
Lift appropriate cam follower (1) with magnet (No. 11 1 846) and remove
oil sink (2).
NOTICE
Use only oil sinks that bear an "X" as an identification mark.
Scrap all unmarked heat sinks.

Lightly lubricate oil sink (2) and install it between cam follower (1) and
the valve.
NOTICE
Finally, check that all oil sinks are correctly seated.
(-) Installing inlet camshaft
Make sure that the crankshaft is locked at firing TDC; cams of the right
cylinder are at overlap (arrows).
Lubricate all bearing faces with engine oil.
ATTENTION
Gears of coolant pump and camshaft incorrectly positioned
Component damage
Make sure that the gears of the coolant pump and the camshaft are not
against each other when the threaded fasteners of the bearing cap are
being tightened down.
Turn exhaust camshaft (1) toward the inlet side and light it at a slight
angle.
Insert inlet camshaft (2), noting the EX mark.
The IN mark is flush with the sealing face
Place inlet camshaft (2) to a slight angle and steer chain (3) .
Insert chain tensioner and operate by hand to tension the timing chain.
Check the marks on the camshaft sprockets.
The IN and EX marks are facing each other and are flush with the
sealing face
Follow-up work
Installing left crankcase cover


Securing radiator
Installing battery
Installing seat

11 31 112 Replacing timing chain slide rails

+ 11 31 784
Preparatory work
Removing seat
Remove the battery
Core activity

Remove screws (1).
(arrow).


hexagon (arrow).
face.
Check
Technical data
cold max 35 °
C


C
Result:
Valve clearance out of tolerance.
Measure:
Turn the engine in its normal direction of rotation until the marks
(arrows) on the camshaft sprockets face away from each other and
parallel with the sealing face.
Inlet and exhaust valves of the right cylinder are closed.
Check valve clearance in the same way.
Make a note of valve clearance and replace the oil sinks accordingly in
the reassembly procedure.
(-) Locking engine at firing TDC

hexagon (arrow).

face.

Check that the notch (arrow) in the front crank web is visible through the
bore.

Install locating screw (No. 11 6 570) until it is hand-tight; the locating

screw must engage perfectly in the notch in the crankshaft.

and remove.

Remove spring (3) and chain tensioner (4) from the bore.

(-) Removing both camshafts
Remove exhaust camshaft (1).
(-) Removing timing chain slide rail
Remove timing chain slide rail (1).
(-) Installing timing-chain slide rail
Push in timing-chain slide rail (1) until seated.

Make sure that the slide rail is flush with the sealing face.

ATTENTION
cylinder head
Engine damage

oil sink (2).
NOTICE
the valve.
NOTICE
(-) Installing exhaust camshaft

ATTENTION
cylinder head

Engine damage
Check the measurements sheet prepared on disassembly and if

necessary, use suitable oil sinks to correct valve clearance.
Take each oil sink (2) in turn out of tray (No. 11 1 844), lightly lubricate
each oil sink with engine oil and install it in its correct position between
cam follower (1) and valve.
NOTICE
Make sure that the crankshaft is locked at firing TDC, cylinder No. 1.
Install exhaust camshaft (1), noting the position of the mark:
EX mark flush with the sealing face (arrow)
EX mark toward the inside
Loop timing chain (2) at the inside on to exhaust camshaft (1).
ATTENTION


Component damage
angle.
sealing face

ATTENTION
Component damage
(do not use tools).
cap is seated flat.
Insert chain tensioner (4) and spring (3) into the bore.
Tightening torques
M18 x 1.5 40 Nm

Check
Result:
Measure:
sequence.
to (12).
Tightening torques
M6 Tightening
sequence: See
repair manual

1st tightening
torque, tightened
uniformly by hand
2nd tightening
torque, 10 Nm
Check
Result:
Measure:
(-) Releasing TDC locator
Remove locating screw (No. 11 6 570).

ATTENTION
Component damage
perceptible.
Check
Result:
Measure:
Sealant
3 - Bond 1209 07 58 9 062 376


Install screws (1).
Tightening torques
M6 Tightening
sequence: tighten
in diagonally
opposite sequence
10 Nm

Follow-up work


Installing battery
Installing seat

11 31 539 Replacing all camshafts (cylinder-head cover removed)
Preparatory work
Core activity
(-) Replacing camshafts

Removing camshaft sprockets
Remove screw (1), while counter-holding the hexagon of camshaft (3).
Remove sprocket (2).
Installing camshaft sprockets
Clean the threads.

Position sprocket (2) on camshaft (3), making sure that the sprocket pin
(arrow) is located in the bore (arrow).
Install screw (1).

Tightening torques
Sprockets to camshafts
M18 x 1.5 - 10.9 50 Nm
Removing coolant-pump drive gear (camshaft)

Remove screw (1) (left-hand thread) and washer (2), while counter-
holding the hexagon (arrow).
Remove drive gear (3).
Installing coolant-pump drive gear (camshaft)
Clean the contact surface and place drive gear (3) in position.
Install screw (1) (left-hand thread) and washer (2), while counter-
Tightening torques
Make sure that the crankshaft is locked at firing TDC.


Note the cam position and install exhaust camshaft (1) with the EX mark
on the camshaft sprocket parallel with the sealing face (arrow).
Slip timing chain (2) inward and onto the exhaust camshaft.
ATTENTION
Component damage
angle.
sealing face
Follow-up work

11 31 551 Removing/installing or replacing timing chain (engine removed)
Preparatory work
Draining engine oil
Removing oil filter
Removing starter
Removing pinion
Removing oil pan
Core activity
(-) Lifting crankshaft
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).

Move crankshaft (3) up by turning it slightly and insert a suitable

provisional support (arrow) to hold it in the raised position.
(-) Removing timing chain (crankshaft raised)
If you intend re-using the timing chain, be sure to mark the direction
of rotation on the chain prior to removal.
Lift timing chain (1) off the sprocket and remove.
(-) Removing timing-chain tensioning rail
Remove screw (1).

Remove timing-chain tensioning rail (2).
(-) Installing timing-chain tensioner rail
Install timing-chain tensioning rail (2).

Clean the threads.
Install screw (1).

Tightening torques
M6 10 Nm
(-) Installing timing chain (crankshaft raised)
If you are re-installing a used timing chain, check the mark indicating
the correct direction of rotation.
Loop timing chain (1) over the pinion.
(-) Lowering crankshaft
Before lowering crankshaft (3), lubricate all bearing seats with engine
oil.
Remove provisional support (arrow).
Carefully ease crankshaft (3) down into position in the bearing shells.
Installing crankshaft main bearing caps (crankshaft installed)

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.


tightening.
Workshop equipment
Tightening sequence for main bearing caps
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
Follow-up work
Installing oil pan
Installing pinion
Installing camshaft bearing cap unit


Installing starter

11 33 295 Removing/installing or replacing all cam followers

+ 11 33 694
Preparatory work
Removing seat
Remove the battery
Core activity

and remove.

Remove spring (3) and chain tensioner (4).

(-) Removing cam followers
Remove circlips (1) with pliers (No. 11 1 911).

Remove cam followers (2).
(-) Installing cam followers
Lubricate cam-follower shaft (1) with engine oil.

Install cam followers (2).
ATTENTION
Re-use of retaining clips.
Engine damage due to loosened retaining clip, security of rocker arms not
ensured
Always replace the retaining clips.
Install circlips (3) with pliers (No. 11 1 911).
(-) Installing oil sinks
follower (1) and valve.
NOTICE



ATTENTION
cylinder head
Engine damage

NOTICE

ATTENTION
Component damage
angle.
sealing face

ATTENTION
Component damage

(do not use tools).
cap is seated flat.
Push spring (3) on to chain tensioner (4).

Tightening torques
M18 x 1.5 40 Nm
Check
Result:
Measure:

sequence.
to (12).
Tightening torques
M6 Tightening
sequence: See
repair manual
1st tightening
torque, tightened
uniformly by hand
2nd tightening
torque, 10 Nm
Check
Result:
Measure:
ATTENTION
Component damage
perceptible.

Check
Result:
Measure:
(-) Installing screw (in hole for TDC locating screw)
Tightening torques
M8 x 16 25 Nm
Check


hexagon (arrow).
face.



Technical data
cold max 35 °
C
C
Result:
Measure:
Follow-up work
Installing battery
Installing seat

11 34 001 Checking valve clearance

+ 11 34 501
Preparatory work
Removing seat
Remove the battery
Core activity

Remove screws (1).
(arrow).
Check


hexagon (arrow).
face.


Technical data
cold max 35 °
C
C
Result:
Measure:
Sealant
3 - Bond 1209 07 58 9 062 376


Install screws (1).
Tightening torques
M6 Tightening
sequence: tighten
in diagonally
opposite sequence
10 Nm

Follow-up work


Installing battery
Installing seat

11 34 502 Checking valve clearance (for maintenance)
Preparatory work
Remove the battery
Core activity

Remove screws (1).
(arrow).
Check
hexagon (arrow).

face.


Technical data
cold max 35 °
C
C
Result:
Measure:
Sealant
3 - Bond 1209 07 58 9 062 376


Install screws (1).
Tightening torques
M6 Tightening
sequence: tighten
in diagonally
opposite sequence
10 Nm

Follow-up work


Installing battery

11 34 504 Adjusting valve clearance (cylinder-head cover removed)
Preparatory work
Core activity

Removing oil sinks
ATTENTION
cylinder head
Engine damage
In accordance with results of valve-clearance measurements, flip up

follower (1) and oil sink with magnet (No. 11 1 846).
Remove oil sink (2) and place, correctly sorted, in tray (No. 11 1 844).
Installing oil sinks
ATTENTION
cylinder head
Engine damage


Take each oil sink (2) in turn, lightly lubricate it and install it in its correct
position between follower (1) and valve.
NOTICE
Check that all oil sinks (2) are correctly seated.

ATTENTION
cylinder head
Engine damage


NOTICE
ATTENTION
Component damage
angle.

sealing face
Follow-up work
Rechecking valve clearance

11 34 740 Replacing one valve (cylinder head removed)
Core activity
(-) Removing valve

851).
Adjust thrust cage (No. 11 0 852) for spring retainer (1).
Secure thrust cage (No. 11 0 852) to valve spring compressor (No. 11 0
851).
Position valve spring compressor on spring retainer (1) and valve (2),
press down spring retainer (1).
Remove valve collets (3) and remove the clamp.
Remove valve (2), spring retainer (1) and valve spring (4).
(-) Removing valve stem seal
Remove valve stem seal (1) with pliers (No. 11 1 250).
(-) Installing valve
Lubricate the valve stem (arrow) with engine oil.

Insert valve (1) into cylinder head (2).
Install the valve stem seal

Clean valve stem (1).

Fit a length of shrink-on hose (2) to valve stem (1) and shrink tight.
The groove for the valve collets (arrow) is covered and cannot damage
valve-stem seal (3).
Slip valve-stem seal (3) into position and remove length of shrink-on
hose (2).
Drive in valve stem sealing ring (3) until seated with drift (No. 11 5 602).
Install bottom valve-spring retainers (1).

Install valve springs (2).
Install top valve-spring retainers (3).

851).
Adjust thrust cage (No. 11 0 852) for spring retainer (1) and secure on
valve-spring compressor (No. 11 0 851).
Align valve spring (4) and spring retainer (1).
Position clamp on spring retainer (1), press down spring retainer (1).
ATTENTION
Loose valves because installation of valve collets not in compliance
with correct procedure.
Engine damage
Make sure that the valve collets are correctly seated in the valve stem
grooves.
Insert valve collets (3) and slowly relieve valve spring (4).
Valve collets (3) locate valve (2).
Install the other valves in the same way.
Remove the special tool.
Lubricate all components with engine oil.

11 41 001 Removing/installing or replacing oil delivery pump

+ 11 41 812
Preparatory work
Core activity
(-) Removing cover of oil delivery pump
Remove screws (1).

Remove cover (2).
(-) Removing oil delivery pump
Remove rotor (3) with rotary piston (1), remove pin (2) from the shaft.
Check pin (2) for damage, replace if necessary.
(-) Installing oil delivery pump

Clean all components and lubricate with engine oil prior to installation.
Insert pin (2) in the shaft.
Seat rotary piston (1) on the shaft with the mark (arrow) facing out,
making sure that pin (2) is correctly positioned.
Install rotor (3) with the mark (arrow) facing out.
(-) Installing cover of oil delivery pump

Place cover (2) in position, noting the reamed pin (arrow).
Install screws (1).
Tightening torques
M6 x 16 10 Nm
Follow-up work

11 41 002 Removing/installing or replacing oil suction pump

+ 11 41 814
Preparatory work
Core activity
(-) Removing cover of oil suction pump
Remove screws (1).

Remove cover (2) with gasket (3).
(-) Removing oil suction pump
Remove rotary piston (1) and remove rotor (2).

Remove pin (3).
(-) Installing oil suction pump
Clean all components and lubricate with engine oil prior to installation.
Check pin (1) for damage; replace if necessary.
Insert pin (1) into shaft (2).
Seat rotary piston (3) with the mark (arrow) facing out on shaft (2),
making sure that pin (1) is correctly positioned.
Install rotor (4) with the mark (arrow) facing out.

(-) Installing cover of oil suction pump

Clean the threads.
Lubricate new O-ring (3) with engine oil and position it on cover (2).
Install cover (2) with screws (1).
Tightening torques
Oil-pump cover (suction pump) to crankcase
M6 x 16 12 Nm
encapsulated)
Follow-up work

11 41 004 Measuring engine oil pressure

+ 11 41 817
Preparatory work
Removing frame cover
Core activity
(-) Removing oil-pressure switch

Remove oil-pressure switch (2).
(-) Measuring engine-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 4 605) with sealing ring (1) in the engine block.
Secure angled adapter (No. 11 4 606).
Secure 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 at idle speed approx.

Engine oil is at 1.5...2.0 bar
normal operating - at engine approx.
temperature (fan speed 5000 min 4.5...6.5 bar
has started) -1
Result:
Oil pressure is lower than specified.
Measure:
Identify and rectify the cause of the fault.
Remove the tools.
(-) Installing oil-pressure switch
Install oil-pressure switch (2).
Tightening torques
M12 x 1.5 20 Nm
Connect plug (1).
Follow-up work

11 41 175 Replace drive gears for oil pumps

+ 11 41 675
Preparatory work
Core activity
(-) Removing oil-pump drive gear
Remove circlip (4) and washer (3).

Remove gear (2).
Remove driver pin (1).
(-) Installing oil-pump drive gear
Check
Check driver pin (1) for wear (scoring, damage).
Result:
Driver pin shows scoring or other signs of damage.

Measure:
Replace driver pin (1).
Install driver pin (1) in the shaft.

Install gearwheel (2), making sure that it engages on driver pin (1).
Install washer (3).
Install new circlip (4).
The sharp edge of the circlip faces out
Follow-up work

11 41 291 Replacing oil strainer

+ 11 41 815
Preparatory work
Draining engine oil
Removing oil pan
Core activity
(-) Removing oil strainer
Carefully disengage oil header (3) off the holders (arrows).

Remove the oil header together with strainer (1) and gasket (2).
Remove strainer (1) and clean; replace if necessary.
(-) Install the oil strainer
Check gasket (2) for the oil header and replace if necessary.
The oil header must be seated securely in the swing-arm shaft cover;
even a slight leak will have a detrimental effect on oil delivery.
Check lugs on oil header (3); replace the oil header if the lugs are
damaged or broken.
Position strainer (1) on oil header (3), making sure that it is installed
right way round.
The land (arrow) on the strainer must face toward the engine.
Secure oil header (3) with gasket (2) on the engine, making sure that all
the lugs are engaged in their holders (arrows).
Follow-up work
Installing oil pan



11 41 310 Replacing oil-pressure control valve

+ 11 41 810
Preparatory work
Draining engine oil
Removing oil pan
Core activity
(-) Checking construction status of engine
ATTENTION
versions
Engine damage
Make sure that component correlation is correct.
Choose the corresponding repair path.
Engines with alternative construction status carry a mark (arrow) on the

crankcase (at rear as viewed in forward direction of travel) by way of
identification.
The following alternative construction statuses exist:

Construction status 1 - steel oil-pressure retaining valve with
rubberised seal (1) (black engine)
Construction status 2 - oil-pressure control piston (2) (black engine
with mark)

(-) Removing cover for swing-arm shaft
Construction status 1
Remove screws (1) and remove oil-pan gasket (2).
Remove screws (1).

Remove swing-arm shaft cover (2).
Remove seal (3).
Operate oil-pressure retaining valve (1) a few times, check spring

loading.
Remove oil-pressure retaining valve (1) with spring (2) and check for
damage.

Remove screws (1) and remove swing-arm shaft cover (2).
Remove spring (3) and oil-pressure control piston (4).
Remove gasket (5).
Clean the bore (arrow) for oil pressure regulating piston (4).
(-) Installing swing-arm shaft cover
Check the seat (arrow) of the oil-pressure retaining valve in the housing
for dirt; clean if necessary.
Clean the valve seat with Emery paper, taking care not to remove metal.
ATTENTION
Mixed installation of metal and plastic types of pressure retaining
valve with corresponding swing-arm shaft cover/engine block
Engine damage due to lack of oil
Mixed installation is not permissible.
Insert oil-pressure retaining valve (1) with spring (2) into the cover.


ATTENTION
Detached pin of the balancing conrod axle
Engine damage
When installing, make sure that the pin of the balancing conrod axle is
correctly seated.
Check that the pin (arrow) is correctly seated.

Lay gasket (3) on swing-arm shaft cover (2) and align it correctly.
Hold swing-arm shaft cover (2) and gasket (3) in position.
Install screws (1) with thread-locking compound and tighten until hand-
tight.
ATTENTION
Detached pin of the balancing conrod axle
Engine damage
When installing, make sure that the pin of the balancing conrod axle is
correctly seated.
Check that pin (1) is correctly seated.

Lubricate the bore (arrow) for oil pressure regulating piston (2) with
engine oil.
Lay gasket (4) on swing-arm shaft cover (5) and align it correctly.
When setting swing-arm shaft cover (5) in position, introduce oil
pressure regulating piston (2) and spring (3) into the bore (arrow),
making sure that spring (3) is correctly guided.

Install screws (6) with thread-locking compound and tighten until hand-
tight.

Place gasket (1) in position and tighten screws (2) with thread-locking
compound until hand-tight.
Tightening sequence, fasteners for cover for swing-arm shaft

Tightening torques
M6 x 25 Tightening
Thread-locking compound (Loctite sequence: See
243, Medium strength) repair manual
12 Nm
Follow-up work
Installing oil pan

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

+ 11 51 563
ATTENTION
Mixed installation of components
Component damage
Always replace coolant pump drive gears as pairs and in combination
with a new coolant pump.
NOTICE
The coolant-pump drive gears that come as part of the scope of supply of
the spare part do not have to be replaced unless either steel gears are
installed or the existing gears are damaged.
Preparatory work
=> Draining coolant, refilling/bleeding system
(Description in item: 17 00 504, Billed as a separate item)
Core activity
(-) Removing coolant-pump housing
Open hose clips (1) with pliers(No. 17 5 571).

Disconnect radiator hoses (2).
Remove screws (1) and washers (2).

Remove coolant-pump housing (3) with gasket (4).

(-) Removing coolant-pump impeller
Engage the pliers in the holes (arrows).

Remove coolant-pump impeller (1) (right-hand thread).
(-) Removing coolant pump with drive gear
Remove screw (1).

Secure adapter (No. 00 8 588), pull rod (No. 00 8 581) and impact
weight (No. 00 8 582) to the pump shaft and remove coolant pump (2)
with the drive gear.
(-) Installing coolant pump with drive gear
Check that the channel (arrow) in the cylinder head is clear; clean if
necessary but do not under any circumstances use compressed air
for the purpose.
Lubricate contact surface (1).

Lubricant
Klüberpaste 46 MR 401 11 00 7 660 831
Clean seat (2) of the pump; remove sealing compound, if applicable.
Lubricate pump shaft (1) with engine oil through the bore (arrow).
Lubricate washers (2), bearing (3) and pin (4).
Lubricant
Klüberpaste 46 MR 401 11 00 7 660 831
Make sure that drive gear (5) is corrected seated on pump shaft (1).
Pin (4) engages drive gear (5).
Replace sealing rings (1) and lubricate, taking care not to clog the hole
(arrow).
Lubricant
Klüberpaste 46 MR 401 11 00 7 660 831
If necessary, clean the hole (arrow), but do not under any

circumstances use compressed air for this purpose.
Introduce coolant pump (1) with drive gear (2) into cylinder head (3),
making sure that the teeth mesh with camshaft gear (4).
Use a suitably sized socket to install coolant pump (1) until seated,
taking care to apply pressure only to the outer edge (arrow) of coolant
pump (1).
Install screw (5).
Tightening torques
Coolant pump to cylinder head
M6 x 16 10 Nm

(-) Installing coolant-pump impeller
Place coolant-pump impeller (1) in position.

Engage the pliers in the holes (arrows).
Tighten coolant-pump impeller (1).
Tightening torques
Pump impeller to pump shaft
M8 5 Nm
(-) Installing coolant-pump housing
Position new seal (4) in housing (3).

Install screws (1) and washers (2), noting the specified tightening
sequence.
Tightening sequence, fasteners for coolant-pump housing

Tighten the screws in the sequence (1) to (5).
Tightening torques
M6 x 25

Tightening
sequence: See
repair manual
12 Nm
Connect hoses (2) and close hose clips (1) with pliers (No. 17 5 571).

11 51 030 Installing drain hose for coolant pump

+ 11 51 530
Preparatory work
Core activity
(-) Installing drain hose for coolant pump
Carefully degrease and dry the hole (arrow) in cylinder head (1).
At the top part of neck (1) apply adhesive thinly, making sure that the
hole remains clear.
Adhesive
Loctite 648 07 58 9 067 732
Slacken screws (1) and move dogs (2) in the direction indicated by the
arrows.
Completely back off spindle (3).

Insert neck (1) glued end up into the spindle.

Set pressing-in tool (No. 11 7 860) flat on engine (2) and engage front
dogs (3).
Locate dogs (3) by tightening screws (4).
Position rear dog (5) on engine (2) (arrow) and secure with screw (6).
Press in neck (1) with spindle (2) until the coloured mark (arrow) is
visible.
Back off spindle (2) and remove pressing-in tool (No. 11 7 860).
Connect drain hose (1) and route it down, making sure it is well away
from the exhaust manifold.
Secure drain hose (1) with the cable ties (arrows).
NOTICE
Do not constrain the drain hose with cable ties; the drain hose must
always be able to move.

Secure drain hose (1) with hose holder (2) to oil pan (3).
After installing the engine guard, route drain hose (1) through engine
guard (2).
Follow-up work

11 51 509 Removing/installing both coolant- pump drive gears (coolant pump removed)
ATTENTION
Mixed installation of components
Component damage
Always replace coolant pump drive gears as pairs and in combination
with a new coolant pump.
Preparatory work
Removing left side panel
Remove the battery
Core activity
(-) Removing inlet camshaft
(-) Replacing both coolant-pump drive gears

Removing coolant-pump drive gear (camshaft)
Remove screw (1) (left-hand thread) and washer (2), while counter-

Install a replacement drive gear (1) on the camshaft

Install a replacement drive gear (2) on the coolant-pump shaft
Installing coolant-pump drive gear (camshaft)

Clean the contact surface and place drive gear (3) in position.
Install screw (1) (left-hand thread) and washer (2), while counter-
Tightening torques
ATTENTION
cylinder head
Engine damage


oil sink (2).
NOTICE
the valve.
NOTICE
ATTENTION
Component damage
angle.

sealing face
Follow-up work
Installing battery
Installing left side panel

11 61 176 Removing/installing/sealing or replacing one intake stub

+ 11 61 578
Preparatory work
Removing seat
Remove the battery
Core activity
(-) Release the throttle-valve stub assembly
Disengage throttle cable (2) from the cable pull.
Slacken knurled nut (1) and remove the throttle cable.
Disconnect the plugs:

Injection valves (1) (mark for reinstallation in original positions)
Pressure sensor (2)
Throttle-valve potentiometer (3)
Open cable tie (arrow).

Open clips (1) with pliers (No. 17 5 500), disconnect the throttle-valve
stub assembly and lay it aside.

Affix masking tape to the frame at this point, or use suitable covers to
prevent marking.
Seal the intake ducts at the engine.
(-) Removing air intake stub
Open clips (1).

Remove air intake (2).
Close the intake with a suitable cover.
(-) Installing air intake stub
Check air intake (2) for damage; replace if necessary.

Remove the cover from the intake.
Push air intake (2) complete with clip (1) onto the intake duct.
NOTICE
It is permissible to use suitable screw-type clamps for the throttle-valve
stubs when performing repair work.
When you position the clamps, it is very important to ensure that they are
clear of adjacent components.
Align clips (1) and secure them with pliers (No. 13 1 500).
(-) Securing throttle-valve stub assembly
Remove the cover from the intake on the engine.

Check the intake stubs for damage and replace if necessary.
Seat the throttle-valve stub assembly in the intake stubs.

NOTICE
Thread the cables down into position, noting the plugs.

Secure the cable tie (arrow).
Connect the plugs:

Injection valves (1) (note mark or cable lengths)
Pressure sensor (2)
Secure the cable with cable ties (arrows).
Engage throttle cable (2) on the pulley.

Seat the throttle cable in the holder and secure it with knurled nut (1).
Follow-up work
Installing battery

Installing seat

11 78 000 Replacing oxygen sensor

+ 11 78 500
CAUTION
Hot exhaust system
Risk of burn injury
Do not touch a hot exhaust system.
Preparatory work
Removing seat
Core activity
(-) Disconnecting cable for oxygen sensor
NOTICE

Release the cable (arrow).

Release the cable (arrows).

(-) Removing oxygen sensor
Remove oxygen sensor (1).
(-) Installing oxygen sensor
Clean the threads.

Install oxygen sensor (1).
Tightening torques
M18 x 1.5 45 Nm
Lubricate thread, Lubricant
(Optimoly TA)
(-) Secure the cable for oxygen sensor
NOTICE

Connect plug (1).

Secure the cable (arrow).
Connect plug (1).

Follow-up work
Installing seat

11 84 000 Replacing crash bar

+ 11 84 500
Core activity
(-) Removing crash bars, left and right, with hailer system
Remove cap (1) and disconnect plug (2) for the hailing system.
Remove the following components:
Screws (3)
Screw (4)
Screw (5)
Remove crash bar (6) with the hailing system.
Remove cap (1) and disconnect plug (2) for the hailing system.
Remove crash bar (5) with the hailing system.
(-) Replacing crash bars
Remove screws (1) and remove hailer (2).

Secure hailer (2) to the new part.
Tightening torques
Horn to crash bar
M6 x 20 8 Nm

(-) Installing crash bars, left and right, with hailer system
Hold crash bar (5) with hailer system in position and tighten screws (3)
and (4) until hand-tight.
Connect plug (2) for the hailer system and install cap (1).
Hold crash bar (6) with hailer system in position and tighten screws (3)
and (5) until hand-tight.
Connect plug (2) for the hailer system and install cap (1).
Tighten all screws.
Tightening torques
Crash bar to engine
Front, M10 x 30 38 Nm
Left, M8 x 20 19 Nm
Right, M8 x 50 19 Nm

Crash bar, left, to crash bar, right

M6 8 Nm
Follow-up work

12 00 014 Performing vehicle test with BMW Motorrad diagnostic system

+ 12 00 516
Preparatory work
Removing seat
Core activity
NOTICE
voltage of 13 V.
cap (3).
(-) 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

vehicle


Follow-up work
Installing seat

12 12 011 Renewing all spark plugs

+ 12 12 513
Preparatory work
Removing seat
Remove the battery
Core activity

Remove direct ignition coil (2) with puller tool (No. 12 3 561).
(-) Replace spark plugs
Use only spark plugs recommended by BMW Motorrad.
Technical data
Spark plugs, NGK DCPR 8 E
manufacturer and
designation
Install spark plug (3) with spark-plug wrench (No. 12 3 510).
Tightening torques
Spark plugs
M12 x 1.25 20 Nm
Install direct ignition coil (2).

cable lengths).
Follow-up work
Installing battery
Installing seat

12 12 509 Replace all spark plugs (for maintenance)
Core activity
(-) Replace spark plugs
Use only spark plugs recommended by BMW Motorrad.
Technical data
Spark plugs, NGK DCPR 8 E
manufacturer and
designation
Install spark plug (1) with socket wrench insert (No. 12 3 510).
Tightening torques
Spark plugs
M12 x 1.25 20 Nm

12 13 155 Replacing direct ignition coil

+ 12 13 655
Preparatory work
Removing seat
Remove the battery
Core activity
(-) Removing direct ignition coil

Remove direct ignition coil (2) with puller (No. 12 3 561).
(-) Installing direct ignition coils
Install direct ignition coils (2).

cable lengths).
Follow-up work
Installing battery


Installing seat

12 31 022 Replace generator

+ 12 31 673
Preparatory work
Removing seat
Disconnecting battery
Core activity
(-) Removing right crankcase cover
Disconnect alternator plug (1) and disengage the cable (arrows).

Work plug (1) down to remove.
Remove screws (1).

Remove cover (2) with gasket (3), using a cloth or other suitable means
to catch dripping oil.
(-) Replacing alternator

Removing magnetic wheel with freewheel gear

NOTICE
If the freewheel housing is to be removed, slacken the screws with the
magnetic wheel installed.

Heat magnet wheel (3).
Technical data
Release 100 °C
temperature,
magnetic gear hub
Use puller (No. 12 5 521) to release magnet wheel (3) and remove with
washer (4).
Check the Woodruff key and replace if necessary.
Removing stator
Remove screws (4).
Remove cable holder (3).
Remove screws (1).
Disengage the rubber grommet from the cover and remove stator (2)
complete with the cable.
Installing stator
Clean the threads in the cover.
Install the stator in the cover, making sure that cable holder (1) is sated
in the recess (arrow).
Turn stator (2) to bring the screw holes into alignment.

Install screws (1).

Tightening torques
M6 x 35 10 Nm
encapsulated)
Seat the rubber grommet in the cover.

Install cable holder (3) and install screws (4).
NOTICE
There are no threads in the new cover: the screw cuts the threads as it is
tightened. Under these circumstances, do not use thread-locking
compound.
Tightening torques
(-) Installing magnetic gear with freewheel gear and thrust

washer
NOTICE
Either a large thrust washer (1) or a small thrust washer (2) can be
installed.
Large thrust washer (1) must be installed with the magnet wheel.
Clean and degrease the taper of magnetic wheel (2).

Apply a thin coat of adhesive to the taper of the magnetic wheel.

Adhesive
Loctite 648 07 58 9 067 732
Clean the collar and inner bearing of freewheel gear (1) and coat them
with engine oil.
ATTENTION
Freewheel bearing in contact with adhesive
Adhesive affecting freewheel bearing
Install the freewheel bearing in the magnet wheel without permitting
contact with adhesive surfaces.
Install the freewheel gear in the magnetic wheel, turning it gently back
and forth to ease it into position, taking care not to allow oil to make its
way onto the taper of the magnetic wheel.
Clean and degrease the taper of the crankshaft.
Clean and degrease the threads of the crankshaft and the screw.
Install the Woodruff key (arrow) in the crankshaft.
Slip magnet wheel (2) with freewheel gear (1) and thrust washer (5) on
to the crankshaft.
NOTICE
Do not install the magnet wheel without the thrust washer; it is not
possible to subsequently retrofit the thrust washer with large outside
diameter. The alternative thrust washer with small outside diameter, by
contrast, can be retrofitted.
Make sure that the Woodruff key (arrow) is in line with the groove
(arrow).
When slipping the components into position, make sure that the splines
engage the freewheel gear.
Tightening torques
M16 x 35 140 Nm
(-) Installing right crankcase cover
Lubricant
Klüberpaste 46 MR 401 11 00 7 660 831

Apply sealant to the sealing faces of rubber grommet (1).
Sealant
3 - Bond 1209 07 58 9 062 376
Make sure that thrust washer (1) or (2) is installed.

Place new gasket (3) and crankcase cover (2) in position.
Install screws (1).

Tightening sequence for crankcase cover, right
Tightening torques
M6 x 30 Tightening
sequence: See
repair manual
12 Nm
Work alternator connector (1) into position and connect the connector.
Follow-up work
Connecting battery


Installing seat

12 32 000 Removing/installing voltage regulator

+ 12 32 500
Preparatory work
Removing seat
Core activity
(-) Removing voltage regulator with bracket
Remove screws (1).

Leave regulator (2) with bracket connected to the cable and lay it to one
side.
(-) Removing voltage regulator
Remove screws (1) with washers (2).

Disengage regulator (3).
Disconnect both plugs (1).

Open cable ties (arrows).

(-) Installing voltage regulator
Connect both plugs (1).

Hold voltage regulator (3) in position.

Install screws (1) with washers (2).
Tightening torques
Voltage regulator to bracket
M6 x 35 7 Nm
(-) Securing voltage regulator with bracket
Hold regulator (2) in position.

Install screws (1).

Follow-up work
Connecting battery
Installing seat

12 41 025 Replacing starter

+ 12 41 528
Preparatory work
Removing seat
Core activity
(-) Removing starter
Remove screw (1) and disconnect the earthing strap.

Remove protective cap (5).
Remove nut (3) and disconnect the positive cable from the terminal.
Remove screws (2).
Remove starter (4).
(-) Installing starter
Check sealing ring (1) for damage; replace if necessary.

Clean sealing ring (1) and position it on starter (4).
Lubricate starter at front (3).
Lubricant
Klüberpaste 46 MR 401 11 00 7 660 831
Lubricate splines (2).
Lubricant
Insert starter (4) and secure it with screws (5).
Tightening torques

Starter to engine block

M6 x 30 10 Nm
Manoeuvre the positive lead into position on the terminal and install nut
(6).
Tightening torques
Positive contact to starter
M6 6 Nm
Install protective cap (7).

Secure the earth lead with screw (8).
Follow-up work
Connecting battery
Installing seat

12 51 010 Replace wiring harness for engine

+ 12 51 510
Preparatory work
Removing seat
Remove the battery
Removing seat retainer bridge
Releasing expansion tank
Core activity
(-) Removing wiring harness for engine

Disengage and disconnect the plugs:
Fan (1)
Camshaft sensor (2)
Disconnect plugs (1) for the ignition coils.
Disengage and disconnect the plugs:

Injection valves (1)

Pressure sensor (2)
Remove screw (1) and disconnect the earthing strap.

Temperature sensor (2)
Oil-pressure sensor (3)
Disconnect plug (1) of the control unit.


Crankshaft sensor (1)
Gearbox potentiometer (2)
Oxygen sensor (3)
Side-stand switch (4)
Manoeuvre the engine wiring harness clear of the motorcycle.
NOTICE



Oxygen sensor (3)
Manoeuvre the engine wiring harness clear of the motorcycle.
(-) Installing wiring harness for engine
Manoeuvre the engine wiring harness into position on the motorcycle.

NOTICE
Connect plug (1) of the control unit.

Close cable ties (arrows).
Manoeuvre the engine wiring harness into position on the motorcycle.

Connect plug (1) of the control unit.

Route the engine wiring harness.

NOTICE
Connect the plugs:

Oxygen sensor (3)
Close the cable ties (arrows).
Route the engine wiring harness.
Connect the plugs:
Oxygen sensor (3)
Connect the plugs:

Oil-pressure sensor (3)
Coolant temperature (2)
Secure the earth lead with screw (1).
Tightening torques

Wiring harness to engine

M6 x 12 8 Nm
Connect the plugs, making sure they are correctly matched (cable
lengths):
Pressure sensor (2)
Connect plugs (1) for the ignition coils, making sure each plug is
matched to its correct ignition coil (cable lengths).
Connect and secure plug (1) of the fan.

Connect plug (1) of the camshaft sensor.

Follow-up work
Secure the expansion tank
Installing seat retainer bridge
Installing battery
Installing seat

12 61 000 Renewal oil pressure switch

+ 12 61 500
Preparatory work
Core activity
(-) Removing oil-pressure switch

Remove oil-pressure switch (2).
(-) Installing oil-pressure switch
Install oil-pressure switch (2).
Tightening torques
M12 x 1.5 20 Nm
Connect plug (1).
Follow-up work

12 62 010 Replacing coolant-temperature sensor

+ 12 62 510
Preparatory work
Removing seat
Removing right side panel
Draining coolant
Core activity
(-) Removing sensor for coolant temperature

Remove sensor for coolant temperature (2).
(-) Installing coolant-temperature sensor
Install coolant-temperature sensor (2).
Tightening torques
M12 x 1.5 16 Nm
Connect plug (1).
Follow-up work
Install the right side panel


Installing seat

12 72 001 Replacing crankshaft sensor

+ 12 72 501
Preparatory work
Core activity
(-) Removing crankshaft sensor
Open the cable tie (arrow) and disconnect plug (1).

Remove screw (2).
Remove crankshaft sensor (3).
(-) Installing crankshaft sensor
Clean the threads.

Check the sealing ring for damage and replace if necessary.
Install sensor for crankshaft (3).
Install screw (2).
Tightening torques
Crankshaft sensor to engine block
M6 x 16 10 Nm
encapsulated)
Connect plug (1) and secure the cable tie (arrow).
Follow-up work


12 72 020 Replacing camshaft sensor

+ 12 72 520
Preparatory work
Removing seat
Core activity
(-) Remove the camshaft sensor
Disengage and disconnect plug (1).

Remove screw (2).
Remove camshaft sensor (3) with seal (4).
(-) Install the camshaft sensor

Install camshaft sensor (3) with sealing ring (4).
Install screw (2).
Tightening torques
Speed sensor, camshaft, to cylinder head
M6 x 16 10 Nm
Connect plug (1) and secure it to the heat shield.
Follow-up work
Installing seat


13 51 001 Replacing fuel pressure sensor

+ 13 51 501
Preparatory work
Removing seat
Removing idle actuator
Core activity
(-) Removing injection-pressure sensor

ATTENTION
Escape of fuel when pressurised fuel lines are opened
Damage to surfaces
Employ suitable means to catch escaping fuel.
Wrap cloths around the injection-pressure sensor.

Remove tensioning spring (1).
Remove injection-pressure sensor (3).
(-) Installing injection-pressure sensor

Install injection-pressure sensor (3), noting the sealing ring.
Install tensioning spring (1).
Connect plug (2).
Follow-up work
Installing idle actuator


Installing seat

13 51 002 Measuring fuel pressure

+ 13 51 502
Preparatory work
Removing seat
Core activity
(-) Measuring fuel pressure
WARNING
Fuel is highly flammable and hazardous to health
Risk of fire, risk of damage to health
Comply with the safety regulations.
Release clip (1).

Seal off hose (2) with hose clamp (No. 13 3 010) and disconnect the
hose, taking suitable measures to catch escaping fuel.
Connect pressure gauge (No. 16 1 501) to hose (No. 16 1 502).

Connect hose (No. 16 1 502) with suitable connecting pieces and hose
clips (1) to flow pipe (2) and fuel flow hose (3).
Remove hose clamp (No. 13 3 010).
Start the engine and read the pressure from pressure gauge (No. 16 1
501).
Technical data
Operating pressure 3.5+0.5 bar
of fuel pump −0.5
Stop the engine and switch off the ignition.

Secure hose clamp (No. 13 3 010) to fuel flow hose (3).
Remove the test equipment.
Use new clip (1) and hose (2), close slip (1) with pliers (No. 13 1 500).

Follow-up work
Installing seat

13 53 000 Renewing injector pipe

+ 13 53 500
Preparatory work
Removing seat
Remove the battery
Core activity
(-) Removing injection line
ATTENTION
Damage to surfaces
Open clip (4) and disconnect the hose.

Pressure sensor (2)
Remove screws (3).
Remove clips (1) and remove injection rail (2).

The injection valves remain in the throttle-valve stub assembly.
(-) Removing injection-pressure sensor
Remove tensioning spring (1).

Remove injection-pressure sensor (2) with sealing ring (3).

(-) Installing injection-pressure sensor

Install injection-pressure sensor (3), noting the sealing ring.
Install tensioning spring (1).
(-) Installing injection line
Check the sealing rings of the injection valves for damage. Replace the
sealing rings if they are swollen or damaged.
Install injection rail (2) and install clips (1).
Install screws (3).
Tightening torques
M5 x 12 2 Nm

Connect plugs (1) for the injection valves and (2) for the pressure
sensor, making sure each plug is matched to its correct injection valve
(cable lengths).
ATTENTION
Refitting hoses with non-reusable clamps at the same place
leaks
Always replace clamps fitted with non-reusable clamps.
Connect the hose and close clip (4) with pliers (No. 13 1 500).
Follow-up work
Installing battery
Installing seat

13 54 015 Installing/removing 35 kW power-output restrictor

+ 13 54 531
0746 - Spain exportNV
0800 - Reduction of power to 35 kWOE
NOTICE
Conversion/retrofit also work without registration with the BMW Motorrad
diagnostic system. Registration is advisable, however, so that they will
subsequently be detected by the system whenever work is carried out
with the diagnostic unit.
Preparatory work
Removing seat
Remove the battery
Core activity
(-) Disengaging throttle cable from throttle-valve stub
assembly
Slacken knurled nut (1).

Disengage throttle cable (2) from cable pull (3) and remove.
(-) Releasing throttle-valve stub assembly
Release clips (1) with pliers (No. 17 5 500) and disconnect throttle-valve
stub assembly (2).

(-) Removing bracket for throttle cable (power not restricted)
Remove screws (2) and bracket for throttle cable (1).

Disengage spring (3) (arrows).
(-) Installing bracket for throttle cable
Clean the threads.

Secure bracket for throttle cable (2) with screws (1).
Tightening torques
Bracket for throttle cable to throttle valve stub assembly
M5 x 14 5 Nm
(-) Securing throttle-valve stub assembly
NOTICE

Install throttle-valve stub assembly (2).

(-) Connecting throttle cable to throttle-valve stub assembly
Engage throttle cable (2) in pulley (3).

Secure the throttle cable with knurled nut (1).
Follow-up work
Installing battery
Installing seat

13 54 016 Removing/installing power reduction

+ 13 54 528
NOTICE
If the engine power variant is changed the appropriate throttle cable has
to be installed.
Preparatory work
Removing seat
Remove the battery
Core activity
(-) Removing throttle cable
Disengaging throttle cable from throttle twistgrip
Release stop screw (3).
Remove screw (4).
Remove cover (1).
Disengage throttle cable (2) and work it clear.


Disengage the holders (arrows).

Disengage throttle cable (1) from guide (2).
(-) Disconnecting injection line
Disconnect plug (1) of the injection valves and plug (2) of the injection-
pressure sensor.
Remove screws (3).
Disengage the injection line with the injection valves and manoeuvre it
to one side out of the way.
(-) Removing throttle-valve stub assembly
Open clips (1) with pliers(No. 17 5 500).

Remove the throttle-valve stub assembly.

(-) Replacing throttle-valve stub assembly
Disconnect hoses (1) from the throttle-valve stub assembly.

Transfer the reusable small items to the new component.
Secure hoses (1).
(-) Install the throttle-valve stub assembly
The standard version (1) and the reduced-power version (2) can be
distinguished by the differences in the cable pulls (arrows)
In the case of variant (2), attach spring (3) to the throttle-cable holder.

Connect plug (2) and install the throttle-valve stub assembly.
NOTICE

(-) Securing injection line
Check the sealing ring (arrow) at each injection valve (1) for damage.
Replace the sealing ring if it is swollen or damaged (arrow).
Install the injection line with injection valves.

Install screws (3).
Tightening torques
M5 x 12 2 Nm
Connect plugs (1) for the injection valves, making sure each plug is
matched to its correct injection valve (cable lengths).
Connect plug (2) for the injection-pressure sensor.
(-) Installing throttle cable
Work throttle cable (1) through retainer (2) and route it correctly, making
sure that it is free of kinks along its entire length.
Install the holders (arrows).


Engaging throttle cable on throttle twistgrip

Engage throttle cable (2).
Tighten stop screw (3).
Install cover (1).
Install screw (4).
Follow-up work
Installing battery


Installing seat

13 54 017 Replacing complete throttle-valve assembly

+ 13 54 521
Preparatory work
Removing seat
Remove the battery
Core activity
(-) Disengaging throttle cable from throttle-valve stub
assembly

pressure sensor.
Remove screws (3).
(-) Removing throttle-valve stub assembly


Remove the throttle-valve stub assembly.

(-) Replacing throttle-valve stub assembly
Disconnect hoses (1) from the throttle-valve stub assembly.

Transfer the reusable small items to the new component.
Secure hoses (1).
(-) Install the throttle-valve stub assembly
The standard version (1) and the reduced-power version (2) can be
distinguished by the differences in the cable pulls (arrows)
In the case of variant (2), attach spring (3) to the throttle-cable holder.

Connect plug (2) and install the throttle-valve stub assembly.
NOTICE

Check the sealing ring (arrow) at each injection valve (1) for damage.
Replace the sealing ring if it is swollen or damaged (arrow).

Install screws (3).
Tightening torques
M5 x 12 2 Nm
(-) Securing throttle cable to throttle-valve stub assembly


Follow-up work
Installing battery
Installing seat

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

software)
Preparatory work
Removing seat
Core activity
(-) Removing engine control unit
Remove screw (1) and remove bracket (2).

Remove engine control unit (3).
Disconnect plugs (4) and (5).
(-) Installing engine control unit
Clean the threads.

Connect plugs (5) and (4).
Install engine control unit (3).
Secure bracket (2) with screw (1).
Tightening torques
M5 x 22 6 Nm
Follow-up work
=> 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)
Installing seat

13 61 522 Programming control unit of engine management system (along with testing
software)
Core activity
(-) Programming engine-management control unit
Start the programming routine and follow the instructions issued by the
BMW Motorrad diagnostic system.

13 62 010 Replacing intake-air temperature sensor

+ 13 62 501
Preparatory work
Removing seat
Core activity
(-) Removing intake-air temperature sensor

Unlatch intake-air temperature sensor (2) (arrow) and remove.
(-) Installing intake-air temperature sensor
Check the sealing ring for damage and replace if necessary.

Install intake-air temperature sensor (2), making sure that the latch
(arrow) engages.
Connect plug (1).
Follow-up work
Installing seat

13 63 020 Replace idle actuator

+ 13 63 520
Preparatory work
Removing seat
Core activity
(-) Removing idle actuator

Remove screws (2) and idle actuator (3).
(-) Installing idle actuator

Install idle actuator (2), noting sealing ring (1).
Install screws (3).
Connect plug (4).
Follow-up work
Installing seat


13 64 165 Renewing one injector

+ 13 64 501
Preparatory work
Removing seat
Remove the battery
Core activity
pressure sensor.
Remove screws (3).
(-) Removing injection valve
ATTENTION
Damage to surfaces
Remove clamps (2).

Remove injection valve (1), using a cloth to catch the remaining fuel.
(-) Installing injection valve
When installing injection valve (1), make sure that the sealing rings
(arrows) are correctly seated.

Push injection valve (1) with new sealing rings into the injection line and
secure it with clamp (2), making sure that clamp (2) engages the groove
in injection valve (1).

Install screws (3).
Tightening torques
M5 x 12 2 Nm
Follow-up work
Installing battery


Installing seat

13 71 010 Replace intake-air silencer

+ 13 71 510
Preparatory work
Removing seat
Remove the battery
Core activity
(-) Removing intake air silencer
Disconnect plug (1) for the idle actuator.
Disconnect plug (1) for the temperature sensor.

Remove nuts (2).
Disengage the wiring harness from the holder (arrow).
Carefully lift up intake air silencer (5).
Disconnect hoses (1) from the idle actuator.

Remove intake air silencer (2).
Cover/seal the throttle-valve stub assembly.
Carefully separate the intake air silencer from the throttle-valve
assembly and tilt it to the side.

Remove screw (1).

Disconnect hose (2) with adapter from the cylinder-head cover, noting
seal (3).
Remove the intake air silencer.
(-) Replacing intake air silencer
Remove screws (1) and cover (2).

Remove air filter (3).
Unlatch intake-air temperature sensor (4) and remove.
Remove intake stub (5).
Remove screws (1) and idle actuator (2) with sealing ring (3).
Open cable ties (4) and remove rubber sleeves (5).
When reinstalling rubber sleeves (5), note the tabs (arrows).
Remove hoses and cap (6).

Transfer the parts you removed and the reusable small items to the new
intake air silencer.
Tightening torques
Idle actuator to intake air silencer
PT screw 3 Nm
(-) Installing intake air silencer
Remove the cover/seal from the throttle-valve stub assembly.

Clean the threads.
Place the intake air silencer in position.
Seat hose (2) with new sealing ring (3) on the cylinder-head cover.
Install screw (1).
Tightening torques
M6 x 16, use thread-locking 10 Nm
compound for repair
Connect idle-actuator hoses (1) to intake air silencer (2).

Carefully push intake air silencer (5) onto the throttle-valve stub
assembly.
Tightening torques
M6 x 25 6 Nm
Install nuts (2).

Connect plug (1) for the temperature sensor.
Connect plug (1) for the idle actuator.
Follow-up work
Installing battery
Installing seat

13 72 001 Renewing air cleaner insert

+ 13 72 532
Preparatory work
Removing seat
Core activity
Remove screws (1).


Install screws (1).

Follow-up work
Installing seat

13 72 505 Replace air filter cartridge (for maintenance)
Core activity
Remove screws (1).


Install screws (1).


13 72 508 Checking or replacing air filter element (for maintenance)
Preparatory work
Core activity
Remove screws (1).

(-) Checking air filter
Check
Check the air filter for clogging and cracking.

Result:
Air filter is dirty:
Measure:
Clean the air filter element.
Result:
Cracks are visible:

Measure:
Replace the air filter element.

Install screws (1).
Follow-up work

16 11 030 Removing/installing fuel tank

+ 16 11 533
Preparatory work
Removing seat
Removing silencer
Remove the grab handle
Removing luggage rack
Disconnecting rear flashing turn indicator plug
Remove the number-plate carrier
Draining fuel tank
Removing rear frame
Core activity
(-) Removing fuel tank
Remove screws (1) and remove side panels (2).

Disconnect hose (3).
Remove screws (4) and bushings (5).
Work fuel tank (6) forward to remove.
(-) Installing fuel tank
Position fuel tank (6) in the rear frame.

Install screws (4) and bushings (5).
Tightening torques
(mechanical)
Secure hose (3).

Secure side panels (2) with screws (1).
Follow-up work
Installing rear frame
Installing silencer
Installing number-plate carrier
Connecting rear flashing turn indicator plug
Installing luggage rack
Installing grab handle
Installing seat
Filling fuel tank

16 11 204 Replacing seal for fuel filler neck

+ 16 11 704
Preparatory work
Removing cap for fuel tank
Core activity
(-) Removing filler-neck gasket
Remove cover (1).

Remove screws (2).
Remove filler neck (3) with gasket (4).
(-) Installing filler-neck gasket
Install filler neck (3) with gasket (4).

Install screws (2).
Tightening torques
M5 x 20 2.5 Nm
Install cover (1).
Follow-up work
Installing cap for fuel tank

16 11 213 Renewing fuel tank cover flap

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

Cover the fuel filler neck.
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.
Push the latching tab (arrow) down using a suitable implement 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 cap for fuel tank
WARNING
Open the lid.

Use a cloth to seal the opening of the fuel filler neck.
Remove screws (1).
Remove the cover.
(-) Installing cap for fuel tank
Position the cap on the fuel tank and align it.

Install screws (1), taking care to tighten the screws in diagonally
opposite sequence.

Tightening torques
M5 x 20 2.5 Nm
Remove the cloths from the opening.
(-) Install the lock barrel for fuel tank
Lubricate lock barrel (5).
Lubricant
Unirex S 2 83 23 9 416 138
Install lock barrel (5) in the "Open" position in fuel filler cap (1).
Lock barrel (5) sits flush inside the 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 11 222 Replace safety valve on fuel tank

+ 16 11 555
Preparatory work
Removing seat
Removing right rear trim panel
Core activity
(-) Removing safety valve
WARNING
Fuel is highly flammable
Risk of fire and explosion
Do not smoke. Never bring a naked flame near the fuel tank.
Disconnect hose (3) from safety valve (2).

Remove screws (1).
Remove safety valve (2) with seal.
(-) Installing safety valve
Check the seal for damage and replace if necessary.

Install safety valve (2) with gasket.
Install screws (1).
Tightening torques
M5 x 20 1.5 Nm
Connect hose (3).
Follow-up work
Installing right rear trim panel
Installing seat

16 11 531 Replacing fuel tank (fuel tank removed)
Core activity
(-) Removing safety valve
WARNING
Fuel is highly flammable
Risk of fire and explosion
Do not smoke. Never bring a naked flame near the fuel tank.
Disconnect hose (3) from safety valve (2).

Remove screws (1).
Remove safety valve (2) with seal.
(-) Removing cap for fuel tank
WARNING
Open the lid.

Use a cloth to seal the opening of the fuel filler neck.
Remove screws (1).
Remove the cover.
(-) Removing filler-neck gasket
Remove cover (1).

Remove screws (2).
Remove filler neck (3) with gasket (4).

(-) Removing fuel-pump unit
Remove pump cover (1).

Remove union nut (2) with pin wrench (No. 16 1 021).
ATTENTION
Removal of the fuel-pump unit not in compliance with correct
procedure (e.g. prying out with screwdriver)
Leak due to damage to the sealing lip of the flange
Pull to remove the fuel-pump unit.
Lift off pump flange.

Remove fuel-pump unit (3) with sealing ring (4).
(-) Replacing fuel tank
Transfer the reusable small items from the old fuel tank to the new fuel
tank.
Remove retaining ring (1) from the old fuel tank with pin wrench (No. 16
1 021).
Clean retaining ring (1) and check for damage; replace if necessary.
Install retaining ring (1) positioned in such a way that the two lugs
(arrows) are seated in the corresponding recesses in the fuel tank.
(-) Installing fuel-pump unit
Position sealing ring (4) in the fuel tank.

Install fuel pump unit (3), noting sealing ring (4).
Install union nut (2) with pin wrench (No. 16 1 021).
Tightening torques
Union nut 35 Nm
Install pump cover (1).
(-) Installing filler-neck gasket
Install filler neck (3) with gasket (4).

Install screws (2).
Tightening torques
M5 x 20 2.5 Nm
Install cover (1).
(-) Installing cap for fuel tank
Position the cap on the fuel tank and align it.

Install screws (1), taking care to tighten the screws in diagonally
opposite sequence.
Tightening torques
M5 x 20 2.5 Nm
Remove the cloths from the opening.
(-) Installing safety valve
Check the seal for damage and replace if necessary.

Install safety valve (2) with gasket.
Install screws (1).
Tightening torques
M5 x 20 1.5 Nm
Connect hose (3).

16 14 003 Replacing fuel-level sensor

+ 16 14 554
Preparatory work
Removing seat
Draining fuel tank if necessary
Removing fuel-pump unit
Core activity
(-) Removing fuel-level sensor

Carefully remove intake strainer (2).
Carefully lift the retainers (arrows) and disengage fuel pump (3) from
bracket (5).
Remove screws (4).
Remove holder (5) with the sensor.
(-) Installing fuel-level sensor
NOTICE
When the lever-type sensor is at its lowest position, the fuel gauge can
still read up to two bars.
Hold bracket (5) with sensor in position, working fuel pump (3) into
position. Make sure that the retainers (arrows) engage.
Install screws (4).
Connect plug (1).
Install intake strainer (2), making sure it is parallel with the fuel-level
sensor.
Make sure that the intake strainer cannot come into contact with the
sensor.
Follow-up work

Installing fuel-pump unit

Filling fuel tank
=> Coding complete vehicle (Description in item: 61 00

511, Billed as a separate item)
Installing seat

16 14 009 Removing/installing fuel-pump unit

+ 16 14 502
Preparatory work
Removing seat
Core activity
(-) Draining fuel tank if necessary
If the fill level is above the fuel-pump unit, drain the fuel tank.
Draining fuel tank
WARNING
Drain the fuel tank, using the commercially available special tool.
(-) Removing fuel-pump unit

Seal off the hose with hose clamp (No. 13 3 010).
Open clip (2) and disconnect the hose.
Remove pump cover (1).

Remove union nut (2) with pin wrench (No. 16 1 021).
ATTENTION
Removal of the fuel-pump unit not in compliance with correct
procedure (e.g. prying out with screwdriver)
Leak due to damage to the sealing lip of the flange
Pull to remove the fuel-pump unit.

Use the lip (arrow) to pull the pump flange out of sealing ring (4); do not
use tools to pry out the pump flange.
Remove fuel-pump unit (3) with sealing ring (4).
(-) Installing fuel-pump unit
NOTICE
Position sealing ring (4) in the fuel tank.

Install fuel pump unit (3), noting fuel-level sensor and sealing ring (4).
Install union nut (2) with pin wrench (No. 16 1 021).
Tightening torques
Union nut 35 Nm
Install pump cover (1).
ATTENTION
leaks
Make sure that connectors are dry and connect plugs (1).
ATTENTION
leaks

Make sure that connectors are dry and connect plugs (1).
Follow-up work
Filling fuel tank
Installing seat

16 14 010 Replace electronics of fuel pump

+ 16 14 521
Preparatory work
Removing seat
Core activity
(-) Removing electronics for fuel pump

Remove the pump cover.
Remove screws (2).
Lift electronics section (3) and disconnect plug (4).
Remove electronics section with sealing ring (5).
(-) Installing electronics for fuel pump

Checking electrical contacts
When installing parts that were in use beforehand, check the condition
of the electrical contacts.
Check
Checking electrical contacts

Result:
Significant signs of corrosion on the contacts.
Measure:
Replace the pump electronics or the fuel-pump unit.
Remove all traces of water or moisture inside the cavity and on the
plugs.
Check sealing ring (5) for damage. Replace the sealing ring if it is
swollen or damaged.
Lubricate sealing ring (5) thinly and position it on electronics section
(3).

Care products
Rubber care product 83 12 0 397 018
Connect plug (4).

Carefully install electronics section (3) with sealing ring (5), making sure
that the sealing ring is correctly seated.
Install screws (2).
Install the pump cover.
Connect plug (1).
Follow-up work
Installing seat

16 14 060 Replacing fuel hose, flow hose

+ 16 14 555
Preparatory work
Removing seat
Remove the battery
Core activity
(-) Removing fuel hose, feed
ATTENTION
Damage to surfaces
Open clips (1).

Disconnect fuel hose (2) and catch the escaping fuel in a suitable
container.
Release fuel hose (2) from the holders (arrows) and remove.
(-) Installing fuel hose, feed

Prefitting anti-chafing pad to fuel hose
Secure anti-chafing pad (1) on fuel hose (2), making sure that the
installed position is correct.
Technical data
Installed position of Distance 220 mm
anti/chafing pad on measured
fuel hose from
fuel/pump
end

ATTENTION
leaks
Insert fuel hose (1) with clips (2) and anti-chafing pad (3).
Position anti-chafing pad (3).
Close clips (2) with pliers (No. 13 1 500).
Secure fuel hose (1) (arrows).
Follow-up work
Installing battery
Installing seat

17 00 010 Checking cooling system for leaks (with cooling system tester)
+ 17 00 502
CAUTION
Working on hot cooling system
Risk of burn injury
Always allow the cooling system to cool down before starting work.
Preparatory work
Removing seat
Core activity
(-) Checking cooling system for leaks
Seal off the coolant hose to the expansion tank with a hose clamp (No.
13 3 010).
Unscrew the filler cap from the radiator.
Secure pump (No. 17 0 002) to the filler neck with main element (No. 17
5 521), plug (No. 17 5 522), spring clip (No. 17 5 523) and hose (No. 17
5 524).
Check
Apply the test pressure to the cooling system.
Technical data
Cooling system Test pressure 1.5 bar
test pressure must remain
unchanged: 5 min
Check all connections between hoses, pipes and/or components of the

cooling system for leaks.
Result:
Pressure in cooling system drops or signs of coolant leaking from the
system are visible.
Measure:
Rectify the leak.
Remove the pump, main element, plug, spring clip and hose from the
filler neck and reinstall the cap.

Follow-up work
Installing seat

17 00 035 Draining coolant, refilling/bleeding system

+ 17 00 504
CAUTION
Risk of burn injury
Preparatory work
Removing seat
Core activity
(-) Draining coolant
Seal off coolant hose (1) to the expansion tank with hose clamp (No. 13
3 010).
Remove screw (1).

Disconnect line (2) and catch the escaping coolant in the container.
Slowly open cap (3) on the radiator and allow the coolant to drain.
(-) Filling cooling system

Make sure that hose (1) is correctly closed off with hose clamp (No. 13 3
010).
Securing coolant line
Clean the threads.

Lubricate new sealing ring (1) and position it on coolant line (2).
Lubricant
Molykote 111 11 00 7 660 832
Secure coolant line (2) with screw (3).
Tightening torques
M6 x 16 10 Nm
encapsulated)
Preparing and priming radiator filler for cooling system

Fill canister (No. 17 5 553) with an adequate quantity of coolant.
Technical data
Coolant, total 1.65 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 Pressure 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 on a (No. 17 5 553) 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 Pressure min 8 bar
requirement,
compressor Delivery rate min 125 l/min
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 vacuum is established
and the needle of the pressure gauge is steady.
Technical data
Requisite vacuum min −0.8 bar
for 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 min −0.8 bar
for 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, bleed the cooling
system.
Priming cooling system
Back off bleed screw (1).
Air escapes initially, then coolant.
Tighten bleed screw (1) as soon as coolant starts to emerge.
Tightening torques
Priming screw to coolant pump
M6 x 25 12 Nm
Close coolant cock (1).

Disconnecting radiator filler from radiator

Disconnect the radiator filler from the radiator and remove it from the
vehicle.
Fill the radiator to the bottom edge (arrow) of the overflow bowl.
Install radiator cap (1).
(-) Checking cooling system for leaks
Seal off the coolant hose to the expansion tank with a hose clamp (No.
13 3 010).
Unscrew the filler cap from the radiator.
Secure pump (No. 17 0 002) to the filler neck with main element (No. 17
5 521), plug (No. 17 5 522), spring clip (No. 17 5 523) and hose (No. 17
5 524).

Check
Apply the test pressure to the cooling system.
Technical data
Cooling system Test pressure 1.5 bar
test pressure must remain
unchanged: 5 min
Check all connections between hoses, pipes and/or components of the

cooling system for leaks.
Result:
Pressure in cooling system drops or signs of coolant leaking from the
system are visible.
Measure:
Rectify the leak.
Remove the pump, main element, plug, spring clip and hose from the
filler neck and reinstall the cap.
Follow-up work
Checking coolant level
Installing seat

17 11 001 Replacing radiator cap

+ 17 11 501
CAUTION
Risk of burn injury
Preparatory work
Removing seat
Core activity
(-) Replacing radiator cap
Seal off hose (1) to the expansion tank with hose clamp (No. 13 3 010).
Remove radiator cap (2).
If applicable, top up the coolant in the radiator until the level reaches the
bottom edge (arrow) of the coolant filler neck.
General consumable
Antifreeze and corrosion inhibitor 83 19 2 211 191
Install new radiator cap (2) and remove hose clamp (No. 13 3 010) .
Checking coolant level

Hold the motorcycle upright and read off the coolant level on the scale
on the coolant reservoir.
Technical data
Coolant, specified level between MIN and
MAX marks on the
expansion tank
General consumable (Antifreeze and

corrosion inhibitor)
Check

Result:
If the coolant level is too low:

Measure:
Topping up coolant
With the engine cold, remove cap (1) and correct the coolant level.
Technical data
MAX marks on the
expansion tank

Install cap (1) on the expansion tank.
Follow-up work
Installing seat

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

+ 17 11 508
Preparatory work
Core activity
(-) Removing fan shroud
Remove nut (1) and screw (2).
Remove fan shroud (1).
(-) Remove the radiator
Open clips (2) at the radiator with pliers (No. 17 5 571) and disconnect
the coolant hoses from the radiator.
Remove screw (1).
Work radiator (4) to the right to remove.

(-) Installing radiator
Seat radiator (1) in the holders (arrows).
Install screw (1).
Tightening torques
Radiator to holder
M6 x 20 5 Nm
Connect plug (3).

Connect the coolant hoses to radiator (4).
(-) Installing fan shroud
Working from below, insert fan shroud (1) into the fan.

Note the holders (arrows); install nut (1) and screw (2).
Follow-up work

17 11 009 Replacing radiator mount (radiator removed)

+ 17 11 548
Core activity
(-) Removing top radiator holder
Remove plug holder (1).

ATTENTION
Drilling into water channels of the radiator
leaks
Take care not to puncture water channels when drilling, for example by
using a stop set to the appropriate depth to keep the twist drill from
penetrating too deeply.
Drill out rivets (2), taking care not to damage the top coolant duct
(arrow).
Technical data
Drill diameter for Drill off rivet 5 mm
drilling out holder head
rivets Drill out 4.2 mm
rivets
Remove radiator holder (3).

ATTENTION
Bending of radiator fins
Damage to radiator fins
Take care not to bend the radiator fins when cleaning.
Carefully remove the remains of the rivets from the radiator.
(-) Installing top radiator holder
Hold radiator holder (3) in position and install rivets (2) to secure.
Secure plug holder (1).


17 11 510 Replacing radiator (radiator removed)
Core activity
(-) Replace the radiator
Removing electric fan
Remove body-bound rivets (1).
Disengage plug (2) from the radiator.
Remove the fan complete with shroud from the radiator.
Transfer the fan and small items to the new radiator

17 12 100 Replacing coolant hose from radiator (without draining/ refilling coolant system)
+ 17 12 600
Preparatory work
Core activity
(-) Removing coolant hose from radiator

Remove coolant hose (2) and catch the escaping coolant in a suitable
container.
(-) Installing coolant hose from radiator
Install coolant hose (2).

Position clip (1) as near to the coolant pump (2) as possible.

The overhang should be as small as possible (arrow).

Follow-up work

17 12 105 Replacing coolant hose to radiator (without draining/ refilling coolant system)
+ 17 12 605
Preparatory work
Core activity
(-) Removing coolant hose to radiator

Remove coolant hose (2) and catch the escaping coolant in a suitable
container.
(-) Installing coolant hose to radiator
Install coolant hose (2), making sure it is correctly positioned.

Follow-up work

17 12 114 Replacing all coolant lines for heat exchanger (without draining/ refilling coolant
system)
+ 17 12 614
Preparatory work
Core activity
(-) Removing coolant lines
Open clips (1) with pliers (No. 17 5 571).

Remove screw (2).
Remove coolant lines (3) and sealing ring (4).
(-) Installing coolant lines
Clean the threads.

Lubricate new sealing ring (4) and position it on coolant line (3).
Lubricant
Molykote 111 11 00 7 660 832
Install coolant lines (3).

Install screw (2).
Tightening torques
M6 x 16 10 Nm
encapsulated)

Follow-up work

17 13 001 Replace expansion tank

+ 17 13 501
Preparatory work
Removing seat
Core activity
(-) Removing expansion tank
Remove screws (3).

Drain the expansion tank.
Open clip (1) with pliers (No. 17 5 571).
Disconnect coolant hose (2).
(-) Installing expansion tank
Install the expansion tank with screws (3).
Tightening torques
Expansion tank to front panel carrier
M6 x 16 2.5 Nm
Connect coolant hose (2) and close clip (1) with pliers (No. 17 5 571).
(-) Topping up coolant
With the engine cold, remove cap (1) and correct the coolant level.
Technical data


MAX marks on the
expansion tank
Install cap (1) on the expansion tank.
Follow-up work
Installing seat

17 21 006 Replacing heat exchanger (without draining/refilling coolant system)

+ 17 21 506
Preparatory work
Core activity
(-) Removing heat exchanger
NOTICE
Ensure that coolant and oil do not mix.
Remove screws (1).

Remove heat exchanger (2).
Catch escaping engine oil in a suitable container
(-) Installing heat exchanger

Hold heat exchanger (2) in position.
Install screws (1).
Tightening torques
Heat exchanger to engine
M6 x 16 10 Nm
Follow-up work

17 40 000 Removing/installing or replacing fan

+ 17 40 500
Preparatory work
Removing seat
Core activity
(-) Removing fan shroud
Remove fan shroud (1).
(-) Disengaging radiator
Remove screw (1).

Ease radiator (2) out toward the side as far as is necessary to permit
work to continue; if necessary, secure it in this position with cable ties.

(-) Removing electric fan
Remove body-bound rivets (1).

Disengage plug (2) from the radiator.
Remove the fan complete with shroud from the radiator.
(-) Installing electric fan
Position the fan and shroud on the radiator.

Install body-bound rivets (1).
Secure fan plug (2) to the radiator.
(-) Securing radiator
Seat radiator (1) in the holders (arrows).

Secure radiator (2) with screw (1).
Tightening torques
Radiator to holder
M6 x 20 5 Nm
(-) Installing fan shroud
Working from below, insert fan shroud (1) into the fan.
Note the holders (arrows); install nut (1) and screw (2).

Follow-up work
Installing seat

17 65 000 Replacing thermostat for coolant (without draining/ refilling coolant system)
+ 17 65 500
Preparatory work
Core activity
(-) Removing coolant thermostat
Remove spring clip (1).

Working through the opening (arrow), slacken cap (2) and remove.
Remove thermostatic insert (3).
(-) Installing coolant thermostat

Lubricate sealing (2) with coolant.
Install thermostatic insert (1) with cap (3).
The lug (arrow) of cap (2) must engage the groove (arrow).
Install spring clip (4).
Follow-up work

18 51 000 Replacing silencer

+ 18 51 500
Core activity
(-) Removing silencer
CAUTION
Hot exhaust system
Risk of burn injury
Remove springs (1) with hook (No. 46 5 721).

Remove silencer (4).
(-) Replacing silencer
Remove bushing (1).

Remove screws (3) and remove clip (2).
Lightly lubricate the inner face of clamp (2).
Lubricant
Optimoly TA 18 21 9 062 599
ATTENTION
Movement of clamp along the rear silencer
Scratching of outer pipe
Do not move the clamp on the rear silencer unless necessary for
adjustment.
Open the clamp far enough and lubricate slightly.
Align clamp (2) and loosely install screws (3).

NOTICE
The final position of the clamp becomes apparent when the silencer is
installed.
Once the silencer has been installed, tighten screws (3) until hand-tight.
Install bushing (1).
(-) Installing silencer
Lightly lubricate the contact faces of the silencer and manifold
Lubricant
Optimoly TA 18 21 9 062 599
Fit silencer (4) onto the manifold.

Tightening torques
M8 x 50 19 Nm
Install springs (1) with hook (No. 46 5 721).
Follow-up work

18 51 001 Replacing exhaust manifold

+ 18 51 502
Preparatory work
Removing silencer
Removing seat
Removing fan shroud
Core activity
(-) Removing exhaust manifold
CAUTION
Hot exhaust system
Risk of burn injury
Disconnecting cable for oxygen sensor
NOTICE

Release the cable (arrow).

Release the cable (arrows).

Remove nut (1), washer (2) and screw (3).
Remove nuts (1).

Remove gaskets (2) with exhaust manifold (3).
(-) Removing oxygen sensor
Remove oxygen sensor (1).

(-) Installing oxygen sensor
Clean the threads.

Install oxygen sensor (1).
Tightening torques
M18 x 1.5 45 Nm
Lubricate thread, Lubricant
(Optimoly TA)
(-) Installing exhaust manifold
Insert seals (2) into the cylinder head.

Install exhaust manifold (3).
Tighten nuts (1).
Tightening torques
Exhaust header to cylinder head
M7 14 Nm
Install screw (3), washer (2) and nut (1).
Tightening torques
Exhaust manifold to frame
M8 x 50 19 Nm

Secure the cable for oxygen sensor
NOTICE
Connect plug (1).

Secure the cable (arrow).
Connect plug (1).

Follow-up work
Securing radiator


Installing seat
Installing silencer

21 00 004 Adjusting clutch operating clearance

+ 21 00 500
Core activity
(-) Adjusting clutch cable
Slacken nuts (1) and adjust clutch play by turning nuts (1) with the
handlebars turned fully left.
Technical data
Clutch play Handlebars 3 mm
turned fully
left, between
handlebar
fitting and
clutch cable
Tighten nuts (1).
Recheck clutch play (A).
Follow-up work

21 21 000 Removing and installing or replacing clutch

+ 21 21 606
Preparatory work
Removing clutch pressure plate
Remove the lined plates
Core activity
(-) Removing clutch hub
Install driver lock (No. 21 4 601).

Remove nut (1) with corrugated washer (2).
Remove clutch hub (3) and spacing washer (4).
(-) Removing clutch cage
Remove clutch cage (1), noting needle roller bearing (2) and spacing
sleeve (3).
Remove drive gear (1) and thrust washer (2).

(-) Installing clutch cage
Install drive gear (1) in clutch cage (2); the drivers (arrows) must mesh.
Install thrust washer (1).
Lubricate needle roller bearing (2) and spacing sleeve (3) with engine oil
and install in clutch cage (1).
Install clutch cage (1) until seated, noting the splines; if necessary turn
until the splines are in correct alignment.

(-) Installing clutch hub
Install spacer (4).

Clean and lubricate the splines on the input shaft and the clutch hub.
Lubricant
Klüberpaste 46 MR 401 11 00 7 660 831
Install clutch hub (3) until it is correctly seated.

Clean the threads.
ATTENTION
Gumming of oil nozzle of input shaft
Engine damage
Apply screw locking agent carefully.
Install corrugated washer (2) and nut (1).
Tightening torques
M24 x 1.5 180 Nm
Remove driver lock (No. 21 4 601).
Follow-up work
Installing lined plates
Installing clutch pressure plate



21 21 122 Replacing clutch hub

+ 21 21 608
Preparatory work
Core activity

Install spacer (4).

Lubricant
Klüberpaste 46 MR 401 11 00 7 660 831

Clean the threads.
ATTENTION

Engine damage
Tightening torques
M24 x 1.5 180 Nm
Follow-up work

21 21 140 Removing and installing or replacing lined plates

+ 21 21 609
Preparatory work
Core activity
(-) Removing clutch pressure plate
Slacken screws (1) in diagonally opposite sequence and remove,

together with washers (2) and springs (3).
Remove clutch pressure plate (4) and release head (5).
(-) Remove the lined plates
Remove lined plates (1) and steel plates (2).
(-) Installing lined plates
ATTENTION
Installation of the clutch plates dry
Burning of the clutch plates

Immerse new clutch disc package in clean engine oil.
Immerse lined plates (1) in engine oil or lubricate them with engine oil.
Begin by installing steel plate (2) with the milled recess (arrow).
Install all steel plates (2) with the sharp edge in.
Then install a lined plate (1) with narrow driver.
Technical data
Width of the lined- of the first 13 mm
plate driver and last lined
plates
of the inner 14 mm
lined plates
Install steel plates (2) and lined plates (1) with wide drivers alternately.
Finish by installing a lined plate (1) with narrow driver offset (arrow) in
the clutch cage.
(-) Installing clutch pressure plate
NOTICE
The stepped washers of the clutch springs are not the same for F 650 GS
and F800 GS. It is very important to install the correct washers.
Place release head (5) with clutch pressure plate (4) in position.
Install screws (1) with washers (2) and springs (3).
Tightening torques
M6 x 45 Tightening
sequence: tighten
in diagonally
opposite sequence
10 Nm
The shoulders of washers (2) face toward the springs.

Follow-up work

21 21 145 Replacing bearing for clutch cage

+ 21 21 610
Preparatory work
Core activity

(-) Removing clutch cage
Remove clutch cage (1), noting needle roller bearing (2) and spacing
sleeve (3).
Remove drive gear (1) and thrust washer (2).

(-) Replacing bearing of clutch cage
Replace needle roller bearings (2), (3) and shim (1).

Check
Check bearing seat of clutch housing (4) for wear (scoring, damage).
Result:
Bearing seat shows scoring or other signs of damage.
Measure:
Replace the clutch cage.
(-) Installing clutch cage
Install drive gear (1) in clutch cage (2); the drivers (arrows) must mesh.
Install thrust washer (1).

Lubricate needle roller bearing (2) and spacing sleeve (3) with engine oil
and install in clutch cage (1).
Install clutch cage (1) until seated, noting the splines; if necessary turn
until the splines are in correct alignment.
Install spacer (4).

Lubricant
Klüberpaste 46 MR 401 11 00 7 660 831

Clean the threads.
ATTENTION
Engine damage
Tightening torques


M24 x 1.5 180 Nm
Follow-up work

21 51 000 Replacing release bearing

+ 21 51 727
Preparatory work
Core activity
(-) Removing clutch pressure plate
Slacken screws (1) in diagonally opposite sequence and remove,

together with washers (2) and springs (3).
Remove clutch pressure plate (4) and release head (5).
(-) Removing release bearing
Lay clutch pressure plate (1) upside down on the workbench.

Heat clutch pressure plate (1).
Technical data
Release/mating 80 °C
temperature
Remove release bearing (2) with internal puller (No. 00 8 573), reaction
support (No. 00 8 572) and spindle (No. 00 8 575).
(-) Installing release bearing
Clean the bearing seat.

Lubricate release bearing (1) with engine oil.

Heat clutch pressure plate (2).
Technical data
Release/mating 80 °C
temperature
Fit release bearing (1) with short spindle (No. 36 5 552), fit 42 mm disc
without thread (No. 36 5 554) and 42 mm and 20 mm discs with thread
(No. 36 5 553), making sure they are seated correctly.
The lettering (arrow) faces toward the engine (visible when installed).
(-) Installing clutch pressure plate
NOTICE
The stepped washers of the clutch springs are not the same for F 650 GS
and F800 GS. It is very important to install the correct washers.
Place release head (5) with clutch pressure plate (4) in position.
Install screws (1) with washers (2) and springs (3).
Tightening torques
M6 x 45 Tightening
sequence: tighten
in diagonally
opposite sequence
10 Nm
The shoulders of washers (2) face toward the springs.
Follow-up work

21 51 150 Replacing shaft/bearing for clutch actuation

+ 21 51 650
Preparatory work
Core activity
Remove circlip (1).

Remove spring (3).
(-) Removing shaft sealing ring of release shaft
Affix masking tape (arrow) to the housing to prevent damage.

Pry out shaft sealing ring (1) with a suitable screwdriver.
(-) Replacing bearing of release shaft

Remove the bottom bearing of release shaft
Requirement

Top bearing of release shaft is still installed.
Remove bottom bearing (1 by pressing it down with mandrel )(No. 21 3

621).
Removing top bearing of release shaft
Affix masking tape to the cover.

Set up internal puller (No. 23 1 850), reaction support (No. 00 8 572)
and drift (No. 23 1 770), making sure that the legs grip in the gap
between bearing and cover.
Remove the bearing.
Installing both bearings of release shaft

Seat bushing (No. 21 3 622) with the chamfer towards the bearing on
mandrel (No. 21 3 621).
Lightly lubricate both bearings with engine oil.
Install needle roller bearings (1) and (2).
Press in top needle roller bearing (2) until it is flush with the sealing ring
seat.
(-) Install the shaft sealing ring of release shaft
Lubricate the sealing lip of shaft sealing ring (1) with engine oil.

Install shaft sealing ring (1) with drift (No. 21 4 630).

The open face of the sealing ring is toward the inside.

ring.
Follow-up work

21 51 151 Replacing shaft sealing ring for cutch actuation

+ 21 51 651
Preparatory work
Core activity
Remove circlip (1).

Remove spring (3).
(-) Removing shaft sealing ring of release shaft
Affix masking tape (arrow) to the housing to prevent damage.

Pry out shaft sealing ring (1) with a suitable screwdriver.
(-) Install the shaft sealing ring of release shaft
Lubricate the sealing lip of shaft sealing ring (1) with engine oil.
Install shaft sealing ring (1) with drift (No. 21 4 630).

The open face of the sealing ring is toward the inside.

ring.
Follow-up work

23 12 078 Replace shaft sealing ring of output shaft

+ 23 12 620
Preparatory work
Removing pinion
Core activity
(-) Removing shaft sealing ring of gearbox output shaft
ATTENTION
Drilling of pilot hole in radial shaft seal not in compliance with
correct procedure
Housing damage
Do not use too large a twist drill.
Centre the hole.
Using a twist drill (< 3mm) and drill stop (No. 00 8 586), carefully drill a
centered hole into, but not through shaft sealing ring (1).
Screw pull rod (No. 00 8 581) with adapter for cone-head self-tapping
screw (No. 00 8 587) and impact weight (No. 00 8 582) into the hole
drilled in the rotary shaft seal.
Remove shaft sealing ring (1).
(-) Installing shaft sealing ring, gearbox output shaft
Position sliding sleeve (No. 23 1 671) on gearbox output shaft (1).

Pack the space between the inner sealing lips of shaft sealing ring (2)
with lubricant.
Lubricant
Remove sufficient lubricant to leave a fillet (arrow).

Clean the housing.
Install shaft sealing ring (2) until flush.
Follow-up work
Installing pinion

Adjust chain sag


23 12 090 Replace shaft sealing ring of selector drum

+ 23 12 590
Preparatory work
Removing gearbox potentiometer
Core activity
(-) Removing shaft sealing ring of selector drum
ATTENTION
correct procedure
Housing damage
Centre the hole.
(-) Installing shaft sealing ring of selector drum
Clean the seat for the shaft sealing ring.

Seat shaft sealing ring (1) on the driver of the selector drum and use
drift (No. 23 4 740) to install; the top edge of the shaft sealing ring must
be flush with the inside circumference at the end of the chamfer face
(arrow).
Follow-up work
Installing gearbox potentiometer

23 12 111 Replacing shaft sealing ring of selector shaft

+ 23 12 621
Preparatory work
Core activity
(-) Removing shaft sealing ring of selector shaft
ATTENTION
correct procedure
Housing damage
Centre the hole.
(-) Installing shaft sealing ring of selector shaft
Clean the shaft sealing ring seat.

Seat sliding sleeve (No. 21 4 620) on the foot-operated selector shaft.
Lubricate the sealing lip.
Lubricant
Press in shaft sealing ring (1) until seated, using tubular drift (No. 11 7
645).
Follow-up work

23 14 051 Replacing potentiometer for gear indicator

+ 23 14 507
Preparatory work
Removing seat
Core activity
(-) Removing gearbox potentiometer
Release plug (1) and the cable (arrows), disconnect plug (1).
Remove screws (1).

Remove gearbox potentiometer (2) with sealing ring (3).
(-) Installing gearbox potentiometer
Clean the threads.

Place sealing ring (3) on gearbox potentiometer (2).
Install gearbox potentiometer (2) with sealing ring (3).
Install screws (1).
Tightening torques


compound for repair
Connect plug (1) and route the cable correctly

Follow-up work
Installing seat

23 21 503 Removing/installing transmission shafts (engine removed)
ATTENTION
versions
Component damage
Mixed installation is only conditionally possible.
Preparatory work
Draining engine oil
Removing oil filter
Removing starter
Removing oil pan
Removing pinion
Core activity
(-) Removing transmission output shaft and transmission
input shaft
Lift out transmission output shaft (1) and transmission input shaft (2)
together.

(-) Installing transmission output shaft and transmission input

shaft
Make sure that locking pin (1) is installed in the crankcase bottom
section.
Clean all bearing seats and lubricate with engine oil.

Install shafts (1) and (2).
Turn the bearing of the gearbox output shaft and the bearing locating
rings to the installation position
The locking element (arrow) must be located in the notch in the
crankcase half.
Turn the gap of the bearing locating ring (arrow) up; make sure it is not
between the sealing faces.
Follow-up work
Installing pinion

Installing oil pan
Installing starter

23 21 504 Disassembling and assembling gearbox input shaft (shaft removed)
Core activity
(-) Checking construction status of engine
ATTENTION
versions
Engine damage
Make sure that component correlation is correct.
Choose the corresponding repair path.
Engines with alternative construction status carry a mark (arrow) on the

crankcase (at rear as viewed in forward direction of travel) by way of
identification.
The following alternative construction statuses exist:

Construction status 1 - bearing without sealing washer with circlip (1)
(black engine)
Construction status 2 - bearing without sealing washer (2) (black
engine)
Construction status 3 - bearing with sealing washer (3) (black engine
with mark)
(-) Removing both bearings of gearbox input shaft
NOTICE
The small gearbox bearings have play on the gearbox shafts. The large
gearbox bearings are a press fit.
Remove bearing (1).

Remove bearing (2) with puller (No. 00 7 501), (No. 00 7 502), (No. 00 7
503), (No. 00 7 504), (No. 00 7 505), (No. 00 7 507).
Construction status 1 bearing with circlip (1) has been discontinued
and after removal must be replaced by a construction status 2
bearing without sealing washer.
Construction status 2 and 3

Remove bearing (1).
Remove bearing (2) with puller (No. 00 7 501), (No. 00 7 502), (No. 00 7
503), (No. 00 7 504), (No. 00 7 505), (No. 00 7 507).
(-) Disassembling gearbox input shaft
Remove fixed gearwheel (1).

Remove free gearwheel (2).
ATTENTION
Removal/installation of needle bearing not in compliance with
correct procedure
Damage to needle bearing against splines of the shaft
Carefully ease open the needle bearing at the gap for
removal/installation.
Remove needle roller bearing (3).

Remove circlip (4) with pliers.
Remove gear shift wheel (5).
Remove washer (7) and free gearwheel (8).
(-) Assembling gearbox input shaft
ATTENTION


versions
Component damage
The serial number is the indicator for one construction status; the other
construction status does not have numbering.
Note the following rules with regard to construction status in mixed
configurations:
Numbered gearwheel pairs on gearbox shaft without construction-status
indicator possible.
Gearwheel pairs without construction-status indicator on numbered
gearbox shaft not possible.
Gearbox without construction-status indicator; replacement of the 2nd /
6th gearwheel: always install gearwheel pair with new construction
status.
ATTENTION
Replacement of only one gear of a pair
Worsening of wear pattern
Always replace a gear together with its paired gear.
Check all components prior to assembly; replace components if

necessary.
Clean the bearing seats and lubricate with engine oil.
Slip free gearwheel (8) onto the shaft; the shift dogs face the sliding
seat.
Install washer (7).
Install new circlip (6) with pliers; take care not to overstretch the circlip.
Clean the sliding seat and coat it with engine oil.
Install gear wheel (5), small gear wheel first.
Install new circlip (4); take care not to overstretch the circlip.
Note the locator of the circlip and make sure it is correctly seated in the
groove.
ATTENTION
correct procedure
Slide needle roller bearing (3) onto the shaft, taking care not to damage
the needle rollers.

Slip free gearwheel (2) onto the shaft, with the shift dogs toward the
inside.
Clean and lubricate the sliding seat.
Lubricant
Klüberpaste 46 MR 401 11 00 7 660 831
Slide fixed gear wheel (1) on to the shaft with the shoulder toward the
inside.
(-) Installing both bearings of gearbox input shaft
NOTICE
Clean and lubricate the bearing seats.
Lubricant
Klüberpaste 46 MR 401 11 00 7 660 831
Install new bearing (1).
Install new bearing (2) by applying pressure with a suitable tool to the
inner bearing race, taking care not to damage the gear wheel and the
bearing seat.
Install new bearing (1) with the sealing washer toward the outside.
Install new bearing (2) by applying pressure with a suitable tool to the
inner bearing race, taking care not to damage the gear wheel and the
bearing seat.

23 21 505 Disassembling and assembling gearbox output shaft (shaft removed)
ATTENTION
versions
Component damage
Core activity
(-) Removing bearing of gearbox output shaft (clutch side)
NOTICE
Remove circlip (1).

Remove bearing (2).
(-) Disassembling gearbox output shaft
Remove washer (6).

Remove needle roller bearing (4).
Remove washer (3).
Remove free gearwheels (9) and (8).

ATTENTION


correct procedure
Remove needle roller bearings (7) and (6), taking care not to damage
the needle rollers.
Remove needle roller bearing (1), taking care not to damage the needle
rollers.
Use a suitable tool to press off bearing (1), taking care not to damage
the bearing seat.
(-) Assembling gearbox output shaft
The serial number is the indicator for one construction status; the other
construction status does not have numbering.
Note the following rules with regard to construction status in mixed
configurations:
Numbered gearwheel pairs on gearbox shaft without construction-status
indicator possible.
Gearwheel pairs without construction-status indicator on numbered
gearbox shaft not possible.
Gearbox without construction-status indicator; replacement of the 2nd /
6th gearwheel: always install gearwheel pair with new construction
status.
ATTENTION
Replacement of only one gear of a pair
Worsening of wear pattern
Always replace a gear together with its paired gear.

Check all components prior to assembly; replace components if

necessary.
ATTENTION
correct procedure
Install needle roller bearing (1), taking care not to damage the needle
rollers.
Install free gearwheel (2), lubricating grooves first.
groove.
The tabs of the circlip must be seated in the vee-groove.
Clean the sliding seat and the internal splines and coat with engine oil.
Slide gear shift wheel (4) onto the shaft with the shift groove toward the
outside.
groove.
ATTENTION
correct procedure
Install needle roller bearings (6) and (7), taking care not to damage the
needle rollers.
Install free gearwheel (8), with the groove for engaging the gear shift
wheel first.
Install free gearwheel (9), with the groove for engaging the gear shift
wheel toward the outside.
groove.
Slide gear shift wheel (2) onto the shaft with the shift groove first.

Oil washer (3) and slide it into position.

Slide needle roller bearing (4) onto the shaft, taking care not to damage
the needle rollers.
Install free gearwheel (5) with the wide collar (arrow) to the inside.
Oil washer (6) and slide it into position.
(-) Installing both bearings of gearbox output shaft
NOTICE
Check both bearings before installing.

Lubricant
Klüberpaste 46 MR 401 11 00 7 660 831
Position bearing (1) with the locating ring (arrow) toward the inside and
apply pressure to the inner bearing race to install the bearing, taking
care not to damage the gear wheel and the bearing seat.
Install bearing (2) with the locating ring (arrow) facing out.

23 31 120 Replacing locking lever

+ 23 31 620
Preparatory work
Core activity
(-) Remove the locking lever
NOTICE
Use rags to plug the openings in the crankcase.

Remove the components:
Screw (1)
Washer (2)
Locking lever (3)
Bushing (4)
Spring (5)

Screw (1)
Locking lever (2)
Bushing (3)
Spring (4)

(-) Installing locking lever
Lubricate the components with engine oil.
NOTICE
Install the components:

Spring (1), noting the correct position (arrow)
Bushing (2)
Locking lever (3)
Install washer (4) and screw (5).
Tightening torques
with washer, M6 x 16, Replace 10 Nm
screw
without washer, M6 x 13, Replace 10 Nm
screw
encapsulated)

Bushing (2)
Locking lever (3)
Install screw (4).
Tightening torques


screw
screw
encapsulated)
Follow-up work

23 31 121 Replacing locking star

+ 23 31 621
Preparatory work
Core activity
(-) Removing star-shaped locking element
Plug the openings in the crankcase.

Turn star-shaped locking element (3) one click away from the neutral
position (arrow).
Remove screw (2).
Swing out locking lever (1) and remove star-shaped locking element (3).
(-) Installing star-shaped locking element
Use a screwdriver to pivot locking lever (1) out and install star-shaped
locking element (3) in the selector drum with the reamed pin (arrow) in
the bore (arrow).
Install screw (2).
Tightening torques
M6 x 25 10 Nm
Turn the selector drum to the neutral position (arrow).
Follow-up work



23 31 130 Replacing selector shaft

+ 23 31 904
Preparatory work
Core activity
(-) Removing left crankcase cover
Removing oil dipstick
Remove screws (1).

Remove gasket (2) and cover (3), noting the sealing ring of the selector
shaft.
Note the thrust washer (arrow); it can remain fixed to the crankcase
cover.
(-) Removing shaft sealing ring of selector shaft
Carefully pry out shaft sealing ring (1) with a screwdriver, applying the
blade of the screwdriver at the inside only.

(-) Removing selector shaft
Remove selector shaft (1).
(-) Installing selector shaft
Push selector shaft (1) with the return spring over reamed pin (2) and
into guide bushing, making sure that projection (3) engages the selector
star.
Install spacer (4).
(-) Installing left crankcase cover
Align the chamfer of release head (1) in the installed position shown
here between the holes (arrows).
Spacer (2) must be in position on the selector shaft.
Make sure that main oil galleries (3) are not dirty or clogged.

Secure sliding sleeve (No. 21 4 620).

Hold crankcase cover (1) in position with new gasket (2), noting reamed
pins (3) and sealing ring (4).
Hand-tighten screws (5).
Tightening sequence for crankcase cover, left
Tightening torques
M6 x 25 Tightening
sequence: See
repair manual
12 Nm
Installing oil dipstick


(-) Installing shaft sealing ring of selector shaft
Clean the shaft sealing ring seat.

Seat sliding sleeve (No. 21 4 620) on the foot-operated selector shaft.
Lubricate the sealing lip.
Lubricant
Press in shaft sealing ring (1) until seated, using tubular drift (No. 11 7
645).
Follow-up work

23 31 502 Replacing shift forks (engine removed)
Preparatory work
Removing starter
Draining engine oil
Removing oil filter
Removing oil pan
Removing oil-pan gasket
Remove the screw (in hole for TDC locating pin)
Operating and removing gearshift lever
Removing pinion
Removing lined plates
Removing clutch hub
Removing clutch cage
Core activity
(-) Removing oil-pump drive gear
Remove circlip (4) and washer (3).

Remove gear (2).
Remove driver pin (1).

(-) Removing cover of oil delivery pump
Remove screws (1).

Remove cover (2).
(-) Removing shift forks for 1st/3rd and 2nd/4th gears
Remove retaining pin (1).

Remove selector rod (2).
Remove shift forks (3).
(-) Removing shift fork, 5th/6th gear
Remove selector rod (1).

Remove shift fork (2).
(-) Installing shift fork, 5th/6th gear
Clean all components and lubricate with engine oil.

Turn the selector drum to the neutral position.
Hold shift fork (2) in position at the selector drum.

Check
Check the selector rod for wear (scoring, damage).
Result:
Selector rod shows scoring or other signs of damage.
Measure:
Replace the selector rod.
Slide selector rod (1) into the crankcase half and the shift fork until
seated.
Check that the shift fork moves freely in the selector drum.
(-) Installing shift forks for 1st/3rd and 2nd/4th gears
Clean all components and lubricate with engine oil.

Hold shift forks (3) in position at the selector drum.
Check
Check selector rod (2) for wear (scoring, damage).
Result:
Selector rod shows scoring or other signs of damage.
Measure:
Replace selector rod (2).
Insert selector rod (2) until seated.
Check that shift forks (3) move freely in the selector drum.
Lubricate retaining pin (1) and install.
Lubricant

(-) Installing cover of oil delivery pump

Place cover (2) in position, noting the reamed pin (arrow).
Install screws (1).
Tightening torques
M6 x 16 10 Nm
(-) Installing oil-pump drive gear
Check
Check driver pin (1) for wear (scoring, damage).
Result:
Driver pin shows scoring or other signs of damage.
Measure:
Replace the driver pin.
Install driver pin (1) in the shaft.

Install gear (2), making sure that the gear engages the driver pin.
Install washer (3).
The sharp edge of the circlip faces out
Follow-up work


Installing clutch cage
Installing clutch hub
Installing pinion
Operating gearshift lever
Installing oil pan
Installing starter

23 31 626 Replacing shift drum (engine removed)
Preparatory work
Removing starter
Draining engine oil
Removing oil filter
Removing oil pan
Removing oil-pan gasket
Remove the screw (in hole for TDC locating pin)
Operating and removing gearshift lever
Removing pinion
Removing lined plates
Removing clutch hub
Removing clutch cage
Removing shift forks for 1st/3rd and 2nd/4th gears
Removing cover of oil delivery pump
Removing shift fork, 5th/6th gear
Core activity
(-) Removing star-shaped locking element
Plug the openings in the crankcase.

Turn star-shaped locking element (3) one click away from the neutral
position (arrow).
Remove screw (2).
Swing out locking lever (1) and remove star-shaped locking element (3).

(-) Remove the locking lever
NOTICE

Screw (1)
Washer (2)
Locking lever (3)
Bushing (4)
Spring (5)

Screw (1)
Locking lever (2)
Bushing (3)
Spring (4)
(-) Removing selector drum
Remove screw (1).

Remove selector drum (2) from crankcase half.

(-) Removing gearbox potentiometer
Remove screws (1).

Disengage gearbox potentiometer (2) and remove with sealing ring (3).
Disengage retaining clip (4) and remove gearbox potentiometer (2).
(-) Removing shaft sealing ring of selector drum
Carefully pry out shaft sealing ring (1) with a screwdriver, applying the
blade of the screwdriver at the inside only.
(-) Installing selector drum
Clean the threads.

Clean the selector drum and the bearing seats and lubricate with engine
oil.
Install the selector drum with bearing (2) in the crankcase half.

Install screw (1).
Tightening torques
Selector-drum bearing to engine block
M6 x 13 10 Nm
(-) Installing shaft sealing ring of selector drum
Clean the seat for the shaft sealing ring.

Seat shaft sealing ring (1) on the driver of the selector drum and use
drift (No. 23 4 740) to install; the top edge of the shaft sealing ring must
be flush with the inside circumference at the end of the chamfer face
(arrow).
(-) Installing gearbox potentiometer
Clean the threads.

Place sealing ring (3) on the potentiometer.
Install potentiometer (2), and when positioning the unit make sure that
the driver shaft engages the potentiometer correctly.
Install screws (1).
Tightening torques
compound for repair
Secure the cable with retaining clip (4).
(-) Installing locking lever
Lubricate the components with engine oil.

NOTICE



Bushing (2)
Locking lever (3)
Install washer (4) and screw (5).
Tightening torques
screw
screw
encapsulated)

Bushing (2)
Locking lever (3)
Install screw (4).
Tightening torques
screw
screw
encapsulated)
(-) Installing star-shaped locking element
Use a screwdriver to pivot locking lever (1) out and install star-shaped
locking element (3) in the selector drum with the reamed pin (arrow) in
the bore (arrow).
Install screw (2).

Tightening torques
M6 x 25 10 Nm
Follow-up work
Installing shift fork, 5th/6th gear
Installing cover of oil delivery pump
Installing shift forks for 1st/3rd and 2nd/4th gears
Installing clutch cage
Installing clutch hub
Installing pinion
Operating gearshift lever
Installing oil pan
Installing starter

23 31 627 Replacing bearing for shift drum (shift drum removed)
Core activity
(-) Removing selector-drum outside bearing
Carefully secure selector drum (1) in a bench vice with protective jaws
(2).
Install original screw (3) in selector drum (1) to protect the thread.
Remove selector-drum outside bearing (4) with puller (No. 00 8 400).
Remove original screw (3) and, if necessary, replace it on installation.
(-) Removing selector-drum inside bearing
Heat the selector drum around the inside bearing.
Technical data
Release 80 °C
temperature,
selector-drum inside
bearing
Set the selector drum with driver down firmly on a wooden surface;
inside bearing (1) drops out.
(-) Installing selector-drum inside bearing
Heat selector drum (1) (arrows).
Technical data
selector-drum inside
bearing
Install inner bearing (2).

The bearing sits flush with the selector drum (arrows).

(-) Installing selector-drum outside bearing
Heat outside bearing (1).
Technical data
selector-drum
outside bearing
Position outer bearing (1) on selector drum (2), making sure that outer
bearing (1) is seated against the bearing seat (arrows).

23 41 300 Removing/installing or replacing gearshift lever

+ 23 41 551
Core activity
(-) Removing gearshift lever
Remove screw (1).

Ease gearshift lever (2) open slightly at the fit (arrow) and remove.
(-) Installing gearshift lever
Slip gearshift lever (2) on to the shaft with the lever positioned such that
the mark (arrow) is aligned with the join.
Install screw (1).
Tightening torques
Shift lever to selector shaft
M6 x 25 8 Nm
Follow-up work

31 42 005 Oil change in telescopic front forks

+ 31 42 899
Preparatory work
Removing bottom front-wheel cover
Releasing brake caliper
Removing front wheel
Removing fork stabiliser
Removing both fork legs
Core activity
(-) Removing spring
Remove sealing cap (1).

CAUTION
Components spring-loaded
Risk of injury caused by flying parts
Carefully relieve and, as applicable, apply spring tension.
Push sealing plug (3) down and remove circlip (2).

Remove sealing plug (3).
Remove spacing sleeve (4) and spring (5).
(-) Draining fork oil
Firmly and repeatedly compress the fork leg to free any dirt that may be
inside.
Pour out the oil while repeatedly pumping with the fixed fork tube.
(-) Filling fork leg with oil
Pour in the correct quantity of the specified oil.
Technical data
Fork oil, capacity 530 ml
per fork leg Telescopic fork oil (Telescope fork oil type 2)
Compress and extend the fixed fork tube a few times to make sure that
the damper is completely filled.
Allow the oil to settle for a few minutes.

Push fixed fork tube (1) all the way in.

Set dipstick (No. 31 6 551) to the correct fork-oil level, insert the dipstick
into fixed tube (1) and draw off the excess fork oil.
Technical data
Level of fork oil in Forks fully 100 mm
fork leg (air compressed,
chamber) spring
removed,
spacer
installed
(-) Installing coil springs
Install spring (5) and spacing sleeve (4).

Push plug (3) down, and install circlip (2).
Install sealing cap (1).
Follow-up work
Installing fork legs
Install the front wheel
Installing bottom front-wheel cover
Securing brake caliper

31 42 011 Checking steering-head bearing

+ 31 42 511
Core activity
(-) Check the steering-head bearing
Relieve load on front wheel.

Turn the handlebars back and forth through the full arc of their travel
and pull the forks forward and back at the fixed fork tubes.
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.
Check
Result:
The bearing has settled and the setting is no longer free of play.
Measure:
=> 31 42 514, Adjusting steering-head bearing (with checking steering-
head bearing) (Billed as a separate item)
Check
Result:
Handlebars feel stiff or there is a perceptible notching effect at the
straight-ahead position.
Measure:
=> 31 42 879, Replacing both steering-head bearings (Billed as a
separate item)
Follow-up work

31 42 028 Replace upper fork bridge

+ 31 42 528
Preparatory work
Removing handlebars
Core activity
(-) Removing top fork bridge
Lay fuel-tank protective cloth (No. 16 1 611) in position.

Remove screw (1).
Remove bracket (2).
Remove cap (1).

Slacken clamping screws (2) on left and right.
Slacken clamping screw (3).
Remove adjusting screw (4) with washer (3).

Remove fork bridge (2).
Remove lid (1).

(-) Removing handlebar clamping block
Remove washer (3) and nut (4).

Remove washer (5), clamping block (6) and screw (7).
Remove rubber sleeves (1) and bushing (2).
(-) Installing handlebar clamping block in top fork bridge
Install rubber sleeves (1) and bushing (2) in the fork bridge.
Install washer (5), clamping block (6) and screw (7).
The higher flat (arrow) of handlebar clamping block (6) must be to the
front.
Install washer (3) and nut (4).
Tightening torques
Handlebar clamping block to top fork bridge
M10 x 70 - 10.9, Replace nut 25 Nm
(mechanical)
(-) Install the top fork bridge
Hold cover (1) in position.

Hold fork bridge (2) in position.
Loosely install washer (3) and adjusting screw (4).

Secure the lines with holder (2).

Install screw (1).
(-) Adjusting steering-head bearing play
Requirement
Front wheel on the ground.
Tighten adjusting screw (1) to specification.
Tightening torques
M18 x 1 Tightening torque,
25 Nm
Swing the forks 3x
to left/right through
full arc of travel
Loosen, 60°
Tightening torque,
11 Nm
Angle (A) indicates the angle for backing off.

Tighten clamping screw (3).

Tightening torques
M8 x 40 19 Nm
Tighten clamping screws (2) on left and right.
Tightening torques
M8 x 25 19 Nm
Install cap (1).
Follow-up work
Checking steering-head bearing
Securing handlebars

31 42 029 Replace lower fork bridge

+ 31 42 527
Preparatory work
Removing both fork legs with wheel cover
Removing cover for fork bridge
Removing handlebars
Core activity
(-) Removing top and bottom fork bridges

Remove cap (2).
Remove adjusting screw (3) with washer (4).
Hold the bottom fork bridge.
Remove fork bridge (5) and dust cap (6).
Remove fork bridge (1).
(-) Removing outer races of steering-head bearing
Remove top steering-head bearing (1).

Remove top bearing shell (2) with internal puller (No. 00 8 561), reaction
support (No. 00 8 562) and support ring (No. 31 6 500).

Remove bottom bearing shell (1) with internal puller (No. 00 8 561),
reaction support (No. 00 8 562) and support ring (No. 31 6 500).
(-) Installing outer races of steering-head bearing
Install top bearing shell (1) with nut (No. 31 5 702), pull-in disc (No. 31 5
752), centering disc (No. 31 5 751), puller sleeve (No. 31 5 704) and
threaded rod (No. 31 5 701).
Install bottom bearing shell (1) with nut (No. 31 5 702), pull-in disc (No.
31 5 752), centering disc (No. 31 5 751), puller sleeve (No. 31 5 704)
and threaded rod (No. 31 5 701).

(-) Installing bottom steering-head bearing
Install new dust cap (2).

Press in bearing (1) until seated, using a suitable adapter that applies
pressure only to the inner bearing race.
Lubricate bearing (1).
Lubricant
(-) Installing bottom fork bridge
Lubricate the steering-head bearing.
Lubricant
Insert the top steering-head bearing into the frame.
Install fork bridge (1).

Hold cover (1) in position.

Hold fork bridge (2) in position.
Install adjusting screw (4) with washer (3).
Follow-up work
Installing both fork legs with wheel cover
Installing cover for fork bridge
Installing front wheel
Adjusting steering-head bearing play
Securing handlebars

31 42 280 Removing/installing/checking or replacing both springs

+ 31 42 878
Preparatory work
Removing handlebars
Core activity
(-) Removing spring
Remove sealing cap (1)

CAUTION
Push sealing plug (3) down and remove circlip (2). Carefully allow the
sealing plug to rise again and remove.
(-) Installing coil springs
Install spring (5) and spacing sleeve (4).

Push plug (3) down, and install circlip (2).
Install sealing cap (1).
Follow-up work
Securing handlebars

31 42 321 Replacing both steering-head bearings

+ 31 42 879
Preparatory work
Removing cover for fork bridge
Removing both fork legs with wheel cover
Removing handlebars
Removing top fork bridge
Removing bottom fork bridge
Core activity

(-) Removing bottom steering-head bearing
Fully tighten adjusting screw (3) in the steering tube.

Clamp the steering tube in a bench vice, using a block of wood as an

insert between the adjusting screw and the face for protection.
Heat steering-head bearing (2).
Technical data
Mating/release 80 °C
temperature,
steering-head
bearing
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.
Remove steering-head bearing (2) and dust cap (1).

Remove adjusting screw (3).

Lubricant

Follow-up work
Installing bottom fork bridge
Installing top fork bridge
Installing both fork legs with wheel cover
Installing cover for fork bridge
Securing handlebars

31 42 341 Removing/installing left fork leg

+ 31 42 841
Preparatory work
Core activity
(-) Removing left fork leg
Clean the fork leg.

Slacken clamping screws (1) and (2).
Slightly open the bottom clamp of the fork bridge and remove the fork
leg.
(-) Installing left fork leg
Slightly spread the clamps in the bottom fork bridge.

Slip the fork leg up into the fork bridges until the top of the leg is against
wire stop (1).
Tighten clamping screws (2) and (3).
Tightening torques
M8 x 25 19 Nm
M8 x 25 Tightening
sequence: Tighten
screws six times in
alternate sequence
19 Nm

Follow-up work

31 42 342 Removing/installing right fork leg

+ 31 42 842
Preparatory work
Core activity
(-) Removing right fork leg
Slacken clamping screws (1) and (2).

Slightly open the bottom clamp of the fork bridge and remove the fork
leg.
(-) Installing right fork leg
Align the right fork leg with the left fork leg.
Tighten clamping screws (1) and (2).
Tightening torques
M8 x 25 19 Nm
M8 x 25 Tightening
sequence: Tighten
screws six times in
alternate sequence
19 Nm
Follow-up work



31 42 514 Adjusting steering-head bearing (with checking steering-head bearing)
Preparatory work
Removing handlebars
Core activity
(-) Adjusting steering-head bearing play
Requirement
Front wheel on the ground.
Remove cap (1).

Slacken clamping screws (2) on left and right.
Slacken adjusting screw (1), then tighten it to specification.
Tightening torques
M18 x 1 Tightening torque,
25 Nm
Swing the forks 3x
to left/right through
full arc of travel
Loosen, 60°
Tightening torque,
11 Nm
Angle (A) indicates the angle for backing off.

Tightening torques
M8 x 40 19 Nm
Tighten clamping screws (2) on left and right.

Tightening torques
M8 x 25 19 Nm
Install cap (1).
(-) Checking steering-head bearing
Check
Check that the steering-head bearing is correctly adjusted.

Result:
Steering-head bearing does not move easily and is not free of play.
Measure:
Repeat the adjustment procedure.
Follow-up work
Securing handlebars

31 42 516 Disassembling and assembling left fork fork leg (fork leg removed)
Core activity
(-) Disassembling fork leg
Remove screw (1) with sealing washer (2).
Removing spring
CAUTION

Draining fork oil

inside.
Slowly turn the slider tube the other way round and remove damping
element (3) with stop spring (4) from the slider tube.

(-) Removing fixed fork tube
Remove sealing boot (1) and circlip (2).

Push fixed tube (6) slightly into the slider tube and pull sharply to
remove fixed tube (6), shaft sealing ring (3) and intermediate ring (4)
with slide bush (5).
Remove stop (7).
(-) Installing fixed tube
ATTENTION
Sharp-edged vent hole in the fixed fork tube
Damage to the radial shaft seal in the slider tube
Do not pull the fixed fork tube out of the slider tube past the as-installed
position.
Check
Check bushings (1) and (2) for damage.

Result:
Bushings reveal scoring or signs of wear in the coating.

Measure:
Replace the bushings.
Slip a bag (1) over the top of fixed fork tube (2) so that the sealing ring
cannot be damaged by sharp edges.
Install stop (7) in the slider tube.

Insert fixed tube (6) into the slider tube.
Install slide bush (5) and intermediate ring (4) with impact sleeve (No.
31 3 650) and sleeve (No. 31 1 511).
Install fork sealing ring (3) lettered side up with impact sleeve (No. 31 3
650) and sleeve (No. 31 1 511).
Pack the grease chamber of sealing boot (1) with grease.
Lubricant
Unirex S 2 83 23 9 416 138
Install sealing boot (1) with the convex end of impact sleeve (No. 31 3
650).
(-) Installing damper unit
Install damper unit (2) with stop spring (3) and piston ring (1).

Install screw (1) with new sealing washer (2).
Tightening torques
M10 x 30 50 Nm
Follow-up work
Filling fork leg with oil
Installing coil springs

31 42 517 Disassembling and assembling right fork fork leg (fork leg removed)
Core activity
(-) Disassembling fork leg
Remove screw (1) with sealing washer (2).
Removing spring
CAUTION

Draining fork oil

inside.
Slowly turn the slider tube the other way round and remove damping
element (3) with stop spring (4) from the slider tube.


Remove stop (7).
ATTENTION
position.
Check

Result:

Measure:

31 3 650) and sleeve (No. 31 1 511).
650) and sleeve (No. 31 1 511).
Lubricant
Unirex S 2 83 23 9 416 138
650).
(-) Installing damper unit
Install damper unit (2) with stop spring (3) and piston ring (1).

Install screw (1) with new sealing washer (2).
Tightening torques
M10 x 30 50 Nm
Follow-up work

31 42 520 Replacing bearer for steering-head bearing (bottom fork bridge removed)
Core activity

(-) Removing bottom steering-head bearing
Fully tighten adjusting screw (3) in the steering tube.

Clamp the steering tube in a bench vice, using a block of wood as an
insert between the adjusting screw and the face for protection.
Heat steering-head bearing (2).
Technical data
Mating/release 80 °C
temperature,
steering-head
bearing
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.
Remove steering-head bearing (2) and dust cap (1).

Remove adjusting screw (3).

Lubricant

31 42 524 Replacing seal for right fork leg (fork leg removed)
WARNING
Fork oil making its way on to brake pads and discs on account of
leaking radial shaft seals
Delayed braking effect. Risk of accident
Renew oily brake pads.
Clean oily brake discs.
ATTENTION
Penetration of dirt into the fork by leaking radial shaft seal
Component damage, accelerated wear
Check all guide bushes and the piston ring of the right damping unit for
wear, particularly after a sporty off-road use, and replace them if
necessary.
Preparatory work
Removing spring
Draining fork oil
Remove the damper unit
Core activity

Remove stop (7).
ATTENTION
position.

Check
Result:

Measure:

31 3 650) and sleeve (No. 31 1 511).
650) and sleeve (No. 31 1 511).
Lubricant
Unirex S 2 83 23 9 416 138
650).
Follow-up work

Installing damper unit


31 42 525 Replacing seal for left fork leg (fork leg removed)
WARNING
Fork oil making its way on to brake pads and discs on account of
leaking radial shaft seals
Delayed braking effect. Risk of accident
Renew oily brake pads.
Clean oily brake discs.
ATTENTION
Penetration of dirt into the fork by leaking radial shaft seal
Component damage, accelerated wear
Check all guide bushes and the piston ring of the right damping unit for
wear, particularly after a sporty off-road use, and replace them if
necessary.
Preparatory work
Removing spring
Draining fork oil
Remove the damper unit
Core activity

Remove stop (7).
ATTENTION
position.

Check
Result:

Measure:

31 3 650) and sleeve (No. 31 1 511).
650) and sleeve (No. 31 1 511).
Lubricant
Unirex S 2 83 23 9 416 138
650).
Follow-up work

Installing damper unit


32 71 040 Renewing handlebar

+ 32 71 514
Additional billing items
32 71 504 Additional work for replacing handlebars (with hand protector)
Preparatory work
Removing both handlebar weights
Releasing clutch lever fitting
Removing cover of multifunction switch
Removing left grip
Release the handbrake fitting
Releasing throttle twistgrip
Core activity
(-) Remove the handlebars
Remove screws (1).

Remove clamping blocks (2).
Separate the handlebar from the throttle-twistgrip unit and remove.
(-) Installing handlebars
Push the throttle twistgrip unit onto the handlebar.

Place the handlebars with clamping blocks (2) in position. The position
of the handlebars is indicated by a mark (arrow) on the handlebars.
WARNING
Incorrect tightening sequence of the handlebar clamps.
Handlebars work loose when vehicle is ridden.
Tighten the handlebar clamps to the specified torque and in the
specified sequence.

Install screws (1).
Tightening torques
M8 x 30 - 10.9 Tightening
sequence: in the
forward direction
of travel, tighten
until seated
28 Nm
Follow-up work
Securing handbrake fitting
Securing throttle twistgrip
Installing cover of multifunction switch
Installing left grip
Securing clutch lever fitting
Installing both handlebar weights

32 72 001 Replacing throttle twistgrip

+ 32 72 620
0519 - Heated handlebar gripsOE
Preparatory work
Removing right handlebar weight
Core activity
(-) Removing throttle twistgrip

Disconnect plug (1) of the multifunction switch and plug (2) of the
heated grip.
Remove screws (3).

Remove the multifunction switch.

Remove screw (4).
Remove lid (1).
Disengage throttle cable (2).
Slacken screw (3).
ATTENTION

Installation of heated grip not in compliance with correct procedure

Damage to heated-grip line
Remove the throttle-cable cover from the throttle grip only when the
throttle grip is installed on the handlebar.
Resecure cover (1) with screw (4) and remove the throttle twistgrip.
(-) Installing throttle twistgrip
Push throttle twistgrip onto handlebar with cover (1) and secure with
screw (3).
Remove cover (1) and attach throttle cable (2).
Attach cover (1).
Install screw (4) and tighten.
Tightening torques
Hold the multifunction switch in position.

Install screws (3).
Turn the throttle twistgrip with the multifunction switch until pin (1)
projects into the gap in the clamp and the multifunction switch is seated
against the handbrake fitting.

Tighten screw (3).
Connect plug (1) for multifunction switch and plug (2) for heated grips.
Secure plugs (1) and (2).
NOTICE
Check throttle-cable play with the engine cold; adjust if necessary.
Check
Turn the handlebars to various positions and check throttle-cable play
(A) at the throttle twistgrip and check that the throttle valve reaches its
limit stop (clearly audible click).

Technical data
Setting, throttle- at outermost 1...2 mm
cable play diameter of
rubber grip,
engine
cold max 35 °
C
Result:
Play at throttle twistgrip not OK or throttle valve does not reach limit
stop.
Measure:
Slacken locknut (1).
Adjust throttle-cable play with adjusting screw (2).
Tighten locknut (1).
Follow-up work
Installing right handlebar weight

32 72 002 Replacing bracket for reservoir

+ 32 72 686
Core activity
(-) Removing bracket for reservoir
Remove screws (1) with washers and remove clamping block (2) with
the mirror.
Carefully turn reservoir (1), taking care not to kink the brake hose.
Remove screw (2) and remove weight (3).
Remove bottom holder (4) and rubber grommet (5).
Remove screws (6) and remove top holder (7).
(-) Installing bracket for reservoir
Carefully turn reservoir (1), taking care not to kink the brake hose.
Secure top holder (7) with screws (6).
Tightening torques
Expansion tank to bracket
Plastic screw, 3 x 20 1 Nm
Seat rubber grommet (5) in bottom holder (4) and position it on top
holder (7).
Secure weight (3) with screw (2).

Tightening torques
Suppressor weight to holder
M5 x 10 5 Nm
Align the handbrake fitting with the marks (arrows).

Secure the clamping block with screws (1) and washers (2).
Tightening torques
M5 x 35 Tightening
sequence: tighten
alternately, at front
on block
5 Nm
Follow-up work

32 72 003 Replacing adapter on handlebar fitting

+ 32 72 687
Preparatory work
Draining brake fluid reservoir on handbrake fitting
Core activity
(-) Removing adapter from handbrake fitting
Open clip (1) and disconnect the hose, catching the escaping brake
fluid.
Remove screws (2) and remove adapter (3).
(-) Installing adapter in handbrake fitting
Install new sealing ring (4).

Hold adapter (3) in position and install screws (2).
Tightening torques
Adapter to handlebar fitting
Screw for plastic, 3.5 x 20, Replace 1.7 Nm
screw
Connect the hose and secure it with clip (1).
Follow-up work
Filling and bleeding brake fluid reservoir on handlebar fitting

32 72 065 Replacing handlebar fitting for clutch actuation

+ 32 72 626
Core activity
(-) Removing clutch lever fitting
Slacken the clutch cable at release lever (1).
Detach Bowden cable (1).

Remove screws (4) along with clamping block (3).
Remove the handlebar fitting.
(-) Installing clutch lever fitting
Position the clutch lever fitting with pin (5) projecting into the gap
between clamping block (3) and bottom section of clamp (6).
Install screws (4).
Tightening torques
Clutch handlebar fitting to handlebar
M5 x 20 Tightening
sequence: tighten
on block
5 Nm

Connect plug (2).

Engage Bowden cable (1).
(-) Check/adjust clutch play
Check
Turn the handlebars all the way to the left
Measure gap (A) between the handlebar fitting and the clutch cable.
Technical data
turned fully
left, between
handlebar
fitting and
clutch cable
Result:
Clutch play is excessive or insufficient.
Measure:
Adjusting clutch cable
Technical data
turned fully
left, between
handlebar
fitting and
clutch cable
Tighten nuts (1).

Follow-up work

32 72 070 Replace clutch lever

+ 32 72 627
Core activity
(-) Removing clutch lever
Slacken the clutch cable at release lever (1).
Disengage clutch cable (1).

Remove the clutch lever.
(-) Installing clutch lever
Install the clutch lever in the handlebar fitting.

Install screw (2) with nut (3) and tighten.
Tightening torques
M5, Replace nut Tightening
Thread-locking compound sequence: Tighten
(mechanical) the nut, counter-
holding the bolt
7 Nm

Engage clutch cable (1).
(-) Check/adjust clutch play
Check
Technical data
turned fully
left, between
handlebar
fitting and
clutch cable
Result:
Measure:
Technical data
turned fully
left, between
handlebar
fitting and
clutch cable
Tighten nuts (1).

Follow-up work

32 72 076 Replacing lever for front-wheel brake

+ 32 72 576
ATTENTION
Changed free-travel setting (blow-by clearance) due to replacement
of/tampering with the lever mount
Malfunction in brake system
Make sure that lever mount with pushrod remains with the handbrake
fitting.
Core activity
(-) Remove the handbrake lever

Remove lever pivot with pushrod (3), noting the rubber sleeve.
Remove sleeve (4), noting spring (5).
Remove lever (6).
(-) Install the handbrake lever
Seat spring (5) and lever pivot with pushrod (3) in lever (6).
Install sleeve (4).
Lubricate screw (2) and sleeve (4).
Lubricant
Teflon spray 83 23 0 154 884
Install the lever unit, making sure that the pushrod engages in the piston
seat.
Install bolt (2) with nut (1).
Tightening torques
M5, Replace nut

Thread-locking compound Tightening

(mechanical) sequence: Tighten
the nut, counter-
holding the bolt
7 Nm
Follow-up work

32 72 078 Replacing brake handlebar fitting for front wheel

+ 32 72 578
Preparatory work
Draining brake fluid reservoir on handbrake fitting
Core activity
(-) Remove the handbrake fitting
Remove banjo bolt (1) with sealing rings (2) and catch the escaping
residual fluid in a suitable container.
Remove brake line (3).
Disconnect brake-light switch (4).
Remove clamping block (7).
Remove the handbrake lever fitting with the brake-fluid reservoir.
(-) Installing handbrake fitting
Secure clamping block (7) and the bracket of the brake-fluid reservoir
with screws (5) and washers (6).
Connect brake-light switch (4).
Secure brake line (3) with banjo bolt (1) and new sealing rings (2).
Tightening torques
M10 x 1 24 Nm

Align the handbrake fitting with the marks (arrows).
Secure the clamping block with screws (1) and washers (2).
Tightening torques
M5 x 35 Tightening
sequence: tighten

on block
5 Nm
Follow-up work
Filling and bleeding brake fluid reservoir on handlebar fitting

32 72 097 Replacing left handlebar grip

+ 32 72 632
Preparatory work
Removing left handlebar weight
Core activity
(-) Removing left grip
Disconnect multifunction-switch plug (1) and heated-grip plug (2).

Remove screws (1).

Remove screw (1).

Remove the grip.

(-) Installing left grip
Push the grip onto the handlebar.

Install screw (1).

Install screws (1).
Tightening torques
KA30 x 10 - 3.6 1 Nm
Connect plug (2) of the heated grip.

Clip in plug (1) of the multifunction switch and plug (2).

Follow-up work
Installing left handlebar weight

32 72 300 Replacing brake-fluid reservoir for front brake

+ 32 72 648
Core activity
(-) Removing reservoir for brake fluid
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.
Using disengagement tool (No. 32 1 511), press back the lugs on the
reservoir and open reservoir cap.(1).
Remove reservoir cap (1), retainer (2) and diaphragm (3).
Draw off the brake fluid.
Open clip (5).
Disconnect the hose, catching the escaping brake fluid in a suitable
container.
Secure the hose to the holder in such a way as to minimise the quantity
of brake fluid escaping from the hose.
Remove screws (4) and remove the reservoir and its bracket.
(-) Installing reservoir for brake fluid
Hold the reservoir with bracket in position and secure with screws (4).
Connect the hose and close hose clip (5), making sure that the hose is
routed free of strain.
Slowly fill the reservoir with brake fluid to the MAX mark, making sure
that the air is expelled from the brake hose.
Hydraulic fluid
Brake fluid, DOT4
Lightly tap the brake hose to enable the residual air to escape into the
reservoir.
Repeatedly apply the brakes.
Top up with fresh brake fluid, if necessary.
Install reservoir cap (1), retainer (2) and diaphragm (3).

Check
Check brake pressure by operating the brakes.

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

32 73 000 Removing/installing or replacing clutch cable

+ 32 73 500
Preparatory work
Removing seat
Remove the battery
Core activity
(-) Removing clutch cable
Undo the fasteners (arrows) and remove retainer (1) from Bowden-cable
adapter (2).
Loosen nuts (1).

Disengage clutch cable (2) from release lever (3).
Disengage clutch cable (2) from the engine cover.
Disengage clutch cable (1) from the handlebar fitting.

Remove clutch cable (1) from retainer (2).

(-) Installing clutch cable
Work clutch cable (1) through retainer (2) and route it correctly, making
Engage clutch cable (1) in the handlebar fitting.
Introduce clutch cable (2) into the engine cover and engage it in release
lever (3).
Secure clutch cable (2) with nuts (1).
Install retainer (1), making sure that the fasteners (arrows) are correctly
seated in cable adapter (2).

Check/adjust clutch play
Check
Technical data
turned fully
left, between
handlebar
fitting and
clutch cable
Result:
Measure:
Technical data
turned fully
left, between
handlebar
fitting and
clutch cable
Tighten nuts (1).

Follow-up work
Installing battery
Installing seat

32 73 101 Replacing throttle cable to handlebar

+ 32 73 509
Preparatory work
Removing seat
Remove the battery
Core activity
(-) Removing throttle cable
Disengaging throttle cable from throttle twistgrip
Remove screw (4).
Remove cover (1).
Disengage throttle cable (2) and work it clear.


Disengage throttle cable (1) from guide (2).

(-) Installing throttle cable
Work throttle cable (1) through retainer (2) and route it correctly, making

Engaging throttle cable on throttle twistgrip

Engage throttle cable (2).
Install cover (1).
Install screw (4).

(-) Checking/adjusting throttle cable
NOTICE
Check

Technical data
rubber grip,
engine
cold max 35 °
C
Result:
stop.
Measure:
Follow-up work
Installing battery
Installing seat


33 35 000 Replacing rear wheel swinging arm

+ 33 35 501
Preparatory work
Removing chain guard
Remove the rear wheel
Removing chain slide rail
Releasing spring strut at bottom
Removing cover for brake hose, rear
Core activity
(-) Removing rear wheel swinging arm
Remove brake caliper (1) from the locator (arrow) and secure it to the
rear frame.

Turn swinging arm (1) and carefully remove it, noting chain (2) and the
manifold.
If necessary, remove chain (2).

(-) Transferring chain slide rail to new component
If applicable, secure dampers (1) to chain slide rail (2).
Remove bottom screw (1), remove rests (2).

Remove chain slide rail (3) and secure it with bottom screw (1) and rest
(2) to the new rear wheel swinging arm.
Tightening torques
M5 x 12 4 Nm
Install top rests (2), using a blob of grease to hold them in position if
necessary.
Transfer the small items to the new component.
Tightening torques
Brake-hose guide to swinging arm, front
encapsulated)

(-) Installing rear swinging arm
Turn swinging arm (1) and install it with chain (2), noting the manifold.
Lubricant

Tightening torques
(mechanical)
Follow-up work
Installing cover for brake hose, rear
Securing spring strut to swinging arm
Securing chain slide rail
Installing rear wheel
Installing chain guard
Adjust chain sag

33 35 001 Replacing swinging-arm bearing

+ 33 35 502
Preparatory work
Removing chain slide rail
Releasing spring strut at bottom
Core activity
rear frame.

manifold.

(-) Removing swinging-arm bearing
Remove caps (1).

Remove bearing bushing (3).
Protect the mating faces of the swinging arm from scratches by covering
them with masking tape, for example.
Drive out needle roller bearing (1) with drift (No. 33 6 661).
Remove the inner sealing ring.
(-) Installing swinging-arm bearings
Protect the mating faces of the swinging arm from scratches by covering
them with masking tape, for example.
Lubricate the needle roller bearing.
Lubricant

Unirex S 2 83 23 9 416 138
Press in sealing ring (1) and inner needle roller bearing (2) with drift (No.
33 6 661) until distance A is to specification.
Technical data
Press-in depth of measured 20 mm
inner needle roller from flat on
bearing in rear outside of
wheel swinging arm rear wheel
swinging arm
to the outer
edge of the
inner needle
cage
Install outer needle roller bearing (1) with drift (No. 33 6 661).
Measure distance (B) between needle roller bearing (1) and the flat;
correct if necessary.
Technical data
Press-in depth of measured 4 mm
outer needle roller from flat on
bearing in rear outside of
wheel swinging arm rear wheel
swinging arm
to the outer
edge of the
outer needle
cage
Install outer sealing ring (2) and caps (1) on left and right.
Install bearing bushings (3).

Lubricant

Tightening torques
(mechanical)
Follow-up work
Securing spring strut to swinging arm
Securing chain slide rail
Adjust chain sag

33 54 000 Replacing rear spring strut

+ 33 54 500
Preparatory work
Removing seat
Core activity
(-) Removing chain slide rail
Remove screws (1).

Lift chain slide rail (2) off the swinging arm until the spring-strut threaded
fastener is accessible, noting metal inserts (3).
(-) Remove the rear spring strut
Remove screws (1).

Remove rubber mount (2) and work spring strut (3) up to remove.
(-) Installing rear spring strut
Clean the threads in the swinging arm.

Install spring strut (3) with rubber mount (2).
Install screws (1).

Tightening torques
Spring strut to frame
M12 x 120- 10.9 100 Nm
Fitted-head screw, M12 x 1.5 x 60 - 100 Nm
10.9, Replace screw
encapsulated)
(-) Securing chain slide rail
ATTENTION
Incorrect positioning of the slide rails
Component damage
Push on the slide rails until seated.
Secure chain slide rail (2) with screws (1), noting inserts (3).
Follow-up work
Installing seat

33 81 000 Replacing chainset

+ 33 81 500
Construction status:
July 2009
Construction status retrofit
Installation of endless drive chain
Installation of open drive chain with pin lock link
ATTENTION
Replacement of a single worn part of the chainset
Accelerated wear
Replace the entire chainset.
NOTICE
The drive chain can be of endless or open (connected by pin lock link)
design.
Select the construction status on the basis of chain type.
Preparatory work
Core activity
(-) Removing frame-mounted chain slide rail
Remove screw (1) and remove chain slide rail (2).
(-) Removing pinion

Lock the rear wheel.

Remove screw (1).
Remove washer (2) and spring washer (3).
Lift drive chain (4) and remove pinion (5) with puller (No. 00 8 400) and
thrust piece (No. 00 5 015).
(-) Splitting and removing drive chain
Position insert with hole (A) and guide screw (B) from drive-chain
splitting/joining tool (No. 27 1 561) in basic unit (D).
Hold basic unit (D) in position and remove drive-chain pin (1) with
mandrel (C).
Remove drive chain (2).
(-) Removing rear wheel
ATTENTION
piston back.


NOTICE
Remove bushings (4) and both chain tensioners (5). Remove rear wheel
(6).
Remove screws (1).

Lift chain slide rail (2) off the swinging arm until the spring-strut threaded
fastener is accessible, noting metal inserts (3).
(-) Releasing spring strut at bottom
Remove screw (1).

Disengage spring strut (2) from the swinging arm and use a strap to
secure it to the rear frame.

rear frame.

manifold.

Remove screws (1) with the shaped retainers.

Remove chain slide rail (2).
(-) Removing judder-damper rubber elements
Remove sprocket carrier (2).

Remove judder-damper rubber elements (1).

Removing sprocket
Remove nuts (1), washers (2) and screws (3).
Remove sprocket (4) from carrier (5).

(-) Checking judder damper for damage
Check
Check the wheel hub, judder-damper elements and sprocket carrier for
cracks, deformation and chipping.
NOTICE
Note that cracked lands is not sufficient reason for replacing the judder-
damper rubber elements.
Result:
Wheel hub, judder-damper elements or sprocket carrier show signs of
damage.
Measure:
Replace the damaged components.

Installing sprocket
Hold sprocket (4) in position on carrier (5) and secure with screws (3),
washers (2) and nuts (1).
Tightening torques
rotation, 90°

(-) Installing judder-damper rubber elements with sprocket

carrier
Install judder-damper rubber elements (1).

NOTICE
Install sprocket carrier (2).
(-) Installing chain slide rail
ATTENTION
Component damage
Manoeuvre chain slide rail (2) into position from in front.

Install screws (1) with the shaped retainers.
Tightening torques
M5 x 12 4 Nm

Lubricant

Tightening torques
(mechanical)
(-) Securing spring strut to swinging arm
Clean the threads.

Hold spring strut (2) in position at the swinging arm and install screw (1).
Tightening torques
Fitted-head screw, M12 x 1.5 x 60 - 100 Nm
10.9, Replace screw
encapsulated)
(-) Securing chain slide rail
ATTENTION
Component damage

Secure chain slide rail (2) with screws (1), noting inserts (3).
NOTICE
Locate brake caliper (1) on the locator (arrow) of the swinging arm.
Clean and lubricate quick-release axle (3).
Lubricant
Optimoly TA 18 21 9 062 599
Clean and lubricate the friction faces of the shaft sealing rings.
Lubricant
Insert bushings (4) into the wheel.

Manoeuvre the wheel into position, taking care not to damage the wheel
-speed sensor, brake disc and wheel rim.
Roll the rear wheel forward and loop the chain over the sprocket.

Install quick-release axle (3) with both chain tensioners (5).

Securing rear wheel-speed sensor
Install screw (1).
Tightening torques
M6 x 16 8 Nm
(-) Installing drive chain and pinion
Clean the threads.

Lubricate internal splines of pinion (1).
Lubricant
MP 3 paste 07 55 9 062 476
Install pinion (1) with the wording facing out.

Hold washer (2) (with large diameter toward pinion) and washer (3) in
position.
Apply thread-locking compound to screw (4).
Fit the bolt (4) and tighten by hand.

Work chain (1) into position and loop it over pinion (2).

Block the rear wheel and tighten screw (1).
Tightening torques
M10 x 35 50 Nm
(-) Joining drive chain
Make sure that the sealing beads (arrow) at the O-rings face out.
Fit the ends of drive chain (1) together.

Fit inside chain link plate (3) with O-rings (2) and slip it into the ends of
the drive chain.
Fit O-rings (2) and lay outside chain link plate in position.
Press inside chain link plate (3) and outside chain link plate (4) together.

Install insert without hole in basic unit (No. 27 1 561).

Install screw (No. 27 1 562) in basic unit (No. 27 1 561) and seat insert
(No. 27 1 563) in screw (No. 27 1 562).
Lubricate insert (No. 27 1 563).
Lubricant
Position basic unit (No. 27 1 561) on chain link plates (1) and (2).
Tighten screw (No. 27 1 562) and alternately press-fit chain link (1)
onto the two pins until seated.
Checking width of chain after joining
Check
Check chain width (A) at press-fitted links with pins (3) and chain link (4)
at front and rear.
Technical data
Chain-link width 19.90+0.1 mm
after press-fitting −0.05
Measured across
outer flats of outer
plates
Result:
Chain width exceeds specification.
Measure:
Repeat the press-fitting process.

Result:
Chain width is less than specification.

Measure:

Remove the chain links and re-join the chain, using a new removable
link.
Position insert without hole (E) and guide screw (F) in basic unit (D) of
drive-chain splitting/joining tool (No. 27 1 561).
Position correctly assembled basic unit (D) on pin (1).
Hold mandrel (G) in position and use a hammer to drive in pin (1).
Turn mandrel (G) through 90 degrees and again rivet the plate to the
pin.
Repeat this procedure with the other pin.
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 removable
link.
(-) Replacing frame-mounted chain slide rail
Install a new chain slider rail after removing the original.

Installing frame-mounted chain slide rail
Hold chain slide rail (2) in position and install screw (1).
Tightening torques
M6 x 40 4 Nm
Follow-up work
Adjust chain sag

33 83 000 Adjusting chain tension

+ 33 83 500
Core activity
(-) Adjust chain sag
Measure/adjust chain sag (A) halfway along the bottom chain run.
Chain stretch is not uniform, so it is important to make adjustments with
the chain at the point of least sag.
Slacken nut (1).

ATTENTION
Rear wheel at an 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).
Use tensioning screws (3) to adjust chain sag, making sure that the rear
wheel is aligned to track correctly (same scale readings (arrow) on both
sides of the rear wheel swinging arm).
Technical data
Chain deflection Motorcycle 20...30 mm
with no
weight
applied,
supported on
its side stand
Tighten locknuts (2) on left and right.
Tightening torques

M8 19 Nm
Tighten nut (1).
Tightening torques
M16 x 1.5 100 Nm
Complete the operation by re-checking that wheel alignment is true

(same scale readings (arrow) on both sides of the rear wheel swinging
arm).
Follow-up work

33 85 002 Replacing bearing for sprocket carrier

+ 33 85 502
Preparatory work
Core activity
(-) Removing sprocket carrier
Remove sprocket carrier (1), noting judder-damper rubber elements (2).
(-) Removing bearings from sprocket carrier
Remove spacing bushing (1).

Pry out shaft sealing ring (2).
Remove circlip (3).
Heat the hub.
Technical data
Release 100 °C
temperature,
bearing of sprocket
carrier
Remove bearing (4) with reaction support (No. 00 8 572), internal puller
(No. 00 8 573) and support ring (No. 31 4 800).
Remove bushing (5).
(-) Installing bearings in sprocket carrier
Heat the sprocket carrier.
Technical data


bearing of sprocket
carrier
Install sleeve (1) with the flat facing toward bearing (2).
Drive in bearing (2) with drift (No. 36 3 660) and handle (No. 00 5 500).
Install new shaft sealing ring (4).
Install spacing bushing (5).
Lubricate the friction face of spacing bushing (5).
Lubricant
(-) Installing sprocket carrier in rear wheel
Make sure that judder-damper rubber elements (1) are correctly

positioned and install sprocket carrier (2).
Follow-up work
Adjust chain sag

33 85 010 Replacing bottom chain slide rail

+ 33 85 513
Core activity
(-) Installing frame-mounted chain slide rail
Tightening torques
M6 x 40 4 Nm
Follow-up work

33 85 011 Replacing top chain slide rail

+ 33 85 514
Preparatory work
Core activity

ATTENTION
Component damage


Tightening torques
M5 x 12 4 Nm
Follow-up work
Adjust chain sag

33 85 012 Removing/installing sprocket carrier

+ 33 85 515
July 2009
Preparatory work
Removing rear wheel
Removing sprocket carrier
Core activity
Removing sprocket
Remove nuts (1), washers (2) and screws (3).

Remove sprocket (4) from carrier (5).

Installing sprocket
Hold sprocket (4) in position on carrier (5) and secure with screws (3),
washers (2) and nuts (1).
Tightening torques
rotation, 90°

Follow-up work
Installing sprocket carrier in rear wheel
Adjust chain sag

33 85 503 Replacing chain slide rails (rear wheel swinging arm removed)
Core activity
(-) Replacing both chain slide rails
Remove bottom screw (1).

Remove pad inserts (2) and chain slide rail (3).
Clean the adhesive faces and secure dampers (1) to chain slide rail (2).
Secure chain slide rail (3) with pad insert (2) and bottom screw (1).
Tightening torques
M5 x 12 4 Nm
Install top rests (2), using a blob of grease to hold them in position if
necessary.
Remove screw (1) and chain slide rail (2).

Secure new chain slide rail (2) with screw (1).
Tightening torques


M6 x 40 4 Nm

33 85 504 Replacing chain slide rails (chain removed)
Core activity

ATTENTION
Component damage

Tightening torques
M5 x 12 4 Nm

(-) Installing frame-mounted chain slide rail
Tightening torques
M6 x 40 4 Nm

34 00 010 Change brake fluid in entire system

+ 34 00 504
Core activity
(-) Changing brake fluid, front, and bleeding brake system
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.
NOTICE
This description applies for brake filling and bleeding units with vacuum
extraction. If other devices are used, comply with the manufacturer's
instructions.
Set the brake lever to maximum span.
ATTENTION
Material damage
reservoir and remove the reservoir cap.
Remove the diaphragm, draw off the old fluid and clean the reservoir.
Press the brake caliper against the brake disc with your hand.
The brake pistons are pushed back.
Draw off the excess brake fluid from the reservoir.

Turn the handlebars to a position in which the brake fluid reservoir is

horizontal.
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.
Top up with fresh brake fluid to the (MAX) mark.
Hydraulic fluid
Brake fluid, DOT4
Connect the brake bleeding device to bleed screw (1) in the handbrake
cylinder.
Slightly open the bleed screw.
Continue bleeding the brake system until fresh brake fluid emerges.
Close the bleed screw.
Tightening torques
M5 2 Nm
Connect the brake bleeding device to bleed screw (1).

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.

Tightening torques
M10 x 1 - 4.9 14 Nm
Again connect the brake bleeding device to bleed screw (1).

Tightening torques
M5 2 Nm
Operate the brake lever to seat the brake pistons.

horizontal.
WARNING
Hydraulic fluid
Brake fluid, DOT4
Clean the edge of the reservoir, diaphragm (3), retainer (2) and cap (1)
and reassemble the components.

Check

Result:
Low brake pressure

Measure:
(-) Changing brake fluid, rear, and bleeding brake system
NOTICE
instructions.
ATTENTION
Material damage
Remove reservoir cap (1) with the diaphragm.

Draw off the brake fluid from the reservoir and clean the reservoir.

WARNING
Top up with fresh brake fluid to the MAX mark (arrow).
Hydraulic fluid
Brake fluid, DOT4

WARNING
fluid if required.
WARNING
extraction
Close the bleed screw and remove the brake bleeding device.
Tightening torques

M10 x 1 - 4.9 14 Nm
Wipe the rim of the reservoir, the diaphragm and reservoir cap (1) to
remove brake fluid, and carefully re-assemble the components.
Operate the brake until the brake pistons are in contact with the brake
disc.
Check operation of the brake system.
Check

Result:
Low brake pressure
Measure:
Follow-up work

34 00 033 Bleeding front brake system

+ 34 00 507
Core activity
(-) Filling front brake system
WARNING
fluid if required.
NOTICE
instructions.
Set the brake lever to maximum span.
ATTENTION
Material damage
reservoir and remove the reservoir cap.
Remove the diaphragm and clean the reservoir.

horizontal.
WARNING

Hydraulic fluid
Brake fluid, DOT4
Connect the brake bleeding device to bleed screw (1) in the handbrake
cylinder.
Tightening torques
M5 2 Nm
Connect the brake bleeding device to bleed screw (1) in the brake
caliper.
WARNING
extraction

Again connect the brake bleeding device to bleed screw (1) in the
handbrake cylinder.
Tightening torques
M5 2 Nm

horizontal.
Carefully clean the edge of the reservoir, diaphragm (3), retainer (2) and
cap (1) and reassemble the components.

Check

Result:
Low brake pressure

Measure:
Follow-up work

34 00 035 Bleeding rear brake system

+ 34 00 509
Core activity
(-) Filling rear brake system
NOTICE
instructions.
ATTENTION
Material damage
Remove reservoir cap (1) with the diaphragm.

Clean the reservoir.
WARNING
Hydraulic fluid
Brake fluid, DOT4
The brake piston is pushed back.


WARNING
fluid if required.
WARNING
extraction
Close bleed screw (1) and remove the brake bleeding device.
Tightening torques
M10 x 1 - 4.9 14 Nm

Wipe the rim of the reservoir, the diaphragm and reservoir cap (1) to
remove brake fluid, and re-assemble the components.
Check

Result:
Low brake pressure

Measure:
Follow-up work

34 11 001 Measuring front brake-disc run-out

+ 34 11 844
Preparatory work
Core activity
(-) Measuring brake-disc runout
Install dial gauge (No. 00 2 510) with extension (No. 34 2 523) in dial-
gauge holder (No. 34 2 524) and install measuring adapter (No. 34 2
510).
Secure dial-gauge holder to the brake caliper mount with a suitable
screw.
Align dial gauge in such a way that the measuring adapter is in contact
with the brake disc close to the outer circumference 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
runout.
Technical data
Brake disc lateral At max 0.15 mm
runout, front circumference
Result:
Lateral runout is excessive.
Measure:
Check the wheel rim for damage.
If necessary, check the brake disc.
See the "Diagnosis tree, braking torque fluctuations" overview for further
information.
Follow-up work



34 11 008 Replacing front brake pads

+ 34 11 832
Core activity
(-) Removing front brake pads
Remove split-pin keeper (2).
Remove retaining pin (3).
Remove screws (1) and remove the brake caliper.
Remove brake pads.
(-) Installing front brake pads
Check that spring (1) is correctly seated.

The mark (arrow) indicates the correct direction of rotation of the wheel.
Install the brake pads and install retaining pin (3) to secure.
Hold the brake caliper in position and install screws (1).
Tightening torques
M10 x 40 38 Nm
Drive in retaining pin (3) until seated.

Install split-pin keeper (2).
Operate the brake several times until the brake pads are bedded.

Follow-up work

34 11 060 Replacing front brake caliper (without bleeding brakes)

+ 34 11 560
Preparatory work
Draining front brake system
Core activity
(-) Removing brake caliper
ATTENTION
Material damage
Remove banjo bolt (1) with sealing rings (2).

Remove brake hose (3).
Remove screws (4) and remove the brake caliper.
(-) Replacing brake caliper
ATTENTION
Material damage
Replace worn brake pads.

Remove locking pin (2).
Remove brake pads (3).

Transfer reusable small parts to the new part (1) or replace by new
ones.
1 x cap
1 x bleeder screw
1 x spring
1 x support plate
Pay attention to the mounting orientation of the spring (1). The mark
(arrow) indicates the correct direction of rotation of the wheel.
Install brake pads (3).

Drive in locking pin (2) up to limit position and install split-pin keeper (1).
(-) Installing brake caliper
Ease the brake caliper onto the brake disc.

Install screws (4).
Tightening torques
M10 x 40 38 Nm
Secure brake hose (3) with new sealing rings (2) and banjo bolt (1).

Tightening torques
M10 x 1 24 Nm
Follow-up work
=> Bleeding front brake system (Description in item: 34

34 11 200 Removing/installing front brake disc

+ 34 11 839
Preparatory work
Core activity
(-) Removing front brake disc
Remove screws (1).

Remove sensor ring (2) and brake disc (3).
If paper washers (4) are installed remove them and do not reinstall.
(-) Installing front brake disc
ATTENTION
Use of an incorrect spacer bush
Brake disc is not centred in the brake caliper. Incorrect sensor gap
Discontinuation of the paper washers between brake disc and wheel rim
means that a spacer bush with circumferential groove (on brake side)
has to be installed.
Clean the threads.

Clean the mating faces of brake disc (3).
Lay brake disc (3) on the rim as illustrated.
Secure brake disc (3) and sensor ring (2) with screws (1).
Tightening torques


encapsulated)
When installing the wheel, install appropriate spacing bushing (4):

Install spacing bushing (4) with circumferential groove (arrow).
Follow-up work
Measuring brake-disc runout

34 21 031 Measuring rear brake-disc run-out

+ 34 21 774
Core activity
(-) Checking rear brake disc for runout
Requirement
No burrs or scoring on brake disc, brake disc thickness above minimum.
No play in wheel bearing.
Remove screw (1).

Disengage speed sensor (2).
Raise the rear wheel clear of the ground so that it can turn freely.
Install dial gauge (No. 00 2 510) in dial-gauge holder (No. 34 2 524) and
install measuring adapter (No. 34 2 510).
Use speed-sensor screw (1) to secure the dial-gauge holder.
Check


runout.
Technical data
runout, rear circumference
Result:
Lateral runout excessive.
Measure:
=> 34 21 772, Removing/installing rear brake disc (Billed as a separate
item)
Secure speed sensor (2) with screw (1).
Tightening torques
M6 x 16 8 Nm
Follow-up work

34 21 060 Replacing rear brake caliper (without bleeding brakes)

+ 34 21 560
Preparatory work
Draining rear brake system
Core activity
(-) Removing rear brake pads
pistons back.

Drive out retaining pin (1).
(-) Removing rear brake caliper

ATTENTION
piston back.




NOTICE
Push the rear wheel forward.

Remove the chain from the sprocket.
Pull the wheel to the rear to remove.
Remove bushings (4) and both chain tensioners (5).
Remove brake caliper (1) from the locator (arrow).
(-) Replacing rear brake caliper
ATTENTION
Material damage

Transfer reusable small parts to the new part (1) or replace the small
parts as necessary.
1 x cap
1 x bleeder screw
1 x spring
1 x support plate
(-) Installing rear brake caliper

NOTICE
Lubricant
Optimoly TA 18 21 9 062 599
Lubricant



Install screw (1).
Tightening torques
M6 x 16 8 Nm
Install banjo bolt (1) with new sealing rings (2).
Tightening torques
M10 x 1 24 Nm
(-) Installing rear brake pads
Check that spring (4) is correctly seated in the brake caliper.
Install brake pads (3), making sure that they are correctly seated in the
brake caliper.

Install pin (1).

Follow-up work
Adjust chain sag
=> Bleeding rear brake system (Description in item: 34 00


34 21 200 Replacing rear brake pads

+ 34 21 769
Core activity
(-) Removing rear brake pads
pistons back.

Drive out retaining pin (1).
(-) Installing rear brake pads
Check that spring (4) is correctly seated in the brake caliper.

Install brake pads (3), making sure that they are correctly seated in the
brake caliper.
Install pin (1).
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).

Remove brake disc (2) and sensor ring (3).
(-) Install the rear brake disc
Clean the threads.

Install sensor ring (3) and brake disc (2) with screws (1).
Tightening torques
M8 x 15.5, Replace screw Tightening
Thread-locking compound (Micro- sequence: tighten
encapsulated) by stages in
diagonally
opposite sequence
30 Nm
(-) Checking rear brake disc for runout with brake disc
removed
Requirement
Brake disc has been cleaned.

Level balancing jig (No. 36 3 601) with knurled screws (1) and level
gauge (2).
Insert balancing shaft (No. 36 5 571) in rear-wheel bearing and secure it
with tensioner (No. 36 5 572), making sure that rear-wheel bearing is
lightly preloaded.
Position the rear wheel on the balancing and install stops (No. 36 5 573)
to prevent it slipping out of position.
Install dial gauge (No. 00 2 510) in a suitable dial-gauge holder (1) and
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

runout.
Technical data
Result:
Measure:
Check positioning of the brake disc/wheel rim.

information.

Follow-up work
Adjust chain sag

34 31 002 Replacing footbrake cylinder (without bleeding brakes)

+ 34 31 502
Preparatory work
Core activity
(-) Removing footbrake cylinder
Release pipe fastener (1).

Remove screws (2) and cover (3).
Remove pin (1).

ATTENTION
Material damage
Open clip (2) and disconnect the brake hose.

Remove footbrake cylinder (3).
(-) Installing footbrake cylinder
Clean the threads.

Install stud (1).
Connect brake hose (2) to footbrake cylinder (3).
Secure the clip with pliers (No. 13 1 500).

Adjusting blow-by clearance at piston rod
Secure the footbrake cylinder with screws (1).

Insert the feeler gauge between the brake-light switch actuator and the
frame stop.
Technical data
Blow-by clearance between 2.5+0.5 mm
of the footbrake footbrake −0.5
lever lever and
stop
Slacken nut (2) on pushrod (3).

Turn push rod (3) to relieve the pressure until it has play.
Turn pushrod (3) until all play at the pushrod is taken up.
Lock nut (2).
Tightening torques
M6 8 Nm
Remove screws (1).
Install cover (3) and screws (2).
Tightening torques
Footbrake cylinder to frame
encapsulated)
Secure brake pipe (1).
Tightening torques


M10/M12 14 Nm
Follow-up work

34 32 031 Replacing front brake hose to right brake caliper (without bleeding brakes)
+ 34 32 531
Preparatory work
Core activity
(-) Remove the front brake hose
ATTENTION
Material damage
Remove the fasteners securing the speed-sensor cable to the brake

hose (arrows).

Disconnect brake hoses (4) and (5).

Remove screw (3).

(-) Install the front brake hose
Install brake hose (4).

Install banjo bolt (1) with sealing rings (2).
Tightening torques
M10 x 1 24 Nm
Install screw (3).
Tightening torques
M6 x 16 8 Nm
Secure brake hose (3) with banjo bolt (1) and sealing rings (2).
Tightening torques
M10 x 1 24 Nm
Install the fasteners securing the speed-sensor cable to the brake hose
(arrows).

Follow-up work

34 32 036 Replacing brake hose to handlebar fitting (without bleeding brakes)

+ 34 32 536
Preparatory work
Core activity
(-) Removing brake hose to handlebar fitting
ATTENTION
Material damage

(-) Installing brake hose for handbrake fitting
Install brake hose (5).

Tightening torques
M10 x 1 24 Nm
Tightening torques


M10 x 1 24 Nm
Follow-up work

34 32 038 Replacing rear brake hose to brake caliper (without bleeding brakes)
+ 34 32 538
Preparatory work
Core activity
(-) Removing cover for brake hose, rear
Remove screw (1) and remove cover (2).
(-) Removing rear brake hose
ATTENTION
Material damage
Remove banjo bolts (1) with sealing rings (2).

Release the brake hose from the holders (arrows) and remove.

(-) Installing rear brake hose
Install banjo bolts (1) with sealing rings (2).
Tightening torques
M10 x 1 24 Nm
Install the brake hose and secure (arrows).
(-) Installing cover for brake hose, rear
Clean the threads.

Hold cover (2) in position and install screw (1).
Tightening torques
encapsulated)
Follow-up work

34 32 040 Replacing front brake line to pressure modulator (without bleeding brakes)
+ 34 32 640
Preparatory work
Removing seat
Remove the battery
Core activity
(-) Removing front brake line to pressure modulator
ATTENTION
Material damage
Open threaded fasteners (1).

Disengage brake line (2) from the holder (arrow) and remove.
(-) Installing front brake pipe to pressure modulator
Install brake line (2).

Secure the brake line in the holder (arrow).
Secure threaded fasteners (1).
Tightening torques


M10/M12 14 Nm
Follow-up work
Installing battery
Installing seat

34 32 044 Replacing front brake line from pressure modulator (without bleeding brakes)
+ 34 32 644
Preparatory work
Removing seat
Releasing expansion tank
Core activity
(-) Removing front brake line from pressure modulator
ATTENTION
Material damage

Disengage the brake line from the holder (arrow).
(-) Installing front brake pipe from pressure modulator

Secure the brake line in the holder (arrow).
Tightening torques


M10/M12 14 Nm
Follow-up work
Secure the expansion tank
Installing seat

34 32 050 Replacing rear brake line to pressure modulator (without bleeding brakes)
+ 34 32 650
Preparatory work
Removing seat
Removing silencer
Removing rear frame
Core activity
(-) Removing rear brake pipe to pressure modulator
ATTENTION
Material damage

Release brake line (2) from the holders (arrows).
(-) Installing rear brake line to pressure modulator

Secure the brake line in the holders (arrows).

Tightening torques
M10/M12 14 Nm
Follow-up work

Installing silencer
Installing seat

34 32 051 Replacing rear brake line from pressure modulator (without bleeding brakes)
+ 34 32 651
Preparatory work
Removing seat
Removing silencer
Removing rear frame
Core activity
(-) Remove the rear brake line from pressure modulator
ATTENTION
Material damage

Disengage brake line (2) from the holders (arrow) and remove.
(-) Install the rear brake line from pressure modulator

Secure the brake line in the holders (arrow).

Tightening torques
M10/M12 14 Nm
Follow-up work

Installing silencer
Installing seat

34 32 302 Replacing rear brake line (without bleeding brakes)

+ 34 32 683
Preparatory work
Removing seat
Removing silencer
Removing rear frame
Core activity
(-) Removing rear brake pipe
ATTENTION
Material damage

Disengage the brake line from the holder (arrows).
(-) Installing rear brake pipe

Secure the brake line in the holder (arrows).

Tightening torques
M10/M12 14 Nm
Follow-up work

Installing silencer
Installing seat

34 32 499 Replacing hose, rear, to reservoir

+ 34 32 525
Core activity
(-) Removing rear brake hose from reservoir
ATTENTION
Material damage
Remove cap (1) and draw off all the fluid from the reservoir.
Open clips (1).

ATTENTION
Material damage
Wrap cloths around the port of the brake cylinder.

Release the brake hose from the holders (arrows) and remove.
(-) Installing rear brake hose from reservoir
Install brake hose (2) and close clips (1) with pliers (No. 13 1 500).
Secure brake hose (2) in holders (arrows).

Slowly top up the brake-fluid reservoir with brake fluid, making sure that
the air escapes from the brake hose.
Hydraulic fluid
Brake fluid, DOT4
Lightly tap the brake hose to enable the residual air to escape from the
hose into the reservoir.
Check
Result:
Low brake pressure
Measure:
Pour fresh brake fluid into the brake-fluid reservoir until the level
reaches the (MAX) mark and install the cap.
Follow-up work

34 51 011 Replacing pressure modulator (without bleeding/testing software/ programming)

+ 34 51 511
NOTICE
Before removal, test the control unit with the BMW Motorrad diagnostic
system and make a backup copy of the data.
Preparatory work
Removing seat
Remove the battery
Core activity
(-) Removing ABS pressure modulator
Open cable tie (arrow).
Disconnect plug (1) of the pressure modulator.

ATTENTION
Material damage
Disconnect brake pipes (1).

Remove nuts (2) and disengage pressure modulator (3) from its bracket.
ATTENTION
Brake lines under strain, kinked or incorrectly routed
leaks
Do not strain, kink or trap brake lines.
Make sure that routing and securing are correct. Swing the handlebars
through the full arc of their travel and make sure that clearance relative
to all other components is adequate in all situations.
Work pressure modulator (1) to one side to remove; first tilt it down then
turn it to the rear.
(-) Installing ABS pressure modulator
Manoeuvre pressure modulator (1) into position: first turn it inward and
then tilt it up.

Secure pressure modulator (3) with nuts (2), checking the positions of
the rubber buffers.
Tightening torques
Pressure modulator to bracket
(mechanical)
Connect brake pipes (1) to pressure modulator (3).
Tightening torques
M10/M12 14 Nm
Connect plug (1) for the pressure modulator.

Follow-up work


Installing battery

as a separate item)

a separate item)
Installing seat

35 21 000 Removing/installing or replacing footbrake lever

+ 35 21 531
Core activity
(-) Removing footbrake lever
Remove pin (5).

CAUTION
Remove footbrake lever (6) with spring (4) and bushing (3).
(-) Installing footbrake lever
Clean the threads.

Lubricate the bearing seats.
Lubricant
Insert bushing (3) into footbrake lever (6).

Hold footbrake lever (6) with spring (4) in position.
Install screw (2) and washer (1).
Tightening torques
Brake lever to footrest plate
M8, Replace screw 19 Nm
encapsulated)
Check that spring (4) is correctly seated.

Install pin (5).
Follow-up work
Removing footbrake-cylinder cover


Installing footbrake-cylinder cover

36 20 510 Replacing RDC control unit (without checking software/programming)

Preparatory work
Removing seat
Core activity
(-) Removing tyre pressure monitoring control unit (RDC
control unit)
Remove screws (1).

Remove control unit (3).
(-) Installing tyre pressure monitoring control unit (RDC

control unit)
Install control unit (3).

Install screws (1).
Connect plug (2).
Follow-up work


as a separate item)

a separate item)
Installing seat

36 20 554 Replacing front RDC sensor (tyre removed)

Core activity
(-) Removing front tyre pressure monitoring sensor (RDC
sensor)
Remove union nut (2).

Remove RDC sensor (1).
(-) Installing front tyre pressure monitoring sensor (RDC

sensor)
Clean the seat and the threads of RDC sensor (1).

Parallel RDC sensor (1) with the wheel rim such that the plastic body
does not touch the wheel rim.
Install union nut (2).
Tightening torques
Thread-locking compound (Micro- Tightening torque,
encapsulated) 12 Nm
or, Thread-locking compound Slacken the nut
Tightening torque,
12 Nm

Follow-up work
Removing seat
Registering tyre pressure monitoring sensor (RDC sensor) with
control unit
Installing seat

36 20 555 Replacing rear RDC sensor (tyre removed)

Core activity
(-) Removing rear tyre pressure monitoring sensor (RDC
sensor)

(-) Installing rear tyre pressure monitoring sensor (RDC

sensor)

Install union nut (2).
Tightening torques
encapsulated) 12 Nm
Tightening torque,
12 Nm

Follow-up work
Removing seat
Registering tyre pressure monitoring sensor (RDC sensor) with
control unit
Installing seat

36 23 001 Replacing wheel-speed sensor, front

+ 36 23 601
Core activity
(-) Removing front wheel-speed sensor
Remove screw (1) and remove wheel-speed sensor (2).

Release the sensor cable (arrows).
Disengage sensor cable from fasteners (arrows) and cable ties (1).
Remove fastener (arrow), disconnect and remove plug (2).

Remove wheel-speed sensor.
(-) Installing front wheel-speed sensor
Install speed sensor (2) and install screw (1).
Tightening torques
M6 x 16 8 Nm
Route the sensor cable and secure it as illustrated (arrows).
Route sensor cable and secure with holders (arrows) and cable tie (1).
Connect plug (2) and clip it into place; secure the cable (arrow).
Follow-up work

36 23 002 Replacing wheel-speed sensor, rear

+ 36 23 602
Preparatory work
Removing seat
Core activity
(-) Removing cover for brake hose, rear
(-) Removing rear wheel-speed sensor
Remove screw (1) and wheel-speed sensor (2).
Release the sensor cable (arrows).

Release the cables from the holders and cable ties (arrows).
Work plug (1) with its cable clear.
(-) Installing rear wheel-speed sensor

Install screw (1).
Tightening torques
M6 x 16 8 Nm
Work sensor cable and plug (1) through toward the front.

Secure the sensor cable (arrows).
(-) Installing cover for brake hose, rear
Clean the threads.

Hold cover (2) in position and install screw (1).
Tightening torques
encapsulated)
Follow-up work
Installing seat

36 23 003 Replacing sensor ring, front

+ 36 23 603
Preparatory work
Core activity
Remove screws (1).

ATTENTION
Clean the threads.

Clean the mating faces of brake disc (3).
Tightening torques
encapsulated)


Follow-up work

36 23 004 Replacing sensor ring, rear

+ 36 23 604
Preparatory work
Core activity
Remove screws (1).

(-) Install the rear brake disc
Clean the threads.

Tightening torques
diagonally
opposite sequence
30 Nm
Follow-up work
Adjust chain sag

36 30 300 Removing/installing front wheel

+ 36 30 628
Core activity
(-) Removing front wheel
Releasing front wheel-speed sensor
Release the cables from the holders (arrows).

Roll the front wheel forward to remove.
NOTICE
Do not damage the wheel-speed sensor when removing and installing the
wheel.
Remove spacing bushings (3) and (4).
(-) Installing front wheel
Clean and lubricate the friction faces of the shaft sealing ring.
Lubricant
Carefully roll the front wheel into position between the fork legs.

Lubricant
Optimoly TA 18 21 9 062 599
ATTENTION
Install quick-release axle (2) with spacing bushings (3) and (4).
Tightening torques
M16 x 1.5 30 Nm
Repeatedly compress the telescopic forks to avoid the build-up of strain

in the fork legs.
Tightening torques
M8 x 25 19 Nm
Securing front wheel-speed sensor
Secure wheel-speed sensor (2) with screw (1).
Tightening torques
M6 x 16 8 Nm
Follow-up work

36 30 320 Removing/installing rear wheel

+ 36 30 629
Core activity
(-) Remove the rear wheel
ATTENTION
piston back.



NOTICE
Push the rear wheel forward.

Remove the chain from the sprocket.
Pull the wheel to the rear to remove.
Remove bushings (4) and both chain tensioners (5).
NOTICE
Lubricant

Optimoly TA 18 21 9 062 599
Lubricant

Install screw (1).
Tightening torques
M6 x 16 8 Nm
Follow-up work
Adjust chain sag

36 30 508 Balancing front wheel (statically) (wheel removed)
Core activity
(-) Static balancing of front wheel
Align balancer (No. 36 3 601) with knurled screw (3) and level gauge
(2).
Install adapter shaft (No. 36 3 606) in the front-wheel bearing and
pretension slightly with nut (1) from measuring bush (No. 36 3 616).
Slightly preload the front-wheel bearing.
Place the front wheel on the balancer and allow it to come to rest.
Clean the attachment points for the adhesive weights.
Affix the adhesive weights uniformly spaced on both sides of the rim
opposite the wheel's heaviest point.
Technical data
Permissible front- max 5 g
wheel imbalance
Balance weight for max 80 g
front wheel
One half of the
weights must be
attached to the left
and the other half to
the right of the
wheel rim
Repeat the balancing procedure as a check.

36 30 518 Balancing rear wheel (statically) (wheel removed)
Core activity
(-) Static balancing of rear wheel
Align balancer (No. 36 3 601) with level gauge (1) and knurled screws
(2).
Check quick-release axle (3) for runout and damage.
Set the rear wheel with quick-release axle (3) on the balancer and wait
until the wheel settles to a stop.
Technical data
Permissible rear- max 45 g
wheel imbalance
the rear wheel
One half of the
weights must be
the right of the
wheel rim

36 30 601 Replacing rim for front wheel (wheel removed)

Core activity
Remove screws (1).

(-) Removing front tyre
ATTENTION
Component damage
Use commercially available tools to strip the tyre off the rim.
(-) Removing front tyre pressure monitoring sensor (RDC

sensor)


(-) Install the front tyre pressure monitoring sensor (RDC

sensor)
Checking battery of tyre-pressure monitoring sensor (RDC sensor)
Check
Check the battery of RDC sensor (1) with the RDC Test Tool (No. 61 1
671).
Result:
Battery too weak.
Measure:
=> 36 20 554, Replacing front RDC sensor (tyre removed) (Billed as a
separate item)

If applicable, affix RDC sticker (1).

Position new sealing ring (3) on sensor (2).
Install new union nut (4).
Tightening torques
encapsulated) 12 Nm

Tightening torque,
12 Nm
Install new valve insert (5).
(-) Install the front tyre
ATTENTION
Component damage
Use commercially available tools/fitting equipment and work to the

manufacturer's specifications to fit tyres, and make sure that the
direction-of-rotation arrows on tyre and rim point in the same direction.
Check
Inflate the tyre to test pressure and check the valve for leaks.
Technical data
Wheel valve test 4 bar
pressure
Result:
Valve leaking
Measure:
Replace the valve insert.
Result:
Valve leaktight
Measure:
Adjust the air pressure
Technical data
Tyre pressure, one-up, at tyre 2.2 bar
front temperature 20 °
C
2.4 bar

two-up and/or
with luggage, at
tyre
temperature 20 °
C
Check the tyre and make sure the line is at a uniform distance from the
rim flange all the way round.
ATTENTION

Tightening torques
encapsulated)

(2).
Technical data
wheel imbalance
front wheel

One half of the

weights must be
the right of the
wheel rim
(-) Installing front wheel
Clean and lubricate the friction faces of the shaft sealing ring.
Lubricant
Carefully roll the front wheel into position between the fork legs.
Lubricant
Optimoly TA 18 21 9 062 599
ATTENTION
Install quick-release axle (2) with spacing bushings (3) and (4).
Tightening torques
M16 x 1.5 30 Nm
Repeatedly compress the telescopic forks to avoid the build-up of strain

in the fork legs.
Tightening torques
M8 x 25 19 Nm
Securing front wheel-speed sensor

Secure wheel-speed sensor (2) with screw (1).

Tightening torques
M6 x 16 8 Nm
(-) Releasing brake caliper
ATTENTION
Remove screws (1).

Carefully ease brake caliper (2) off the brake disc.
(-) Measuring brake-disc runout
Install dial gauge (No. 00 2 510) with extension (No. 34 2 523) in dial-
gauge holder (No. 34 2 524) and install measuring adapter (No. 34 2
510).
Secure dial-gauge holder to the brake caliper mount with a suitable
screw.
Check


runout.
Technical data
runout, front circumference
Result:
Measure:
information.
(-) Securing brake caliper
Ease brake caliper (2) onto the brake disc.

Install screws (1).
Tightening torques
M10 x 40 38 Nm
Bedding in brake pads


36 30 611 Replacing rim for rear wheel (wheel removed)

Core activity
(-) Removing judder-damper rubber elements
Remove sprocket carrier (2).

Remove judder-damper rubber elements (1).
Remove screws (1).

(-) Removing rear tyre
ATTENTION
Component damage
Use commercially available tools to strip the tyre off the rim.
(-) Removing rear tyre pressure monitoring sensor (RDC

sensor)


(-) Installing rear tyre pressure monitoring sensor (RDC

sensor)
Checking battery of tyre-pressure monitoring sensor (RDC sensor)
Check
671).
Result:
Battery too weak.
Measure:
=> 36 20 555, Replacing rear RDC sensor (tyre removed) (Billed as a
separate item)


If applicable, affix RDC sticker (1).

Position new sealing ring (3) on sensor (2).
Install new union nut (4).
Tightening torques
encapsulated) 12 Nm
Tightening torque,
12 Nm
Install new valve insert (5).
(-) Installing rear tyre
ATTENTION
Component damage
Use commercially available tools/fitting equipment and work to the

manufacturer's specifications to fit tyres, and make sure that the
direction-of-rotation arrows on tyre and rim point in the same direction.
Check
Technical data
pressure
Result:
Valve leaking

Measure:

Result:
Valve leaktight
Measure:
Technical data
temperature 20 °
C
two-up and/or 2.8 bar
with luggage, at
tyre
temperature 20 °
C
(-) Installing rear brake disc
Tightening torques
diagonally
opposite sequence
30 Nm
(-) Checking rear brake disc for runout with brake disc
removed
Requirement
Brake disc has been cleaned.
Level balancing jig (No. 36 3 601) with knurled screws (1) and level
gauge (2).
Insert balancing shaft (No. 36 5 571) in rear-wheel bearing and secure it
with tensioner (No. 36 5 572), making sure that rear-wheel bearing is
lightly preloaded.

Position the rear wheel on the balancing and install stops (No. 36 5 573)
to prevent it slipping out of position.
Install dial gauge (No. 00 2 510) in a suitable dial-gauge holder (1) and
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

runout.
Technical data
Result:
Measure:
Check positioning of the brake disc/wheel rim.

information.

(2).
Technical data
wheel imbalance
the rear wheel
One half of the
weights must be
the right of the
wheel rim
(-) Installing judder-damper rubber elements with sprocket

carrier
Install judder-damper rubber elements (1).

NOTICE
Install sprocket carrier (2).

36 31 851 Renewing front wheel bearing (wheel removed)
Core activity
(-) Removing wheel bearings of front wheel
Remove shaft sealing ring (1) on left.
Heat the bearing seat.
Technical data
Release 100 °C
temperature, wheel
bearing
Remove the right wheel bearing with reaction support (No. 00 8 572),
internal puller (No. 00 8 573) and support ring (No. 31 5 708).
Remove tubular spacer (1).

Remove left bearing (2).
(-) Installing wheel bearings of front wheel
Clean the bearing seats.


Technical data
wheel bearing
Begin by introducing right 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 (A) dia. 40 mm
Washer (B) with thread dia. 17 mm
Washer (C) with thread dia. 40 mm
Pull in right bearing (1) until seated.
Remove washer (A) and pull-in nut.
Install tubular spacer (1).

Install left bearing (2) in the same way.
Technical data
wheel bearing
Allow the wheel to cool.
Install shaft sealing ring (1) on left.

36 31 861 Replace wheel bearing for rear wheel (wheel removed)
Preparatory work
Removing judder-damper rubber elements
Core activity
(-) Removing wheel bearings of rear wheel
Remove shaft sealing ring (1) on left.

Remove circlip (2).
Technical data
Release 100 °C
temperature, wheel
bearing
Remove the left wheel bearing with reaction support (No. 00 8 572),
internal puller (No. 00 8 573) and support ring (No. 31 5 708).
Remove the tubular spacer.
Turn the rear wheel over and remove the right wheel bearing in the
same way.
(-) Installing wheel bearings of rear wheel
Clean the bearing seats.

Heat the left bearing seat.
Technical data
wheel bearing
Introduce 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):


Pull in bearing (1) until seated.
Remove washer (A) and pull-in nut.
Heat the right bearing seat.
Technical data
wheel bearing

Spacing bushing (2) sits flat and square on bearing (1).
Introduce bearing (3) into the bearing seat.
Install the washers and pull-in nut.
Pull in bearing (3) until seated against spacing bushing (2).

Install shaft sealing ring (1).
Follow-up work
Installing judder-damper rubber elements with sprocket carrier

36 32 501 Renewing front tyre (wheel removed)

ATTENTION
Re-use of tyre valve
Pressure loss in tyre
When fitting a new tyre, also install a new tyre valve.
Core activity
(-) Changing front tyre
Removing front tyre
ATTENTION
Component damage
Pry off the tyre opposite (arrow) the valve/tyre pressure monitoring
sensor (RDC sensor).
Hold a lever against the rim at the RDC label (1), to prevent the tyre
bead from damaging the RDC sensor.
Remove the tyre from the rim.
Checking battery of front tyre-pressure monitoring sensor (RDC

sensor)
Check
671).
Result:
Battery too weak.
Measure:

=> 36 20 554, Replacing front RDC sensor (tyre removed) (Billed as a

separate item)
Installing front tyre
When fitting the tyre, note the tyre pressure monitoring sensor (RDC
sensor).
ATTENTION
Component damage
Install the tyre, making sure the direction of rotation is correct as

indicated.
Check
Technical data
pressure
Result:
Valve leaking
Measure:
Result:
Valve leaktight
Measure:
Technical data
Tyre pressure, one-up, at tyre 2.2 bar
front temperature 20 °
C
with luggage, at
tyre
temperature 20 °
C

(2).
Technical data
wheel imbalance
front wheel
One half of the
weights must be
the right of the
wheel rim

36 32 511 Removing rear tyre (wheel removed)

ATTENTION
Re-use of tyre valve
Pressure loss in tyre
When fitting a new tyre, also install a new tyre valve.
Core activity
(-) Changing rear tyre
Removing rear tyre
ATTENTION
Component damage
Pry off the tyre opposite (arrow) the valve/tyre pressure monitoring
sensor (RDC sensor).
Hold a lever against the rim at the RDC label (1), to prevent the tyre
bead from damaging the RDC sensor.
Remove the tyre from the rim.
Checking battery of rear tyre-pressure monitoring sensor (RDC

sensor)
Check
671).
Result:
Battery too weak.
Measure:

=> 36 20 555, Replacing rear RDC sensor (tyre removed) (Billed as a

separate item)
Installing rear tyre
When fitting the tyre, note the tyre pressure monitoring sensor (RDC
sensor).
ATTENTION
Component damage
Install the tyre, making sure the direction of rotation is correct as

indicated.
Check
Technical data
pressure
Result:
Valve leaking
Measure:
Result:
Valve leaktight
Measure:
Correct the tyre pressure.
Technical data
temperature 20 °
C
with luggage, at
tyre
temperature 20 °
C

(2).
Technical data
wheel imbalance
the rear wheel
One half of the
weights must be
the right of the
wheel rim

36 32 528 Checking wheel rims for deformations, dents (tyres removed)
Core activity
(-) Checking front-wheel rim/rear-wheel rim for runout
(2).
Install adapter shaft (No. 36 3 606) with measuring bush (No. 36 3 616)
in the wheel bearing and pretension slightly with nut (1) from measuring
bush (No. 36 3 616).
Slightly pretension the wheel bearing and place the front wheel on the
balancer.
(2).
Set the rear wheel with quick-release axle (3) on the balancer.
Clamp the adapter shaft on the balancer with locators (No. 36 3 615) in
such a way that the adapter shaft cannot drift.
Locate the adapter shaft with pin (1).
Install dial-gauge holder (No. 36 3 609) with dial gauge (No. 00 2 510)
and measuring shoe (No. 34 2 510).
Check
Set the dial gauge on the machined inner face and check lateral
runout.
Technical data
Lateral runout, front max 1.5 mm
wheel
Lateral runout, rear max 1.5 mm
wheel
Result:

Nominal value exceeded

Measure:
Replace the wheel rim.
Check
Set the dial gauge on the machined inner face and check vertical
runout.
Technical data
Vertical runout, front max 1.5 mm
wheel
Vertical runout, rear max 1.5 mm
wheel
Result:
Nominal value exceeded
Measure:
Replace the wheel rim.

46 51 050 Replacing rear frame

+ 46 51 563
Preparatory work
Removing seat
Removing silencer
Removing rear-wheel cover
Draining fuel tank
Removing control unit for anti-theft alarm system
Core activity
(-) Removing rear frame
Open cable strap (arrow).
Open cable straps (arrows).

Disconnect connector (1).
Close off the fuel line with hose clamp (No. 13 3 010) and open hose
clip (4).
Work the wiring harness forward and through.
ATTENTION
Damage to surfaces

Disconnect the fuel line and seal off the fuel-pump outlet.
Remove screw (2) and disengage control unit (3) from the holder.
Remove screw (1) and allow brake-fluid reservoir (2) to dangle to one
side.
Disengage the brake hose from the holder (arrow).
Remove screws (3) on left and right.
Remove the rear frame and set it down safely where it cannot be
damaged.
(-) Removing fuel tank
Remove screws (1) and remove side panels (2).

Disconnect hose (3).
Remove screws (4) and bushings (5).
Work fuel tank (6) forward to remove.
(-) Removing left and right rear footrests
Remove split pin (1) and washer (2).

Remove bolt (3) and footrest (4).
Adopt the same procedure to remove the right rear footrest.

(-) Replacing rear frame
Disengage tank breather hose (1) from frame (2) (arrows), and connect
it to the new part.
(-) Installing left and right rear footrests
Lubricate pin (3).
Lubricant
Hold footrest (4) in position.

Install pin (3).
Install washer (2) and split pin (1).
Adopt the same procedure to install the right rear footrest.
(-) Installing fuel tank
Position fuel tank (6) in the rear frame.

Install screws (4) and bushings (5).
Tightening torques


(mechanical)
Secure hose (3).

Secure side panels (2) with screws (1).
(-) Installing rear frame
Clean the threads.

Hold the rear frame in position and install screws (3) on left and right.
Tightening torques
Rear frame to main frame, top
encapsulated)
Rear frame to main frame, bottom
encapsulated)
Hold brake-fluid reservoir (2) in position, align it correctly and install

screw (1).
Tightening torques
Brake-fluid reservoir to frame
(mechanical)
Secure the brake-fluid hose in the holder (arrow).

Route the rear wiring harness back into position.
NOTICE
Connect the fuel line to the fuel pump and close hose clip (4) with pliers
(No. 13 1 500).

Connect plug (1) to fuel pump unit.

Insert control unit (3) and secure the bracket with screw (2).
Route the rear wiring harness back into position.

Connect the fuel line to the fuel pump and close hose clip (4) with pliers
(No. 13 1 500).
Connect plug (1) to fuel pump unit.
Insert control unit (3) and secure the bracket with screw (2).
Secure the cable strap (arrow).
Follow-up work
Installing control unit for anti-theft alarm system
Installing rear-wheel cover
Installing silencer


Installing seat

46 51 120 Removing/installing frame

+ 46 51 575
46 51 510 Additional work for removing/installing frame (with ABS)
Preparatory work
Removing centre stand
Removing seat
Remove the battery
Removing silencer
Removing rear frame
Removing throttle cable
Removing clutch cable
Removing ZFE (central vehicle electronics) control unit
Releasing spring strut at top
Releasing rear brake lines from frame
Removing heel guard
Removing footbrake lever

Removing front right footrest

Releasing footbrake cylinder
Removing rear wheel swinging arm complete with wheel and spring
strut
Removing rear-wheel brake
Disengaging left multifunction-switch plug
Disengaging right multifunction-switch plug
Releasing wiring harness from handlebars
Removing handlebars
Disengaging starter-relay holder
Removing headlight
Removing instrument cluster
Draining coolant
Removing front panel carrier
Removing ignition switch/steering lock
Releasing brake hose to front wheel from steering head
Releasing brake lines from frame
Disconnecting brake lines from pressure modulator
Releasing wiring harness from forks
Removing top fork bridge
Removing complete forks
Releasing exhaust manifold from frame
Releasing wiring harness from frame
Removing radiator holder
Core activity
(-) Removing frame

Remove cap (1).

Remove screws (2), (3) and (4).
Remove cap (7).

Remove screw (6).
Remove spacing sleeves (1), (3) and (5).
Carefully lift the frame, paying particular attention to the region of the
swinging-arm pivot bearing.
(-) Installing frame

Carefully lower the motorcycle onto the engine, taking particular care in
the region of the swinging-arm pivot bearing.
Tightening torques
M10 x 40 38 Nm
M10 x 40 40 Nm
M12 x 50 66 Nm
Install cap (1).

Install spacing sleeve (1) with screw (2).
Tightening torques
M10 x 65 40 Nm
ATTENTION

Frame damage
Install spacing sleeves (3) and (5) with screws (4) and (6).
Tightening torques
M12 x 50 66 Nm
M10 x 40 38 Nm
Install cap (7).

Remove masking tape from the frame and engine.
Follow-up work
Installing radiator holder
Installing complete forks
Install the top fork bridge
Securing wiring harness to forks
Securing wiring harness to frame
Securing exhaust manifold to frame
Installing ignition switch/steering lock
Securing brake pipes to pressure modulator
Securing brake lines to frame
Securing brake hose to front wheel to steering head
Installing front panel carrier
Installing instrument cluster
Install the headlight
Securing starter-relay holder
Installing handlebars
Connecting left multifunction switch plugs
Connecting right multifunction switch plugs
Securing wiring harness to handlebars
Installing rear-wheel brake

Installing rear wheel swinging arm complete with wheel and spring
strut
Installing front right footrest
Installing heel guard
Installing footbrake lever
Securing footbrake cylinder
Adjust chain sag
Securing rear brake lines to frame
Securing spring strut to frame
Installing silencer
=> Bleeding front brake system (Description in item: 34 00 507,
Billed as a separate item)
=> Bleeding rear brake system (Description in item: 34 00 509,
Billed as a separate item)
Installing ZFE (central vehicle electronics) control unit
Installing clutch cable
Installing throttle cable
Installing battery
Installing seat
Installing centre stand
Checking headlight beam angle


46 51 180 Checking motorcycle with frame- measuring system

+ 46 51 676
Preparatory work
Removing seat
Core activity
(-) Checking vehicle with frame measuring system
Use the frame measuring system recommended by BMW Motorrad.
Follow-up work
Installing seat

46 51 520 Replacing frame (frame removed)
Core activity
(-) Replacing frame
Use number and letter punches to transfer Vehicle Identification Number

(1) (VIN) to new part (2).
Clean the prepared face with a suitable cleaning product and apply a
clear varnish finish.
Allow the clear lacquer to dry and apply adhesive film over VIN (1).
Render VIN (1) on the old part invalid and dispose of the old part in
accordance with national regulations.
Affix new type plate (3) to new part (2) after cleaning the surface with a
suitable cleaning product.
Affix new label for tyres (4) to new part (2) after cleaning the surface
with a suitable cleaning product.
Dispose of the old frame in accordance with locally applicable

legislation.
Secure small items to the new frame, as applicable.
Tightening torques
Locking element, brake-light switch to footrest plate
M6 x 12, Replace screw Threaded pin
Thread-locking compound (Micro- screws in until
encapsulated) projecting 3 mm, but
at least 8 mm
M6 x 40 4 Nm
Remove heat shield (1).

Remove screws (2) with washers (3) and remove control-unit holder (4)
from the old frame.
Secure heat shield (1) and control-unit holder (4) to the new frame.
Tightening torques
Control-unit bracket to frame
M6 x 30 8 Nm
Remove screw (1), nut (2), insert (3) and (4) and transfer them to new
part (5).

Tightening torques
Spacers for front footrest, right, to frame
M6 x 30 8 Nm
Follow-up work
Removing fork bridge cover
Removing bottom steering-head bearing
Installing bottom steering-head bearing
Install the fork bridge cover
Installing outer races of steering-head bearing

46 52 009 Removing/installing or cleaning/ lubricating centre stand

+ 46 52 509
Centre standOA
Preparatory work
Core activity
(-) Removing centre stand
Retract the centre stand.

Remove tension springs (1), using hook (No. 46 5 721).
Heat nuts (2).
Technical data
Release 100 °C
temperature of
centre-stand
threaded fastener
Remove nuts (2) with screws (3).

Remove the centre stand.
(-) Installing centre stand
Clean the threads.

Lubricant
Unirex S2 83 23 9 416 138
Hold the centre stand in position and install nuts (2) with screws (3).
Tightening torques
Install tension springs (1), using hook (No. 46 5 721).
Follow-up work



46 52 011 Renewing tension spring for centre stand

+ 46 52 503
Preparatory work
Core activity
(-) Removing centre-stand springs
Retract the centre stand and remove springs (1) with hook (No. 46 5
721).
(-) Installing tension springs of centre stand
Install tension springs (1), using hook (No. 46 5 721).
Follow-up work

46 53 007 Replacing side stand pivot

+ 46 53 507
Preparatory work
Removing tension springs of side stand
Core activity
(-) Remove the side stand

Remove side-stand switch (3).
Remove screw (6).
Remove side stand (4) and bearing sleeve (5).
Using a suitable tool, remove the sleeve from the frame if necessary.
(-) Replacing side-stand bearing bushing in frame
Remove bushing (1).

Install the new bushing, making sure it is flush.
(-) Install the side stand
Using a suitable tool, install the new sleeve, if applicable, in the frame.
Clean bearing sleeve (5).
Lubricate the bearing seats.
Lubricant

Unirex S2 83 23 9 416 138
Hold side stand (4) with bearing sleeve (5) in position and install screw
(6).
Tightening torques
encapsulated)
Seat the recess of side-stand switch (3) in the pin on the frame.
Tightening torques
(mechanical)
Follow-up work
Installing tension springs of side stand

46 53 011 Renewing tension spring for prop stand

+ 46 53 602
Core activity
(-) Removing tension springs of side stand
Position assembly/disassembly tool (No. 00 9 521) at mounting point (1)

and engage it in the spring bow (arrow).
CAUTION
Turn assembly/disassembly tool (No. 00 9 521) carefully counter-

clockwise until side-stand spring (2) disengages; repeat this operation if
necessary.
Disengage side-stand spring (2) from side stand (3).
(-) Installing tension springs of side stand
Remove hand protector (1) from assembly/disassembly tool (No. 00 9

521).
Engage side-stand spring (1) in side stand (2) and

assembly/disassembly tool (No. 00 9 521).
CAUTION

Position assembly/disassembly tool (No. 00 9 521) at mounting point (3)

and carefully press forward.
Side-stand spring (1) slips on to mounting point (3).
Engage side-stand spring (1) in the groove (arrow).
Follow-up work

46 54 330 Replace case holder

+ 46 54 512
0130 - CasesOE
Case carrierOA
Preparatory work
Removing seat
Disengaging 360° marker light from case carrier
Removing radio-equipment case (empty)
Removing grab handle
Removing silencer
Core activity
(-) Removing case carrier
Remove the following components:

Screws (1) with washers (2)
Nuts (3) with washers (4)
Screws (5)
Remove case carrier (6).
(-) Installing case carrier
Insert case carrier (6).

Install the following parts and tighten until hand-tight:
Screws (5)
Bushings (4)
Nuts (3)
Install washers (2) and nuts (1) and tighten until hand-tight.

Lightly lubricate the contact faces of the silencer and exhaust manifold.
Lubricant
Optimoly TA 18 21 9 062 599
Install silencer (4) with shouldered bushing (5), install screw (2) and
washer (3) and tighten until hand-tight.
(-) Tightening screws
Tighten screws (1) on both sides.
Tightening torques
M8 x 25 19 Nm
Tighten screws (2) with nuts (3).
Tightening torques
M8 x 25 19 Nm
Tighten screw (4).
Tightening torques
M8 x 75 19 Nm

Follow-up work
Installing radio-equipment case (empty)
Securing 360° marker light to case carrier

46 61 030 Remove/install or replace top front wheel cover

+ 46 61 505
Core activity
(-) Removing top front-wheel cover
Remove screws (1).

Remove wheel cover (2).
(-) Installing top front-wheel cover
Hold wheel cover (2) in position and install screws (1).

NOTICE
Take care not to trap the fork-bridge cover between the front-wheel cover
and the side panel.
Follow-up work

46 61 037 Removing/installing front-wheel cover, bottom

+ 46 61 506
Core activity
(-) Removing bottom front-wheel cover

Remove front-wheel cover (2).
(-) Installing bottom front-wheel cover
Clean the threads.

Install wheel cover (2).
Install screws (1).
Tightening torques
Front-wheel cover to forks
encapsulated)
encapsulated)
Follow-up work

46 62 000 Replacing rear-wheel cover

+ 46 62 502
Preparatory work
Removing seat
Removing control unit for anti-theft alarm system
Core activity
(-) Remove the number-plate carrier
Remove screws (1).
Remove screw (1) and cover (2).

Remove bulb socket (3) from the number-plate light.

Disconnect plug (1) for the rear light.
Remove screws (1).

Remove number-plate carrier (2) with the rear light and number-plate
light, working the cables through toward the inside.
(-) Removing rear-wheel cover
Remove screws (1).

Remove the wheel cover.

(-) Replacing wheel cover

Transfer brackets (1) and rubber bushings (2) to the new part.
(-) Installing rear-wheel cover
Work the wheel cover into position.

Install screws (1).
(-) Installing number-plate carrier
Work number-plate carrier (2) with the rear light and number-plate light
into position from behind, routing the cable of the rear-light unit correctly
at the same time.
Install screws (1).

Connect plug (1).
Install screws (2).
Tightening torques
M8 x 25 10 Nm
Install screws (1).
Install screws (1).

Secure bulb (3) in the number-plate light.

Install cover (2) and install screw (1).
(-) Affixing sticker for tyres to wheel cover
Clean the surface for the adhesive.

Affix the sticker (arrow).
Follow-up work
Installing control unit for anti-theft alarm system
Installing seat

46 62 050 Renewing number plate carrier

+ 46 62 508
Preparatory work
Removing seat
Removing both rear flashing turn indicators
Core activity
(-) Remove the number-plate carrier
Remove screws (1).
Remove screw (1) and cover (2).

Remove bulb socket (3) from the number-plate light.

Disconnect plug (1) for the rear light.
Remove screws (1).

Remove number-plate carrier (2) with the rear light and number-plate
light, working the cables through toward the inside.
(-) Changing number-plate carrier

Removing rear-light unit
Remove screws (1).

Remove rear light (2), noting the projection (arrow).

Removing number-plate light bulb

Remove nuts (1) with washers (2).
Remove number-plate light (3).

Installing number-plate light
Insert number-plate light (3) from the rear.
Install nuts (1) with washers (2).
Installing rear-light unit
Install rear light (2), noting the projection (arrow).

Install screws (1).

(-) Installing number-plate carrier
Work number-plate carrier (2) with the rear light and number-plate light
into position from behind, routing the cable of the rear-light unit correctly
at the same time.
Install screws (1).
Connect plug (1).
Install screws (2).
Tightening torques
M8 x 25 10 Nm
Install screws (1).

Install screws (1).
Secure bulb (3) in the number-plate light.

Install cover (2) and install screw (1).
Follow-up work
Installing both rear flashing turn indicators
Installing seat

46 63 333 Replacing side panel, left

+ 46 63 900
Preparatory work
Removing seat
Removing front flashing turn indicator
Core activity
(-) Removing left side panel
Remove screws (1).

Remove screws (2), noting washers (3).
Remove side panel (4), noting the windscreen.
(-) Replace side panel of fairing
Unclip cover (1).

Working from the inboard side, press out badge (2).
Remove bracket (3).
Transfer the parts and the small items removed beforehand to the new
panel.
(-) Install the left side panel
Hold side panel (4) in position.

NOTICE

and the side panel.
Install screws (2), noting washers (3).
Tightening torques
M5 x 18 2.5 Nm
Install screws (1).
Tightening torques
Trim panels
M5 2.5 Nm
Follow-up work
Installing front flashing turn indicator
Installing seat

46 63 334 Replacing side panel, right

+ 46 63 901
Preparatory work
Removing seat
Removing front flashing turn indicator
Core activity
(-) Removing right side panel
Remove inboard screws (1).

Remove screws (2), noting washers (3).
Remove side panel (4), noting the windscreen.
(-) Replace side panel of fairing
Unclip cover (1).

Working from the inboard side, press out badge (2).
Remove bracket (3).
Transfer the parts and the small items removed beforehand to the new
panel.
(-) Install the right side panel
Hold side panel (4) in position.

NOTICE

and the side panel.
Install screws (2), noting washers (3).
Tightening torques
M5 x 18 2.5 Nm
Install screws (1).
Tightening torques
Trim panels
M5 2.5 Nm
Follow-up work
Installing front flashing turn indicator
Installing seat

46 71 200 Replacing front left footplate

+ 46 71 821
Preparatory work
Removing tension springs of side stand
Remove the side stand
Core activity
(-) Removing left front footrest
Remove split pin (2) and washer (3).

Remove pin (4).
Remove footrest (1) with spring (5) and spacing sleeve (6).
(-) Removing front left footrest plate
Remove screws (1).

Remove footrest plate (2).
(-) Installing front left footrest plate
Hold footrest plate (2) in position.

Install screws (1).
Tightening torques

Side-stand pivot mount/footrest plate, left, to frame

M10 x 20 - 10.9, Replace screw 50 Nm
encapsulated)
(-) Installing front left footrest
Lubricate bearing seats and pin (4).
Lubricant
Install footrest (1) with spring (5) and spacing sleeve (6).
Install pin (4).
Install washer (3) and split pin (2).
Follow-up work
Install the side stand
Installing tension springs of side stand

51 25 020 Replacing lock barrel for fuel tank

+ 51 25 591
Core activity
(-) Removing lock barrel for fuel tank

ATTENTION
Component damage
Technical data
(-) Install the lock barrel for fuel tank
Lubricant
Unirex S 2 83 23 9 416 138
cap (1).
Follow-up work

51 25 038 Replace lock cylinder in ignition/steering lock

+ 51 25 538
Preparatory work
Removing seat
Core activity
(-) Removing lock barrel from ignition switch/steering lock
Insert the ignition key and turn it to the ON position.

Push in the retainer (arrow) by inserting a length of stiff wire or similar
into the hole (arrow).
Pull out lock barrel (1) with the ignition key.
(-) Installing lock barrel in ignition switch/steering lock
Lubricant
Unirex S 2 83 23 9 416 138
Using the ignition key, insert lock barrel (1) in the ON position until the
retainer (arrow) engages.
Follow-up work
Installing seat

51 25 044 Replace handlebar-lock housing

+ 51 25 544
Preparatory work
Removing seat
Core activity
(-) Removing lock barrel from ignition switch/steering lock

(-) Removing ignition switch/steering lock
Remove screws (1) with bit (No. 51 0 532), remove washers (2).
Lift ignition switch/steering lock (3) and disconnect plug (4).
(-) Replacing ignition switch/steering lock
Remove screws (1) and remove ignition switch (2).

Remove screws (3) and remove ring aerial (4).

Secure ring aerial (1) with sealing ring (2) on ignition switch/steering
lock (3).
Secure ignition switch (2) with screws (1).

Secure ring aerial (4) with screws (3).
(-) Installing ignition switch/steering lock
Connect plug (4) and install ignition switch/steering lock (3).

Install screws (1) and washers (2) with bit(No. 51 0 532).
Tightening torques
M8 x 40 19 Nm

(-) Installing lock barrel in ignition switch/steering lock
Lubricant
Unirex S 2 83 23 9 416 138
Follow-up work
Installing seat

51 25 050 Removing/installing or replacing seat lock

+ 51 25 595
Preparatory work
Removing seat
Removing lock barrel for seat
Core activity
(-) Removing seat retainer bridge
Disconnect and disengage plug (1) for the wheel-speed sensor.

Release diagnosis plug (2) and open the cable ties (arrows).
Remove nuts (3).
Lift retaining bridge (4) and work it to the rear to remove.
(-) Removing seat latch
Remove screws (1).

Remove top section (2), noting the hooks (arrows).
Remove latch (3) with spring (4).

(-) Installing seat latch
Install seat latch (3), noting springs (4).

Place top section (2) in position, noting the hooks (arrows).
Install screws (1).
(-) Installing seat retainer bridge
Install retaining bridge (4).

Install nuts (3).
Tightening torques
Seat retainer bridge to rubber mount
M5 2.5 Nm
Intake air silencer to seat bridge
M5 2.5 Nm
Secure diagnosis plug (2) and close the cable ties (arrows).
Install screws (1) on left and right.
Secure and connect plug (1) for the wheel-speed sensor.

Follow-up work
Installing lock barrel for seat
Installing seat

51 25 060 Removing/installing or replacing lock barrel for seat lock

+ 51 25 596
Preparatory work
Removing seat
Core activity
(-) Removing lock barrel for seat
Press in the retainer (arrow) by inserting a suitable tool in the hole

(arrow) and remove lock barrel (1) with the key.
(-) Installing lock barrel for seat
Lubricate the lock barrel.
Lubricant
Unirex S 2 83 23 9 416 138
Push lock barrel (1) into the lock until the retainer (arrow) engages.
Follow-up work
Installing seat

51 25 091 Install a single key locking system set

+ 51 25 605
Preparatory work
Removing seat
Core activity
(-) Replacing the lock barrel in the ignition steering lock
Removing lock barrel from ignition switch/steering lock
Installing lock barrel in ignition switch/steering lock
Lubricant
Unirex S 2 83 23 9 416 138
(-) Replacing control unit, engine management system

Removing engine control unit
Remove screw (1) and remove bracket (2).

Remove engine control unit (3).

Installing engine control unit

Clean the threads.
Connect plugs (5) and (4).
Install engine control unit (3).
Secure bracket (2) with screw (1).
Tightening torques
M5 x 22 6 Nm
(-) Renewing the lock barrel of the fuel filler cap
Open fuel filler cap.

Removing lock barrel for fuel tank

ATTENTION
Component damage
Technical data

Install the lock barrel for fuel tank

Lubricant
Unirex S 2 83 23 9 416 138
cap (1).
Close fuel filler cap.
(-) Replacing the seat lock

Removing lock barrel for seat
Press in the retainer (arrow) by inserting a suitable tool in the hole

(arrow) and remove lock barrel (1) with the key.
Installing lock barrel for seat

Lubricate the lock barrel.
Lubricant
Unirex S 2 83 23 9 416 138
Push lock barrel (1) into the lock until the retainer (arrow) engages.

Follow-up work
Checking software
Programming engine-management control unit
Installing seat

61 00 002 Testing software

+ 61 00 502
Preparatory work
Removing seat
Core activity
NOTICE
voltage of 13 V.
cap (3).
(-) Checking software
Perform diagnosis. Rectify faults, if found, before starting

programming/coding.
=> Programming control unit of engine management system (along

with testing software) (Description in item: 13 61 522, 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)
vehicle


Follow-up work
Installing seat

61 00 003 Resetting/learning adaptation values (with replacing component)

+ 61 00 503
Preparatory work
Removing seat
Core activity
NOTICE
voltage of 13 V.
cap (3).
(-) Reading fault memory with BMW Motorrad diagnostic

system and resetting adaptation values
After replacing the component, be sure to read the fault memories of the
control units with the BMW Motorrad diagnostic system and rectify the
corresponding faults, if any. You must also reset the adaptation values.
From this point on, follow the instructions issued by the BMW Motorrad
diagnostic system. This is the only way of ensuring correct operation of
the vehicle.

vehicle


Follow-up work
Installing seat

61 00 004 Coding complete vehicle

+ 61 00 511
Preparatory work
Removing seat
Core activity
(-) Complete coding of motorcycle
Requirement
Engine is off.
Battery is fully charged and battery charger is connected.
Switch off all electrical consumers.
NOTICE
Do not attempt to perform work of any other kind on the motorcycle while
programming/coding is in progress.
Perform diagnosis. Rectify faults, if found, before starting

programming/coding.
Start programming/coding with the CIP program.
Start Complete coding of vehicle.
Follow-up work
Installing seat

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.

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
61 11 514 Additional work for removing/installing or replacing main wiring harness (with ABS)
Preparatory work
Removing seat
Remove the battery
Removing headlight
Removing instrument cluster
Releasing spring strut at top
Disengaging left multifunction-switch plug
Disengaging right multifunction-switch plug
Releasing wiring harness from engine
Removing starter-relay holder with relay
Removing ZFE (central vehicle electronics) control unit
Removing ignition switch/steering lock
Core activity
(-) Releasing front wiring harness
Remove the cable ties (arrows) and disengage the cables.

Cut through cable tie (1).
Disconnect plug (1) for the horn.
Disconnect plug (2) for the wheel-speed sensor, noting the clip (arrow).

Open the cable ties (arrows) and disengage plug (1) for the flashing turn
indicator.
Open the cable ties (arrows) and disengage plug (1) for the flashing turn
indicator.
(-) Removing frame wiring harness
Remove all the cable ties (arrows).

Disconnect plug (1) of the pressure modulator.
Disconnect plug (1) of the brake-light switch.

Disconnect plug (2) for the voltage regulator.
Disconnect wheel-speed sensor plug (1).

Disconnect both fuel-pump plugs (1).

Disconnect ZFE plug (2).
Disconnect and disengage anti-theft alarm plug (1).

Remove the wiring harness from the motorcycle.
(-) Installing frame wiring harness
Position the wiring harness in the motorcycle; note that the mark (arrow)
must be secured at cable holder (1).

Route the rear wiring harness to the rear underneath the frame
transverse tube (arrow).
Connect both fuel-pump plugs (1).

NOTICE
Connect ZFE plug (2).

Connect both fuel-pump plugs (1).

Connect ZFE plug (2).

Connect and secure anti-theft alarm plug (1).

Route the wiring harness forward and secure it with cable ties (arrows).
Connect plug (1) of the brake-light switch.

Connect plug (2) of the voltage regulator.

Connect plug (1) for the pressure modulator.
(-) Securing front wiring harness
Connect plug (1) for the horn.
Connect and secure plug (2) for the wheel-speed sensor, noting the clip
(arrow).

Install the cable ties (arrows) and secure plug (1) for the flashing turn
indicator.
Install the cable ties (arrows) and secure plug (1) for the flashing turn
indicator.

Follow-up work
Securing spring strut to frame
Installing starter-relay holder with relay
Installing ignition switch/steering lock
Installing ZFE (central vehicle electronics) control unit
Securing engine wiring harness at front
Connecting left multifunction switch plugs
Connecting right multifunction switch plugs
Installing instrument cluster
Install the headlight
Installing battery
Installing seat

61 21 011 Renewing battery

+ 61 21 522
Preparatory work
Removing seat
Core activity
(-) Remove the battery
Requirement
Remove screws (1) and remove battery holder (2).

Disengage plug (3) and remove holder (2).
ATTENTION
sequence.
Disconnect the leads from negative terminal (4) and positive terminal
(5).
Remove battery (6).
(-) Charging Absorbent Glass Mat (AGM) 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 the battery with the BMW Motorrad battery charger, taking care
to comply with the instructions for use.
Requirement

Install the battery.

Secure battery holder (1) with screws (2).
ATTENTION
Battery not connected in accordance with correct procedure
Always proceed in compliance with specified installation sequence.
Connect the leads to battery terminals (4) (positive terminal first),

making sure that the connecting cable is routed correctly.
Tightening torques
M6 5 Nm
Secure plug (3).
Follow-up work
Installing seat

61 21 019 Charging battery

+ 61 21 523
Core activity
(-) Checking battery charge state
ATTENTION
Commercially available battery chargers connected to the on-board
power socket
Damage to charger and to central frame and suspension electronics
(ZFE)
Use only battery chargers approved by BMW Motorrad for use with
vehicles equipped with ZFE.
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)
Disconnect all electrical consumers from the on-board socket or
sockets.
Check
Switch on the ignition.

ZFE (Central Vehicle Electronics) switches on.
Switch off the ignition.
Technical data
Deactivation delay, if no 30...60 s
Central Vehicle consumers
Electronics are active
ZFE remains on, because of the deactivation delay.

Within the deactivation delay, connect BMW Motorrad battery charger
to the on-board socket first.
The battery charge state is displayed.
Result:
Battery is not fully charged.

Measure:
Connect BMW Motorrad battery charger to the electricity supply.
NOTICE
If the battery charger indicates that on-board voltage has dropped to the
lower voltage limit for the on-board system, you can recharge the battery
only by connecting the charger directly to the battery terminals. The on-
board socket is switched off if the voltage is below this lower voltage limit.
Technical data
Undervoltage in on- ≤7 V
board system
Charge the battery with the BMW Motorrad battery charger, taking care
to comply with the instructions for use.
Follow-up work

61 31 005 Replacing additional multifunction switch, left or right

+ 61 31 954
Core activity
(-) Removing extra switches
Remove screws (1).

Remove extra switches (2).
Disconnect plug (3), noting the retainer (arrow).
(-) Installing extra switches
Connect plug (3).

Plug engages the retainer (arrow).
Hold extra switches (2) in position.
Install screws (1).
Tightening torques
Extra switches to bracket
M4 x 8 2 Nm
Follow-up work

61 31 006 Replacing microswitch for rear brake

+ 61 31 547
Preparatory work
Removing footbrake-cylinder cover
Core activity
(-) Removing rear brake-light switch

Disengage the cable from the holders (arrows) and work the cable clear.
Remove screw (1) and remove brake-light switch (2).
(-) Installing rear brake-light switch
Hold brake-light switch (2) in position on the frame and install screw (1).
Tightening torques
Brake-light switch to footrest plate
M6 x 10 5 Nm

Route the cable correctly and connect plug (1).

(-) Adjusting blow-by clearance at piston rod
Secure the footbrake cylinder with screws (1).

Insert the feeler gauge between the brake-light switch actuator and the
frame stop.
Technical data
Blow-by clearance between 2.5+0.5 mm
of the footbrake footbrake −0.5
lever lever and
stop
Slacken nut (2) on pushrod (3).

Turn push rod (3) to relieve the pressure until it has play.
Turn pushrod (3) until all play at the pushrod is taken up.
Lock nut (2).
Tightening torques
M6 8 Nm
Remove screws (1).

Follow-up work
Installing footbrake-cylinder cover

61 31 007 Replacing microswitch for front brake

+ 61 31 548
Core activity
(-) Removing front brake-light switch

Remove screw (3).
Remove the brake-light switch, noting thrust piece (1).
(-) Installing front brake-light switch
Clean the threads.

Install the brake-light switch with new thrust piece (2).
Install grubscrew (3).
Tightening torques
Brake-light switch to handlebar fitting
encapsulated)
Connect plug (2).
Follow-up work

61 31 063 Renewing complete multi-function switch on left handlebar

+ 61 31 904
Core activity
(-) Removing cover of multifunction switch
Remove screws (1).

Remove cover (2).
(-) Removing left multifunction switch
Release plugs (1) and (2) from the multifunction switch.

heated grip.
Remove screws (1) and remove the multifunction switch.

(-) Installing left multifunction switch
Install the multifunction switch and align it correctly.

Install screws (1).
Tightening torques
KA30 x 10 - 3.6 1 Nm
Secure plugs (1) and (2) in the multifunction switch.
(-) Installing cover of multifunction switch
Install cover (2) and secure with screws (1).

Follow-up work

61 31 073 Renewing complete multi-function switch on right handlebar

+ 61 31 905
Preparatory work
Release the handbrake fitting
Core activity
(-) Removing cover of multifunction switch
Remove screws (1).

Remove cover (2).
(-) Removing right multifunction switch
Release plugs (1) and (2) from the multifunction switch.

heated grip.
Remove screws (3) and remove the multifunction switch.

(-) Installing right multifunction switch
Install the multifunction switch and align it correctly.

Install screws (3).
Tightening torques
KA30 x 10 - 3.6 1 Nm
Secure plugs (1) and (2) in the multifunction switch.
Install cover (2) and secure with screws (1).

Follow-up work

61 31 295 Removing/installing or replacing clutch switch

+ 61 31 911
Core activity
(-) Removing clutch switch

Remove screw (2).
Remove clutch switch (3).
(-) Installing clutch switch
Seat clutch switch (3) in the handlebar fitting.

Install screw (2).
Check operation of the clutch switch (listen for switch click).
Connect plug (1).
Follow-up work

61 31 302 Replacing switch for side stand

+ 61 31 913
Core activity
(-) Removing side-stand switch

Disengage the cable from the holders (arrows) and work the cable clear.

Remove side-stand switch (3) from screw (4).
(-) Installing side-stand switch
Seat side-stand switch (3) on screw (4), making sure that the groove in
the pin is at the footrest plate.
Install washer (2) and nut (1).
Tightening torques
(mechanical)

Route the cable correctly and connect plug (1).

Secure the cable in the holders (arrows).
Follow-up work

61 31 390 Replacing starter relay

+ 61 31 924
Preparatory work
Removing seat
Removing left side panel
Core activity
(-) Removing starter relay

Disconnect cable (1).
Remove screws (3) and remove the relay.
(-) Installing starter relay
Secure the starter relay with screws (3).

Secure cable (1).
Connect plug (2).
Follow-up work
Installing left side panel
Connecting battery


Installing seat

61 32 000 Removing/installing or replacing ignition switch

+ 61 32 511
Preparatory work
Removing seat
Core activity
(-) Removing ignition light switch
Remove screws (1) and remove switch (2).
(-) Installing ignition light switch
Hold switch (2) in position, noting the driver pin.

Install screws (1).


Tightening torques
M8 x 40 19 Nm
Follow-up work
Installing seat

61 33 001 Replacing hailing system

+ 61 33 505
Preparatory work
Removing seat
Core activity
(-) Removing loudspeaker for hailing system
Remove cap (1).

Disconnect plug (3) for the loudspeaker.
Remove screws (2) and remove speaker (4).
(-) Installing loudspeaker for hailing system
NOTICE
The control unit is built into the left loudspeaker. Make sure that the
loudspeakers are installed on the correct sides.
Hold speaker (4) in position and secure with screws (2).
Tightening torques
Horn to crash bar
M6 x 20 8 Nm
Connect plug (3) for the loudspeaker.

Install cap (1).

Follow-up work
Connecting battery
Coding hailing system
Installing seat

61 35 012 Setting calendar date

+ 61 35 506
Preparatory work
Removing seat
Core activity
NOTICE
voltage of 13 V.
cap (3).
(-) Setting 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.
NOTICE
Alternatively, use the Software Service Station (SSS).

vehicle


Follow-up work
Installing seat

61 35 150 Replacing ring aerial on ignition lock

+ 61 35 650
Preparatory work
Removing seat
Core activity
(-) Removing ring aerial
Remove screws (1).

Remove ring aerial (2) from ignition switch/steering lock (3).
(-) Installing ring aerial
Place ring aerial (1) and O-ring (2) on ignition switch/steering lock
housing (3).

Secure ring aerial (2) with screws (1) on ignition switch/steering lock (3).

Tightening torques
M8 x 40 19 Nm
Follow-up work
Installing seat

61 35 503 Setting service-due date with BMW Motorrad diagnostic system (for maintenance)
Core activity
(-) Setting service-due date
Start ISTA and perform the vehicle test.

Select Activities from the menu, call up the Service schedules and set
the service date.

61 35 504 Setting service countdown distance with BMW Motorrad diagnostic system (for
maintenance)
Core activity
(-) Setting service countdown distance

the countdown distance.

61 35 505 Setting service-due date and service countdown distance with BMW Motorrad
diagnostic system (for maintenance)
Core activity
(-) Setting service-due date and service countdown distance

the service date and the countdown distance.

61 35 511 Replacing control unit of central running-gear electronics (without testing

software/programming)
Preparatory work
Removing seat
Remove the battery
Core activity
(-) Removing ZFE (central vehicle electronics) control unit
Open the cable tie (arrow).

Remove rubber strap (1).
Disconnect the plug and remove control unit (2).
(-) Installing ZFE (central vehicle electronics) control unit
NOTICE
Do not, under any circumstances temporarily install control units from
other vehicles by way of testing.
The possible consequences include:
Coding data could be overwritten.
The control units could malfunction.
Connect the plug and seat ZFE control unit (2) in the holder.
Secure rubber strap (1).
Secure the cable to the holder with a cable tie (arrow).

Follow-up work
Installing battery

as a separate item)

a separate item)
Installing seat

62 11 199 Replacing instrument cluster (without (testing software/programming)

+ 62 11 510
NOTICE
Before removal, test the control unit with the BMW Motorrad diagnostic
system and make a backup copy of the data.
Preparatory work
Removing windscreen
Core activity
(-) Removing instrument cluster
Remove retaining clips (3).

Remove instrument panel (2).
(-) Installing instrument cluster
NOTICE
When control units (for example engine management system, ABS,
instrument cluster) are replaced on a motorcycle with CAN bus, the BMW
Motorrad diagnostic system has to be used to register each new
component.
Connect plug (1).

Install instrument cluster (2).
Install retaining clips (3).

Follow-up work
as a separate item)

a separate item)
Install the windscreen

63 12 000 Adjust headlight

+ 63 12 500
Core activity
(-) Checking headlight beam angle
Requirement
Motorcycle standing on a smooth, level surface
Check
Apply the rider's weight to the motorcycle.
Bear in mind the setting for spring-strut preload.
Distances:
(a): Distance between headlight and vertical surface
(b): Height of centre of headlight
(c): Distance to light/dark cut-off
Technical data
Distance between 5m
headlight and
vertical surface
For headlight
adjustment
Distance between Suspension 7.5 cm
light/dark cut-off and set to basic
mark at height of setting and
centre of headlight vehicle
loaded
with 85 kg
Result:
Headlight beam angle not correct.
Measure:
Correcting headlight beam angle
Requirement
Motorcycle standing on a smooth, level surface.
Start the engine.

Slightly slacken screws (1) on left and right.
The headlight can be moved; apply sufficient pressure to overcome the
slight resistance.

Adjust beam throw by tilting the headlight housing.
Technical data
loaded
with 85 kg
If necessary, adjust lateral throw by pivoting the headlight housing.

Tighten screws (1) without altering the setting.
Tightening torques
encapsulated)
Follow-up work

63 12 091 Replacing headlight

+ 63 12 637
Core activity
(-) Removing headlight
Disconnect headlight plug (1).

Remove headlight (5) with washers (4).
(-) Install the headlight
Install headlight (5) with both washers (4).

Connect headlight plug (1)
Pre-adjust the headlight with the aid of the indicator on the side (arrows)
and tighten screws (1).
Tightening torques
encapsulated)

Follow-up work

63 12 101 Installing headlight guard

+ 63 12 559
headlight guardOA
Core activity
(-) Removing right screw from headlight
Remove right screw (1) with washer (2) from headlight (3).
(-) Installing right holder for headlight guard
Position holder (1) with retainer in groove (2).

Install screw (4) with washer (3) and tighten until hand-tight.
Adjust the headlight with the aid of the indicator on the side (arrows).
Tighten screw (4).
Tightening torques
M8 x 16 8 Nm

(-) Removing left screw from headlight
Remove left screw (1) with washer (2) from headlight (3).
(-) Installing left holder for headlight guard

Tighten screw (4).
Tightening torques
M8 x 16 8 Nm

Requirement
Check
Distances:
Technical data
Distance between 5m
headlight and
vertical surface
For headlight
adjustment
loaded
with 85 kg
Result:
Measure:
Requirement

Start the engine.

slight resistance.
Technical data
loaded
with 85 kg

Tightening torques
M8 x 16 8 Nm
(-) Engaging headlight guard
NOTICE
Use the headlight guard only when off-roading. Riding on public roads
with the headlight guard fitted to the motorcycle is prohibited.
Engage headlight guard (1) in the adapters of the holders.

63 12 499 Headlight conversion, tourist solution, RHD/LHD traffic

+ 63 12 999
Core activity
(-) Affixing adhesive film for tourist solution, driving on
right/driving on left conversion, to headlight
ATTENTION
Use of ordinary commercially available adhesive tape
Damage to plastic lens
Use special black adhesive film for bodywork applications available from
trade outlets.
Cut out the template to the correct size to match the marks on the
headlight from the special adhesive film for changing from driving on
right to driving on left.
Affix the special adhesive film to the headlight at the location indicated.
Cut out the template to the correct size to match the marks on the
headlight from the special adhesive film for changing from driving on
left to driving on right.
Affix the special adhesive film to the headlight at the location indicated.
(-) Removing adhesive film for tourist solution, driving on

right/driving on left conversion, from headlight
ATTENTION
Use of cleaning agents and solvents not in compliance with correct
procedure
Damage to plastic lens
Do not use solvents such as acetone, cellulose thinners or similar.
Do not use cleaning agents such as powder or scouring fluid and
scouring pads or similar.
Remove the adhesive film from the headlight.

Use only a proprietary alcohol-based windscreen cleaning fluid to

remove residues of the adhesive, if necessary.
Follow-up work

63 21 380 Removing and installing or replacing complete rear light

+ 63 21 502
Preparatory work
Removing seat
Core activity
(-) Removing rear-light unit
Remove screws (1).

Remove rear light (2), noting the projection (arrow).
(-) Installing rear-light unit
Install rear light (2), noting the projection (arrow).

Install screws (1).

Connect plug (1).
Follow-up work
Installing seat

65 61 000 Replacing two-way radio box

+ 65 61 500
Core activity
(-) Removing lock for radio-equipment case
Open the radio-equipment case.

Remove screws (1), remove lock (2).
(-) Removing radio-equipment case (empty)
Remove screws (1).

Remove radio-equipment case (2).
(-) Replacing radio-equipment case
Remove screws (1) and remove the trim (2).

Secure trim (2) to the new part.
Tightening torques
Cover to backing plate (radio-equipment case)
TS5 x 12 4 Nm

(-) Installing radio-equipment case (empty)
Hold radio-equipment case (2) in position.

Install screws (1).
Tightening torques
M5 x 12 4 Nm
(-) Installing lock for radio-equipment case
Position lock (2).

Install screws (1).
Tightening torques
M5 x 12 4 Nm
Follow-up work

65 75 020 Replace batteries for control unit of anti-theft alarm system

+ 65 75 520
Preparatory work
Removing seat
Core activity
(-) Replacing batteries in DWA control unit
Removing batteries in control unit for anti-theft alarm system
(DWA)
Remove screws (1) and lift off upper section (2).
Disconnect plug (3) and remove top section (2).
Remove cap (1).

Remove batteries (2).
WARNING
Attempt to charge dry batteries.
Heat development and explosion.

Do not attempt to charge dry batteries.
Dispose of batteries in a manner compliant with national regulations.

Installing batteries in control unit for anti-theft alarm system
(DWA)
Install batteries (2).
Technical data
3V
Install cap (1).
Check gasket (4) for damage; replace if necessary.

Connect connector (3).
Install upper section (2) and secure with screws (1).
Follow-up work
Installing seat

65 75 510 Replacing control unit of anti-theft alarm (without testing software/ programming)
Preparatory work
Removing seat
Core activity
(-) Removing control unit for anti-theft alarm system
Remove screw (1).

Disconnect connector (2).
Remove anti-theft alarm (3).
(-) Installing control unit for anti-theft alarm system
Install anti-theft alarm system (3).

Install screws (1).
Connect connector (2).
Follow-up work

as a separate item)


a separate item)
Installing seat

65 81 050 Replacing ambient-temperature sensor

+ 65 81 550
0539 - On-board computerOE
Core activity
(-) Installing ambient-temperature sensor

Remove ambient-temperature sensor (2).
(-) Installing ambient-temperature sensor
Clip ambient-temperature sensor (2) into position.

Connect plug (1).
Follow-up work

77 02 002 Installing automatic chain-lubrication system

+ 77 02 503
Chain lubrication systemOA
Preparatory work
Core activity
(-) Removing blanking plug from distributor for idle actuator
Using a suitable tool, remove blanking plug (1).
(-) Installing vacuum adapter
Connect vacuum hose (1) to vacuum adapter (2).

Firmly connect vacuum adapter (2) with vacuum hose pointing to the
side to connector (3) of distributor for idle actuator.
(-) Removing voltage regulator with bracket
Remove screws (1).

Leave regulator (2) with bracket connected to the cable and lay it to one
side.

(-) Affixing BMW Motorrad sticker
ATTENTION
Use of unsuitable cleaning and care products
Damage to surfaces
Use a mild solution of soap in water and a soft sponge for cleaning.
Do not use other solvents or fuel.
NOTICE
Faces that will be in contact with the adhesive must be dry, clean and free
from dust and grease.
Clean the surface for gluing.

Peel backing paper off sticker (1).
Affix the sticker in a suitable position given the installed position of oil
tank (2).
(-) Installing oil tank

Assembling holder
Position retaining elements (1) on rubber fitting (2).
Insert screw (3) with washer (4).
Hold bracket (5) in position.
Install nut (6) with washer (7) and tighten until hand-tight.

Insert oil tank (1) (vacuum side to the front and filler adapter facing up)
into bracket (2).
Hold bracket (3) with oil tank in position at mount for voltage regulator
(4).
Seat washer (5) with bracket for voltage regulator (6) on mount for
voltage regulator (4).
Install screws (7).
Tightening torques
Bracket for voltage regulator to frame
M6 x 12 7 Nm
(-) Connecting vacuum hose
Hold vacuum hose (1) against oil-tank port (2) from above and mark.
Cut vacuum hose to marked length.
Connect vacuum hose to oil-tank port (2).
(-) Removing screw from chain guard
Remove screw (1) from chain guard (2).

(-) Installing bracket for supply tube nozzle
Seat supply tube nozzle (1) in bracket (2) and install by tightening hose
clip (3) until hand-tight.
Install screw (4).
Tightening torques
M6 x 50 8 Nm
Position bracket (2) for supply tube nozzle on screw (4) and secure with
nut (5) and washer (6), tightening until hand-tight.
(-) Positioning and securing supply tube nozzle
Requirement
Cut end of the nozzle is facing out.
Lightly rest supply tube nozzle (1) on the flat of the sprocket and
position it as shown in the illustration. Make sure that the supply tube
nozzle does not come into contact with the teeth of the sprocket or the
securing screws.
Tighten hose clip (2).
Counter-hold at screw (3) and tighten nut (4).
Tightening torques
Bracket for supply tube nozzle to swinging arm
M6, when carrying out repairs, 8 Nm
replace nut
(mechanical)

(-) Routing supply hose
ATTENTION
Damage to surfaces
NOTICE
Clean the inner face of rear wheel swinging arm (1).

Peel the backing paper off holder (2) and affix the holder.
Clean surface on rear wheel swinging arm (1) beside chain slide rail (3).
Peel off backing paper and affix holder (4).
Seat hose (5) in holder (2).

Work hose (5) between chain guard (6) and chain slide rail (3) and seat
it in holder (4).
Route hose (5) behind brake line (7) and up over rear frame tube (8).
Route hose (5) between brake line (7) and frame tube (9) to the oil tank.
Connect hose to oil-tank port (10); shorten hose to length beforehand if
necessary.
Secure the hose with the cable ties (arrows).

(-) Installing breather hose
Install rubber adapter (1) on oil tank (2).

Connect breather hose (3) to grommet (4) on rubber adapter.
Route breather hose (3) down so that water cannot enter.
Lightly secure the breather hose with a cable tie (arrow) do not tighten
the cable tie as this could constrict the breather hose to the point at
which it is completely closed.
(-) Aligning and securing oil tank
Align the oil tank (1) and secure it with screw (2) with nut (3).
Tightening torques
Holder for oil tank to bracket
M6 x 40, when carrying out repairs, 8 Nm
replace nut
(mechanical)
(-) Affixing sticker to handlebars
ATTENTION
Damage to surfaces

NOTICE
Clean the surface for gluing.

Peel backing paper off sticker (1).
Affix the sticker at a clearly visible location on the handlebars; the
optimum position depends on the equipment complement of the
motorcycle.
Follow-up work

77 11 010 Installing sports silencer

+ 77 11 510
February 2011
Sports silencerOA
Case carrierOA
Core activity

Remove screw (2) with washer (3) and lay them safely aside; both are
subsequently needed for reassembly.
Remove silencer (4), removing shouldered bushing (5) and laying it
safely aside; the shouldered bushing is subsequently needed for
reassembly.
(-) Installing rubber plug
Install rubber plug (1).
(-) Installing Carbon retaining clamp
Slip Carbon retaining clamp (1) onto sports silencer (2).

(-) Installing sports silencer
Lightly lubricate the contact faces of the sports silencer and exhaust
manifold.
Lubricant
Copper paste 81 22 9 400 794
Fit sports silencer (1) on to the exhaust manifold.

Seat small spacer (2) on Carbon retaining clamp (3) on the inside and
large spacer (4) on Carbon retaining clamp (3) on the outside.
Position shouldered bushing (5) at large spacer (4) and pivot the sports
silencer up between case carrier bow (6) and mounting point (7).
Bring all the components into alignment, making sure that the assembly
is free of strain.
Tighten screw (8).
Tightening torques
M8 x 75 19 Nm
Engage springs (10) with hook (No. 46 5 721).
(-) Checking clearance between sports silencer and case
Requirement
Small and large spacers are positioned as described.
ATTENTION

Hot exhaust gases

Component damage
Install the sports silencer such that the hot exhaust gases are not
discharged toward the number plate or the case.
NOTICE
Check
Check the clearances (arrows) between sports silencer (1) and case (2).
Technical data
Distance between <20 mm
sports silencer and
case
Result:
Clearance between sports silencer and case is below specification.
Measure:
Check the arrangement of the different spacing bushings as per the
construction status
Result:
Clearance between sports silencer and case is below specification.
Measure:
Slacken screw (3).
Slightly turn sports silencer (1) in clamp (4).
Tighten screw (3).
Tightening torques
M8 x 75 19 Nm
Recheck the clearances (arrows) between sports silencer (1) and case
(2).
Technical data
<20 mm

Distance between
sports silencer and
case
Result:
Clearance between sports silencer and case is correct.
Measure:
No action necessary.
Follow-up work

77 14 000 Installing aluminium engine guard

+ 77 14 551
Aluminium engine guardOA
Core activity
(-) Install the aluminium engine guard
Clean the threads.

Screw the long end of engine-guard adapters (1) into the oil pan.
Tightening torques
Hold aluminium engine guard (2) in position on engine-guard adapters

(1) and install nuts (3).
Install screw (4) in tapped bore (5) of aluminium engine guard.
Tightening torques
M8 8 Nm
M8 x 115 8 Nm
Follow-up work

77 14 001 Installing plastic engine guard

+ 77 14 552
engine guardOA
Core activity
(-) Installing engine guard
NOTICE
Select the appropriate procedural steps.
Installing engine guard (with screw)

Clean the threads.
Screw the long end of engine-guard adapter (1) into the oil pan.
Tightening torques
Hold engine guard (2) in position and install nuts (3).

Install screw (4) and nut (5).
Tightening torques
M8 8 Nm
M8 x 115 8 Nm
Installing engine guard (without screw)

Clean the threads.
Screw the long end of engine-guard adapter (1) into the oil pan.
Tightening torques
Hold engine guard (2) in position and install nuts (3).
Tightening torques


M8 8 Nm
Follow-up work

77 14 100 Installing crash bars

+ 77 14 500
Crash barsOA
Core activity
(-) Installing right crash bar
Align right crash bar (1) with the tapped bore in the engine block.
Hand-tighten screw (2).
(-) Installing left crash bar
Introduce left crash bar (1) into the right crash bar (arrow).
Align with the tapped bore in the engine block.
Place washer (3) between lug (4) and engine, install screw (5) and
tighten until hand-tight.
Install screw (6) and tighten until hand-tight.
Install screws (7) and tighten until hand-tight.
(-) Securing crash bar
Bring all the components into alignment.

Tighten screw (1).
Tightening torques
M10 x 20 19 Nm

Tighten screws (2) and (3).
Tightening torques
Crash bar, right, to engine
M8 x 40 19 Nm
M8 x 55 19 Nm
Tighten screw (4).
Tightening torques
M10 x 20 19 Nm
Tighten screws (5) and (6).
Tightening torques
Crash bar, left, to engine
M8 x 16 19 Nm
Tighten screws (7).
Tightening torques
Connection of crash bars
M5 x 16 6 Nm
Tighten screw (8).
Tightening torques
Lug, crash bar
M8 x 25 19 Nm
Follow-up work

77 22 185 Installing heated handlebar grips

+ 77 22 795
Heated handlebar gripsOA
Preparatory work
Removing handlebar weight on the left and right
Core activity
(-) Removing multifunction switch cover
Remove screws (1).

Remove the cover.
(-) Removing throttle twistgrip

Disconnect plug (1) for the multifunction switch.

Remove screw (4).
Remove cover (1).
Disengage throttle cable (2).
Slacken screw (3).
Remove the throttle twistgrip.

(-) Installing throttle twistgrip
ATTENTION
Installation of heated grip not in compliance with correct procedure
Damage to heated-grip line
Remove the throttle-cable cover from the throttle grip only when the
throttle grip is installed on the handlebar.
Push throttle twistgrip onto handlebar with cover (1) and secure with
screw (3).
Remove cover (1) and attach throttle cable (2).
Attach cover (1).
Install screw (4) and tighten.
Tightening torques

Install screws (3).
Tightening torques
KA30 x 10 - 3.6 1 Nm

Turn the throttle twistgrip with the multifunction switch until pin (1)
projects into the gap in the clamp and the multifunction switch is seated
against the handbrake fitting.
Tighten screw (3).
Tightening torques
Clamp, multifunction switch to handlebar
M5 x 20 5 Nm
Clip plugs (1) and (2) into position.
NOTICE
Check

Technical data
rubber grip,
engine
cold max 35 °
C
Result:
stop.
Measure:
(-) Removing left grip
Disconnect multifunction-switch plug (1) and disengage plug (2) for the
heated-grip wiring.
Remove screws (1).


Remove screw (1).

Remove the grip.
(-) Installing left grip
Push the grip onto the handlebar.

Install screw (1).
Tightening torques
Handlebar grip, left, to handlebar
M3.5 x 32 2 Nm
Place new multifunction switch in position.

Install screws (1).
Tightening torques
KA30 x 10 - 3.6 1 Nm

Connect plug (2) of the heated grip.

Clip in plug (1) of the multifunction switch and plug (2).
Manoeuvre the cover into position.

Install screws (1).
Follow-up work
Installing handlebar weight on the left and right
Performing software update with ISTA/P

77 31 143 Installing rear spray guard

+ 77 31 543
Spray guardOA
Core activity
(-) Removing screws from number-plate carrier and rear-wheel
cover
Remove screws (1) from the number-plate carrier.

Remove screws (2).
Remove screws (3).
Remove screws (4).
Remove screws (5).
(-) Removing flat nuts.
Remove flat nuts (1) from rear-wheel cover (2); set the flat nuts carefully
aside for subsequent re-installation.
(-) Finishing to shape
Using a screwdriver, pierce the component at the points indicated by the

shading (arrows).

(-) Installing flat nuts
Slip flat nuts (1) into position on rear-wheel cover (2), pulling the rear-
wheel cover down slightly to facilitate installation.
Push flat nuts (3) onto spray guard (4).
(-) Installing screws in number-plate carrier and rear-wheel

cover
Install screws (1), (2), (3).
Tightening torques
M5 x 12 6 Nm

(-) Installing spray-guard extension
From below, work spray-guard extension (1) into position against

number-plate carrier (2).
NOTICE
Do not attempt to use the brackets of the spray-guard extension as a grip
for recovering the motorcycle or for lifting it onto a stand.
Hold left and right brackets (3) in position.

Install screws (4), (5) and (6) and tighten until hand-tight.
Tighten screws (4).
Tightening torques
Number-plate carrier to rear-wheel cover
M5 x 16 2.5 Nm
Tighten screws (5).
Tightening torques
Spray guard to rear-wheel cover
M5 x 16 2.5 Nm
Tighten screws (6).
Tightening torques
Spray-guard extension to number-plate carrier
M5 x 16 2.5 Nm
Installing lid
Hold lid (7) in position and install screw (8).
Tightening torques

Cover to rear-wheel cover

M5 x 12 6 Nm
Follow-up work

77 32 001 Installing hand protector, left and right

+ 77 32 500
Hand protectorsOA
Core activity
(-) Remove both handlebar weights
Remove screw (1) and remove handlebar weight (2).

Adopt the same procedure to remove the right handlebar weight.
(-) Mounting protector-mounted spoiler on hand protector,

large
Seat protector-mounted spoiler (1) against the contour of hand

protector, large (2).
Using a suitable rest, drill a hole (arrow) at the inside.
Technical data
Hole drilled in HSS drill bit, 5...5.5 mm
protector-mounted dia.
spoiler on hand
protector, large
Install screw (3) with washer (4) and nut (5).
Tightening torques
M5 x 14 3 Nm
(mechanical)
Using a suitable rest, drill a hole (arrow) at the outboard side.

Technical data
Hole drilled in HSS drill bit, 5...5.5 mm
protector-mounted dia.
spoiler on hand
protector, large
Install screw (6) with washer (7) and nut (8).
Tightening torques
M5 x 14 3 Nm
(mechanical)
(-) Mounting hand protector on bow
Push hand protector (1) on to bow (2), making sure that the wording
stamped on the inside is the right way round for legibility.
Install screws (3).
Tightening torques
M5 x 12 3 Nm
(-) Installing bow
Clean the threads.

Seat handlebar weight (3) with milled recess against bow (2).
Seat the bow and handlebar weight against the spacing bushing.
Engage screw (4) in the threads, leaving the screw loose.
Repeat this procedure for the other side.
(-) Installing clamp
Insert nut (1) into clamp half (2).

From the front, seat clamp half (2) against the handlebar.

From the rear, position clamp half (3) against clamp half (2) and engage
screw (4) in the threads, leaving the screw loose.
Repeat this procedure for the other side.
(-) Securing bow to clamp, left
Seat bow (1) against clamp (2) on left, making sure that the lines (arrow)
are routed above the bow.
From the rear, install screw (4) with washer (3), leaving the screw loose.
(-) Securing bow to clamp, right
Seat bow (5) against clamp (6) on right, making sure that the lines
(arrow) are routed underneath the bow.
From the rear, install screw (7) with washer (8), leaving the screw loose.
(-) Securing hand protectors on both sides
Seat the bow of the hand protector against the clutch-lever or brake-
lever fitting, as applicable, and turn it down approximately one
millimetre.
Tighten all the screws, making sure that the bow and the clamp do not
twist out of their original positions.

NOTICE
Check clearance by swinging the handlebars though the full arc of their
travel from lock to lock.
Check the ease of movement of the throttle twistgrip.
Consult an authorised BMW Motorrad dealer if you encounter problems.
Tighten screw (1).
Tightening torques
Screw, clamp in bow
M8 x 25 12 Nm
Tighten screw (2).
Tightening torques
Screw to clamp
M5 x 16 5 Nm
Tighten screw (3).
Tightening torques
encapsulated)
Follow-up work

77 33 025 Installing high windscreen

+ 77 33 525
Windscreen, highOA
Windscreen, tintedOA
Core activity
(-) Removing windscreen

Remove windscreen (3).
(-) Installing windscreen
Hold windscreen (3) in position and secure it with screws (1) and
washers (2).
Tightening torques
M5 x 18 2.5 Nm
Follow-up work

77 40 001 Installing rear softbag

+ 77 40 551
Rear softbagOA
Core activity
(-) Removing screws for number-plate carrier
Remove screws (1) for the number-plate carrier.
(-) Securing rear softbag
Insert spacing bushings (1) into the holes in the number-plate carrier.
Position retainer (2) in line with the holes in rear softbag (3).
Hold rear softbag (3) in position at the spacing bushings.
Slip screws (4) with washers (5) through the holes in the retainer and
the rear softbag and install them in the number-plate carrier and the rear
frame.
Tightening torques
Rear softbag to number-plate carrier and rear frame
M8 x 35 4.0 Nm
Or if motorcycle is fitted with luggage carrier.
Tightening torques
Rear softbag to luggage carrier with number-plate carrier on rear
frame
M8 x 60 4.0 Nm
(-) Packing rear softbag

The full-length zip fastener for the main compartment is water- and dirt-
repellent.
Always place heavy items at the bottom.
Technical data
Payload of rear max 1.5 kg
softbag
Do not exceed the maximum permissible speed for riding with a rear
softbag fitted to the motorcycle.
Technical data
Maximum max 130 km/h
permissible speed
for riding with the
rear softbag fitted to
the motorcycle
Follow-up work

77 40 154 Installing cases/topcase

+ 77 40 554
CasesOA
TopcaseOA
Case carrierOA
Core activity
(-) Installing lock barrel for case or topcase
NOTICE
Never attempt to remove the key from the lock barrel after it has been
removed, because the tumblers would pop out of position.
Hold down latch (1) and pull out carry handle (2).
Insert key (1) into lock barrel (2).

Lubricant
Unirex S 2 83 23 9 416 138
Insert lock barrel (2) with key (1) completely into lock housing (3) and
turn the key clockwise.
Retainer (4) engages (with an audible click).
Lock barrel (2) is secure in lock housing (3) and cannot be pulled out.
(-) Opening cases
Turn key (1) in the case lock to right angles with the forward direction of
travel.
Hold down latch (2) and pull up carrying handle (3).

Press the ribbed part of rocker switch (4).

Hold the rocker switch down and open the lid of the case.
(-) Adjusting case volume
The case is open.

Remove all its contents from the case.
To adjust the volume of the case, engage pivot lever (1) at the top or
bottom limit position, as applicable.
Pivot lever at top limit position: minimum volume.
Pivot lever at bottom limit position: maximum volume.
(-) Preassembling anchorage
The case is open.

Seat both counter-holders (1) (metal to the ribbed side of anchorage) in
anchorage (2).
WARNING
Missing washers or installation of other washers.
Damage to or loss of the case.

Use only the washers supplied as part of the scope of supply.
Install screws (3) with washers (4) in holes (5) in the case bottom.
Position anchorage (2) complete with counter-holders (1) in recess in
case bottom and secure the assembly with screws (3).
(-) Closing cases
Turn the lock with the key until it is at right angles to the forward
direction of travel.
Close case lid (1).
The lid engages with an audible click.
ATTENTION
Closure of carrying handle with case lock latched
Damage to locking tab
Make sure that the case lock is at right angles to the forward direction of
travel when you close the carry handle.
Push carry handle (2) down.

The handle engages with an audible click.
Turn the key in the case lock in line with the forward direction of travel
and remove the key from the lock.
(-) Installing case
travel.
Pull red release lever (4) up.

Latching flap (5) pops up.

Fully open latching flap (5).
Engage anchorage (6) on curved tubular section (7).

Tilt the case up and set it on mushroom head (8), until mushroom head
(8) is at the rear end of anchorage (9).
Then push latching flap (5) down while pivoting red release lever (4)
down.
The latching flap engages.
Make sure that the case is now latched in position on the mushroom
head.
ATTENTION
Closure of carrying handle with case lock latched
Damage to locking tab
Make sure that the case lock is at right angles to the forward direction of
travel when you close the carry handle.
Push the carry handle down until closed.

The handle engages with an audible click.
Turn the key in the case lock in line with the forward direction of travel
and remove the key from the lock.
Adjusting anchorage
Opening cases
travel.


Hold the rocker switch down and open the lid of the case.
Slacken screws (1) at anchorage (6).

Push anchorage (6) down on curved tubular section, making sure that
inboard catch (2) on curved tubular section (7) is in recess (3) in
anchorage (6).
Tighten screws (1).
Tightening torques
Screw in anchorage
M6 8 Nm
WARNING
Case securing not in compliance with correct procedure.
Impairment of road safety.
Cases may not wobble and must be secured free from play. Re-adjust
the retainer if play develops over the course of time.
Do not exceed the maximum permissible payload and the maximum

speed limit.
Technical data

Payload of cases see label in case

Maximum see label in case
permissible speed
for riding with cases
fitted to the
motorcycle
Follow the same procedure to install and adjust the second anchorage
on the other side of the motorcycle.
(-) Removing cases
travel.
Pull red release lever (4) up.

Latching flap (5) pops up.
Fully open latching flap (5).
Take a grip of the carry handle and ease the case clear of the
mushroom head and the curved tubular section.
(-) Opening topcase
Turn key (1) in the topcase lock until it is at right angles to the road
surface.


Hold the rocker down and open the lid of the topcase.
(-) Adjusting topcase volume
The topcase is open.

Remove all its contents from the topcase.
To adjust the volume of the topcase, engage pivot lever (1) at the front
or rear limit position, as applicable.
Pivot lever at rear limit position (toward carry handle): minimum volume.
Pivot lever at front limit position (toward bottom of topcase): maximum
volume.
(-) Closing topcase
Turn the key in the topcase lock to the vertical position.

Close topcase lid (1).
The lid engages (with an audible click).
Push carry handle (2) up.
The handle engages (with an audible click).

Turn the key in the topcase lock to the horizontal position and remove
the key from the lock.
(-) Installing topcase
surface.
Pull red lever (4).

Latching flap (5) is unlocked.
Fully open latching flap (5) with your hand.
Engage the topcase in front holders (6) of the topcase carrier plate.

Push the rear of the topcase onto the topcase carrier plate and engage
latching flap (5).
Push red lever (4) in.
Latching flap (5) is secured.
Check that the topcase is secure.
Close the carry handle and lock the topcase.
Do not exceed the maximum permissible payload and the maximum
speed limit.
Technical data
Payload of topcase see label in topcase
Maximum see label in topcase
permissible speed
for riding with
topcase fitted to the
motorcycle
(-) Removing topcase
surface.
Pull red lever (4).

Latching flap (5) is unlocked.
Fully open latching flap (5) with your hand.

Take a firm grip of the handle and remove the topcase.
Follow-up work

77 42 151 Installing case carrier

+ 77 42 504
February 2011
Case carrierOA
Preparatory work
Removing seat
Core activity
(-) Removing grab handle
Remove screws (1).

Lay the screws safely aside for subsequent re-use.
Remove grab handle (2).
(-) Removing luggage rack
Remove screws (1).

Remove luggage carrier (2), noting the guide (arrow).
CAUTION
Hot exhaust system
Risk of burn injury


Remove silencer (4).
(-) Piercing rear-wheel cover
Pierce rear-wheel cover (1) at the appropriate point (arrows), using

suitable tools.
(-) Installing case carrier
Push retainers (1) of case carrier (2) all the way through the
corresponding openings in the rear-wheel cover (arrows).
Insert screws (3) through the holes in rear frame cross-member (4) and
the holes in retainers (1).
Install nuts (6) with washers (5) and tighten until hand-tight.
On each side, position bracket (7) of the case carrier at the tapped
bores in the rear frame, install screws (8) with washers (9) and tighten
until hand-tight.
Lightly lubricate the contact faces of the silencer and exhaust manifold.

Lubricant
Optimoly TA 18 21 9 062 599
Fit silencer (1) on to the exhaust manifold.

Position shouldered bushing (2) at mount for clamp (3) and pivot the
silencer up between case carrier (4) and mounting point (5).
Install new screw (6) with washer (7).
(-) Installing new case carrier
Guide lugs (1) of the case carrier (2) through the openings in the rear-
wheel cover (arrows).
Slip screws (3) through rear frame cross-member (4) and lugs (1) and
secure with washers (5) and nuts (6).
Hold bracket (7) in position and install with washers (8) and screws (9).
Requirement
New case carrier is installed.
Lubricate the contact faces of silencer (1) and exhaust manifold (2).
Lubricant
Optimoly TA 18 21 9 062 599
Position silencer (1) on exhaust manifold (2).

Position silencer (1) at the rear-frame mount (arrow) and secure with
washer (3) and screw (4).

Tightening torques
M8 x 25 19 Nm
Tightening torques
M8 x 25 19 Nm
Tighten screw (4).
Tightening torques
M8 x 75 19 Nm
Requirement
New case carrier is installed.
Tightening torques
M8 x 25 19 Nm
Tightening torques
M8 x 25 19 Nm
Tighten screw (4).
Tightening torques
M8 x 50 19 Nm
(-) Installing luggage rack
Install luggage carrier (2), noting the guide (arrow).

Install screws (1).

(-) Installing grab handle and mushroom heads
Position rubber pads (1) with grab handle (2).

Install screws (3) and (4).
Tightening torques
M8 19 Nm
M8 x 35 19 Nm
Install plug (5).
Install mushroom heads (1) with screws (2) in grab handle (3).
Tightening torques
Mushroom head to grab handle
M8 x 25 19 Nm
Follow-up work
Installing seat

77 43 125 Install rubber seal for aluminium topcase

+ 77 43 625
Core activity
(-) Position adhesion surface area
Position adhesion surface area (arrow) at the height of the retaining clip.
(-) Press top left rubber seal
Press rubber seal uniformly in the top left corner.
(-) Press rubber seal on the bottom right
Press rubber seal uniformly in the lower right corner.

(-) Align rubber seal
Place rubber seal on the entire profile seal, but do not press in.
(-) Press rubber seal in corners
Press rubber seal uniformly in the remaining top right as well as bottom
left corners.
(-) Press in rubber seal completely
Press rubber seal uniformly starting from the centre on the longitudinal
and transverse sides.
Spread rubber seal smoothly in the same way.
NOTICE

After the installation no unevenness should be visible or feelable on touch.

77 44 046 Installing luggage carrier

+ 77 44 501
Luggage carrierOA
Core activity
(-) Removing screws from grab handle and number-plate
carrier
Remove screws (1) from the grab handle and the number-plate carrier.
(-) Installing luggage carrier
Insert long spacing bushings (1) and short spacing bushings (2).
Hold luggage carrier (3) in position on the spacing bushings.
Install screws (4).
Tightening torques
Luggage carrier to grab handle and number-plate carrier
M8 x 55 19 Nm
Follow-up work

77 44 047 Installing luggage carrier for topcase

+ 77 44 502
Topcase carrierOA
Core activity
(-) Removing screws for grab handles and number-plate
carrier
Remove plugs (1).

Remove screws (2).
(-) Installing luggage carrier for topcase
Insert front spacing sleeves (1) into grab handles (2).

Insert rear spacing sleeves (3) into number-plate carrier (4).
Position luggage carrier for topcase (5) on the spacing sleeves.
Clean the threads.
Apply thread-locking compound to screws (7).
Install washers (6) with screws (7).
Tightening torques
Luggage carrier for topcase to grab handle and number-plate
carrier
M8 x 55 19 Nm
Follow-up work


77 44 055 Installing backrest pad

+ 77 44 555
Backrest pad for topcaseOA
Preparatory work
Opening topcase
Removing lock strip
Core activity
(-) Removing lid finisher
Remove screws (1).

Remove screws (2).
Remove lid finisher (3) from topcase (4), noting the retaining lugs
(arrows).
(-) Installing backrest pad, top, for topcase
Requirement
Rubbing strip resting on a clean, soft surface.
Drill holes at marks (1) in lid finisher (2).
Technical data

Drilling to size HSS drill bit, 5.5 mm

dia.
Position top backrest pad for topcase (3) on lid finisher (2), align it flush
and install screws (4) and tighten until hand-tight.
(-) Installing lid finisher with backrest pad, top, on topcase
Install lid finisher (3) with top backrest pad on topcase (4), noting the
retaining lugs (arrows).
Install screws (2).

Install screws (1).
(-) Installing lock strip
Install lock strip (2) with screws (1).

(-) Closing topcase
Close the topcase, see Rider's Manual.
(-) Installing bottom backrest pad for topcase
Place topcase (1) on its handle side.

Engage screws (2) at the lugs (arrows) in bottom backrest pad (3) and
screw them in slightly.
Position bottom backrest pad (3) at lugs (4) and tighten screws (2).
Follow-up work

77 44 149 Installing topcase carrier

+ 77 44 553
Topcase carrierOA
Core activity
(-) Removing screws from grab handle and number-plate
carrier
Remove screws (1) from the grab handle and the number-plate carrier.
(-) Installing topcase carrier plate
Hold topcase carrier plate (1) in position at the threaded fastener for the
grab handle and the tapped bore for the number-plate carrier.
Tightening torques
Topcase carrier plate to rear frame
M8 x 65 19 Nm
Follow-up work

77 45 002 Installing tank rucksack

+ 77 45 552
Tank rucksackOA
Preparatory work
Removing seat
Core activity
(-) Affixing self-adhesive Velcro strip
Push tabs (1) of the attachment adapter through openings (2) at the
intake air silencer and close the Velcro fastener.
Pull the attachment adapter up and hold it tight against centre trim panel
(3).
Using a pencil and taking care not to damage the paintwork, mark the
top edge of "loop-side" strip (4) of the Velcro fastener on the centre trim
panel.
Release the attachment adapter.
NOTICE
ATTENTION
Restricted retaining force if adhesive not allowed sufficient time to
dry after application of the Velcro attachment
Loose Velcro attachment
Be sure to allow the 24 hours it takes for the adhesive securing the
Velcro pad to cure and reach maximum strength.
Make sure that the ambient temperature is correct.
Technical data
Ambient Make sure 20 °C
temperature for that the
adhesive bond ambient
temperature
is not too low
for the
adhesive to
bond
correctly.
Peel backing (5) off Velcro pad (6) and affix the Velcro pad to the centre
trim panel, making sure that it is centred and correctly positioned along
the top edge of the pencil mark.

Briefly apply firm pressure to press the Velcro strip onto the fuel tank.
(-) Installing attachment adapter
NOTICE
It is not necessary to remove the attachment adapter before riding the
motorcycle without the tank rucksack fitted.
Pull the attachment adapter up and lay it snug against Velcro pad (6)
glued to the centre trim panel.
(-) Installing seat
Engage seat (2) in the holders at the rear.

Engage seat lock (1) by pressing down on the front seat.
(-) Securing tank rucksack
ATTENTION
Dust and dirt between tank rucksack and centre trim panel
Paint damage
Thoroughly clean the top of the centre trim panel and the underside of
the tank rucksack.
Clean the contacting surfaces at regular intervals if the tank rucksack is
in use over a prolonged period of time.
Engage hook (1) in eye (2) of the attachment adapter and allow the tank
rucksack to rest on the centre trim panel.

ATTENTION
Securing of tank rucksack not in compliance with correct procedure
Loose tank rucksack
Tighten the straps in such a way that the tank rucksack is seated safely
and securely on the centre trim panel.
Engage hooks (3) of the straps in holes (4) at the frame.

Tension straps (5) at both sides.
(-) Packing tank rucksack
WARNING
Packing or securing of tank bag not in compliance with correct
procedure.
Before riding off, always check that the tank rucksack is secure and that
there is nothing to obstruct the movement of the handlebars through the
full arc of their travel.
Make sure that the tank rucksack cannot obscure the rider's view of the
vehicle instruments.
Do not exceed the maximum permissible payload for the tank rucksack.
The tank rucksack has a wide-opening top, so it is easy to pack.

Open zip fastener (1) and the drawstring underneath it.
Always place heavy items at the bottom.
Technical data
Payload of tank max 5 kg
rucksack

Do not exceed the maximum permissible speed for riding with a tank
rucksack fitted to the motorcycle.
Technical data
Maximum max 130 km/h
permissible speed
for riding with the
tank bag fitted to the
motorcycle
The interior of the tank rucksack is waterproofed by welded interior liner

(2).
In order to ensure that water cannot seep into the tank rucksack, secure
stopper (3) to snap fastener (4) before closing the lid.
The stowage compartments (5) on the outside are sprayproof.
If liner (3) is not needed to protect the contents against moisture, it can
be buttoned on at the four inside corners (8), making it easier to pack
items in the inside compartment.
(-) Opening and closing map pocket
ATTENTION
Moisture in map compartment in inclement climatic conditions
Damage to electronic devices
Remove electronic devices from the map compartment to the main
compartment.
The lid incorporates a waterproof map pocket (1) made of tough

transparent plastic.
Open zip fastener (2) and open the top.
To insert an MP3 player, a navigation system or a mobile phone, for
example, open zip fastener (3), insert the device into holder (4) provided
for the purpose in the top, and reclose the zip fastener.

Open zip fastener (2) and open the top.

To insert a roadmap, open zip fastener (3), slip the folded map into the
pocket, and reclose the zip fastener.
Follow-up work

77 51 004 Installing headlight guard

+ 77 51 653
headlight guardOA
Core activity
(-) Removing right screw from headlight
Remove right screw (1) with washer (2) from headlight (3).
(-) Installing right holder for headlight guard

Tighten screw (4).
Tightening torques
M8 x 16 8 Nm

(-) Removing left screw from headlight
Remove left screw (1) with washer (2) from headlight (3).
(-) Installing left holder for headlight guard

Tighten screw (4).
Tightening torques
M8 x 16 8 Nm

Requirement
Check
Distances:
Technical data
Distance between 5m
headlight and
vertical surface
For headlight
adjustment
loaded
with 85 kg
Result:
Measure:
Requirement

Start the engine.

slight resistance.
Technical data
loaded
with 85 kg

Tightening torques
M8 x 16 8 Nm
(-) Engaging headlight guard
NOTICE
Use the headlight guard only when off-roading. Riding on public roads
with the headlight guard fitted to the motorcycle is prohibited.
Engage headlight guard (1) in the adapters of the holders.
Follow-up work


77 51 151 Installing LED flashing turn indicators

+ 77 51 651
LED flashing turn indicatorsOA
Preparatory work
Removing seat
Core activity
(-) Removing front flashing turn indicator
On right: disconnect plug (1).
On left: disconnect plug (1).
Remove screw (1) with nut (2).

Remove flashing turn indicator (3), taking care not to place tensile strain
on the cable.

(-) Installing both LED front flashing turn indicators
Insert flashing turn indicator (3) and install screw (1) with nut (2).
Tightening torques
Flashing turn indicator to side panel, front
M6 x 20 2.5 Nm
On left: connect plug (1) and secure it.
Connect and secure plug (1).

(-) Removing both rear flashing turn indicators
Cut through the cable ties (arrows) and disconnect plug (1).
Remove screw (1).

Remove flashing turn indicator (2), taking care not to place tensile strain
on the cable.
(-) Installing both LED rear flashing turn indicators
Route the plug into position and install LED flashing turn indicator (2)
with screw (1).
Tightening torques
Flashing turn indicator to rear side panel
M6 x 20 2.5 Nm

Connect plug (1) and secure the excess cable with cable ties (arrows).
Follow-up work
Performing software update with ISTA/P
Installing seat

77 52 012 Installing Smartphone Cradle

+ 77 52 512
Smartphone CradleOA
Preparatory work
Removing seat
Core activity
(-) Removing screws for left handlebar clamping block
NOTICE
In order to retain the basic setting of the handlebars unchanged, always
slacken only one side of the handlebar clamping block.
Remove screws (1) for left handlebar clamping block.
(-) Installing securing screws for left handlebar clamping block
Clean and lubricate the securing screws.

Install the mounting bolts in the left handlebar clamping block; begin by
installing front mounting bolt (2) and then install rear mounting bolt (3).
Tightening torques
Lubricate screw, Lubricant (MP 3 sequence: in the
paste) forward direction
of travel, tighten
until seated
25 Nm

(-) Removing screws for right handlebar clamping block
NOTICE
In order to retain the basic setting of the handlebars unchanged, always
slacken only one side of the handlebar clamping block.
Remove screws (1) for right handlebar clamping block.
(-) Install the securing screws for right handlebar clamping

block

Install the mounting bolts in the right handlebar clamping block; begin by
installing front mounting bolt (2) and then install rear mounting bolt (3).
Tightening torques
Lubricate screw, Lubricant (MP 3 sequence: in the
paste) forward direction
of travel, tighten
until seated
25 Nm
(-) Securing holder on securing screws
Insert spacing bushings (1) into rubber grommets (2).

Install holder (3) with screws (4) and washers (5) on mounting bolts (6).
Tightening torques
M5 x 16 5 Nm
(-) Smartphone Cradle Installation
Remove screws (1) and clamping block (2) with transverse axis (3) from
holder (4).
Remove nuts (1) and bolts (2).

Disconnect clamping block upper section (3) and -lower section (4) and
remove transverse axis (5) and keep them safely aside (will be
reused).
Position new clamping block lower section (1) and new clamping block
upper section (2) centred at cross-member (3).
Position Smartphone Cradle (4) on the new clamping block upper
section (2).
Install Smartphone Cradle (4) with screws (5).
Tightening torques
Smartphone Cradle to bracket

M4 x 30 2 Nm
Insert mounting elements (1) with mounted Smartphone Cradle (2) into
the holder (3).
Position Smartphone Cradle (2) and install it with screws (4).
Tightening torques
Cross-member to bracket top section
M5 x 12 5 Nm
(-) Exposing optional-accessories connector
Pull optional-accessories connector (1) out of the holder (arrow) and

remove protective cap (2).
(-) Routing the access line for Smartphone Cradle
WARNING
Steering angle constrained by routing of cables or Bowden cables
not in compliance with correct procedure.
Check the freedom of movement of the handlebars.

Route access line (1) through guide clip (2) and secure with cable strap
to mounting bolt (3).
Connect connector for Smartphone Cradle (1) with optional

accessories connector (2) and secure to battery holder (3).
Secure connector for additional power supply (5) (with protective cap) to
battery holder (3).
Secure the access line (1) with cable straps (arrows).
Follow-up work
Installing seat

77 52 200 Installing retrofit kit, navigation system

+ 77 52 700
Core activity
(-) Removing screws of left handlebar clamping block
NOTICE
In order to ensure that the handlebars do not slip out of position, slacken
only one handlebar clamping block at a time.
Remove screws (1) from the left handlebar clamping block.
(-) Installing securing screws in left handlebar clamping block

Install the securing screws in the left handlebar clamping block; begin by
installing front securing screw (2) and then install rear securing screw
(3).
Tightening torques
Lubricate screw, Lubricant sequence: tighten
(Optimoly TA) the front screw (as
viewed in the
forward direction
of travel) first, then
the rear screw.
25 Nm
(-) Removing screws of right handlebar clamping block
NOTICE

In order to ensure that the handlebars do not slip out of position, slacken
only one handlebar clamping block at a time.
Remove screws (1) from the right handlebar clamping block.
(-) Installing securing screws in right handlebar clamping

block

Install the securing screws in the right handlebar clamping block; begin
by installing front securing screw (2) and then install rear securing screw
(3).
Tightening torques
Lubricate screw, Lubricant sequence: tighten
(Optimoly TA) the front screw (as
viewed in the
forward direction
of travel) first, then
the rear screw.
25 Nm
(-) Mounting holder on securing screws
Push spacing bushings (1) into rubber grommets (2).

Use screws (4) to secure holder (3) to securing screws (5).
Tightening torques
Follow-up work

77 52 225 Installing retrofit kit, power supply for navigation system

+ 77 52 725
Preparatory work
Removing seat
Core activity
(-) Exposing optional-accessories connector
Pull optional-accessories connector (1) out of the holder (arrow) and

remove protective cap (2).
(-) Connecting connecting cable to optional-accessories

connector
Push plug (1) onto the plug mount (arrow) on the battery holder until it
engages.
Connect optional-accessories connector (2) to plug (1).
(-) Routing connecting cable
Turn the handlebars all the way to the right.

Secure connecting cable (1) to battery lead (2) with a cable tie (arrow).

Work the connecting cable forward underneath the fork bridge and
secure it to both Bowden cables with a cable tie (arrow).
Work the connections (arrows) on the connecting cable singly up

through holder (3) on the fork bridge.
Mounting Advanced Mount Cradle on holder
If the connecting cable for the BMW Motorrad Navigator is installed,

prior to assembly insert round plug (1) of the connecting cable into
Advanced Mount Cradle (2).
When connecting, note coding (3) of plug and socket.
Use screws (4) to secure Advanced Mount Cradle (5) to holder (6).
Tightening torques
Advanced Mount Cradle to holder
M4 x 25 2 Nm

Mounting BMW Motorrad Navigator on Advanced Mount Cradle

Connecting plug of integrated connecting cable
Before installing the BMW Motorrad Navigator, connect plug (1) of the
integrated connecting cable.
Slacken screw (1) at the top.

Pull up latch (2) at the top of the Advanced Mount Cradle until it
engages; a red bar is visible on the latch.
Position BMW Motorrad Navigator (3) on projections (4) at the bottom.
Pins (6) on the Advanced Mount Cradle must be seated in holes (5) in
the BMW Motorrad Navigator.
Push down latch (2) at the top of the Advanced Mount Cradle until it
engages; make sure that the red bar is no longer visible.
Tighten screw (1).
Before setting off with the BMW Motorrad Navigator not installed,
secure unconnected end (7) of the connecting cable to holder (8) am
Advanced Mount Cradle as described.

WARNING
Steering angle constrained by routing of cables or Bowden cables
not in compliance with correct procedure.
Check the freedom of movement of the handlebars.
Loop the excess length of cable and secure it to the brake line with a
cable tie (arrow).
Follow-up work
Installing seat

BMW F 650 GS, K72 0218

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BMW F 650 GS, K72 0218

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BMW-Motorrad - 0218 - F 650 GS, K72

Technical data 0218 - F 650 GS

0774 - Seat, lowOE

0499 - Lowered suspensionOE

0703 - Power reductionOE

00 - Maintenance and general notes

Designation Precondition Value Valid

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

Technical data 0218 - F 650 GS

0703 - Power reductionOE

Designation Precondition Value Valid

Engine design Two-cylinder four-stroke, DOHC with

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

Wear, from top max 82.03 mm

Wear limit max 2.5 mm

Wear limit max 1.8 mm

092017 BMW Motorrad, UX-VA-4 2/4

Radial play of big-end bore of When new 0.044...0.08 mm

092017 BMW Motorrad, UX-VA-4 3/4

Exhaust valve stem diameter When new 4.963 mm

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

Technical data 0218 - F 650 GS

Designation Precondition Value Valid

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

Technical data 0218 - F 650 GS

Designation Precondition Value Valid

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

Technical data 0218 - F 650 GS

Designation Precondition Value Valid

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

Technical data 0218 - F 650 GS

Designation Precondition Value Valid

General consumable (Antifreeze and corrosion inhibitor)

Coolant, total capacity 1.65 l

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

Technical data 0218 - F 650 GS

Designation Precondition Value Valid

Wear limit min 3.4 mm

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

Technical data 0218 - F 650 GS

Designation Precondition Value Valid

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

Technical data 0218 - F 650 GS

Designation Precondition Value Valid

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

Technical data 0218 - F 650 GS

Designation Precondition Value Valid

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

Technical data 0218 - F 650 GS

0499 - Lowered suspensionOE

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

Designation Precondition Value Valid

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

Technical data 0218 - F 650 GS

Designation Precondition Value Valid

34 11 - Front wheel brakes

Brake disc diameter, front 300 mm

092017 BMW Motorrad, UX-VA-4 1/2

Brake disc diameter, rear 265 mm

092017 BMW Motorrad, UX-VA-4 2/2

Technical data 0218 - F 650 GS

Designation Precondition Value Valid

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

Technical data 0218 - F 650 GS