BMW R1250 GS Adventure K51 11 Service Manual

BMW
MOTORRAD
BMW R1250 GSAdventure

K51/11
(0J51/0J53/0J50/0J54)
Repair Guide
BMW Motorrad
General Information
Repair Guide
BMW Motorrad
BMW-Motorrad - R 1250 GS Adventure
Technical data - R 1250 GS Adventure

Equipment trim-level variant:
0770 - China exportNV
0703 - Power reductionOE
0739 - Brazil exportNV
11 - Engine
Designation Precondition Value Valid

Engine design Air/liquid-cooled, two-cylinder four-
stroke opposed-twin engine with two
overlying, spur-gear-driven
camshafts, a counterbalance shaft
and BMW ShiftCam variable intake
camshaft control
Guide value for carbon monoxide at engine speed 1050 max 0.00 %
concentration (CO) in exhaust gas +100
min-1
−100
Running-in speeds Odometer <5000 min-1

reading 0...1000 km
Odometer No full load
reading 0...1000 km
Guide value for concentration of at engine speed 1050 max 1.19 ppm
hydrocarbons (HC) in exhaust gas +100
min-1
−100
Maximum engine speed max 9000 min-1

Displacement 1254 cm3
Piston stroke 76 mm
Compression test pressure Good min 14 bar
Normal 10...14 bar
Poor <10 bar
Idle speed Engine at regular 1050 min-1
operating temperature
Torque at engine 140 Nm
– with power reductionOE (0703)
speed 5000 min-1
at engine 143 Nm
– with China exportNV (0770)
speed 6250 min-1
Press loss Engine at regular max 25 %
through valves or cylinder operating temperature
Engine type A74B12M

Nominal capacity at engine 79 kW
speed 7750 min-1
at engine 100 kW
speed 7750 min-1
Engine number location Crankcase, bottom right, below
starter motor
Compression ratio 12.5:1
Maximum noise limit for tests Measured with vehicle at max 91.20 dB (A)
a standstill, at a distance
of 0.5 m from the
exhaust system in the
sense of standard NBR-
9714, at engine
rpm 3875 min-1
Cylinder bore 102.5 mm
Engine oil, capacity with filter change approx. 4 l
052021 BMW Motorrad, UX-VA-4 1/5

Engine oil, capacity with filter change max 4 l
Specification (SAE 5W-40, API SL / JASO MA2, Additives (e.g. molybdenum-based) are
not permissible because they can attack coated components of the engine,
BMW Motorrad recommends BMW Motorrad ADVANTEC Ultimate oil.)
Engine oil, specified level between MIN and MAX mark
Engine oil, quantity for topping up Difference between MIN max 0.8 l
and MAX
11 11 - Engine block
Total wear clearance between piston max 0.08 mm
and cylinder
Permitted out-of-roundness of from top edge 20 mm max 0.010 mm
cylinder bore from top edge 100 mm max 0.015 mm
Cylinder bore When new 102.500+0.005 mm
−0.005
Wear limit max 102.530 mm

11 12 - Cylinder head with cover
Inside diameter of valve guide 5.500...5.507 mm
Wear limit, tilt clearance, valve to at valve lift 10+0.1 mm max 0.40 mm
valve guide −0.1
11 21 - Crankshaft with bearings

Radial play of crankshaft guide 0.041+0.016 mm
bearing −0.016
Colour codes of crankshaft bearing Crankcase yellow Bearing shells yellow

shells Crankcase green Bearing shells, green
Crankcase violet Bearing shells violet
Crankshaft yellow Bearing shells yellow
Crankshaft green Bearing shells, green
Crankshaft violet Bearing shells violet
Radial play of crankshaft main When new 0.041+0.016 mm
bearing −0.016

Endplay of crankshaft When new 0.075...0.259 mm
ID marks of crankshaft baring Colour mark on outside yellow/green/violet
Mark for classification of the A: Mark/colour point Y (yellow) / G (green) / V (violet)
crankshaft bearings near oil pump
to identify the bearing shells in the left in direction of travel, Guide bearing, front (three parts)
crankcase front
in direction of travel, rear Main bearing, rear (single part)
Marks on crankshaft A front: Identification for Yellow/green/violet dots

to identify the bearing shells in the right guide bearing
right crankcase / the connecting rod (three parts)
bearing shells B inside: near blue/red dots
corresponding
crankshaft journals:
identification for
connecting rod bearing
Yellow/green/violet dots

C rear: identification for
right main bearing
(single part)
11 24 - Conrod with bearings

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

coding on the
connecting rod foot
Conrod endplay When new 0.130...0.312 mm

ID mark for conrod weight classes Labelling on the big end 0 ... 4
(on 4th position)
ID mark for conrod weight classes Connecting rod weight 542.0...547.9 g

class 0: colour points 2 x
white
Connecting rod weight 548.0...553.9 g
blue
white
yellow
class 4: colour point 1 x
blue
Colour codes, conrod bearings Connecting rod hole red/ Bearing shell red
Assignment, conrod/conrod cap crankshaft journal red
Connecting rod hole Bearing shell blue
blue/ crankshaft journal
blue
Connecting rod hole Bearing shell violet
blue/ crankshaft journal
red
Connecting rod hole red/ Bearing shell violet
crankshaft journal blue
Colour codes, conrod bearings red/violet/blue dots
Assignment, conrod/conrod cap

Radial play of small-end bearing bore When new 0.015...0.030 mm

Overview of conrod marks A Correlation, conrod bearing cap to
conrod
B Weight class
C Hole diameter
D Production date
11 25 - Piston with rings and bolts

Piston, installed direction Arrow in direction of travel
Piston-pin radial play in piston When new 0.005...0.015 mm
Piston diameter When new 102.475+0.012 mm
−0.012
Wear limit min 102.4 mm

Piston installation clearance 0.008...0.052 mm
Piston ring float When new 0.05+0.02 mm
−0.02
1st groove
Piston ring shape B-ring with symmetrically curved
1st groove friction face and inside chamfer (top)
Piston ring height When new 1.03+0.01 mm

−0.01
1st groove
Piston ring end gap When new 0.20...0.35 mm
1st groove Wear limit max 0.40 mm
−0.025
2nd groove
Piston ring shape Taper-face compression ring
2nd groove
−0.01
2nd groove
Piston ring end gap When new 0.45+0.1 mm
−0.1
2nd groove
−0.02
3rd groove
Piston ring shape Oil scraper ring with coil spring
3rd groove
−0.01
3rd groove
Piston ring end gap When new 0.30+0.1 mm
−0.1
3rd groove
Piston-ring direction of installation "Top" marking uppermost
11 31 - Camshaft
Endplay of camshaft When new 0.05...0.25 mm

Radial play of camshaft When new 0.020...0.071 mm
Backlash of camshaft sprocket 0.003...0.020 mm
Radial clearance of the intermediate Specified value 0.016...0.060 mm
shaft axle Wear limit min 0.060 mm
11 33 - Rocker/follower with bearing
Cam-follower endplay 0.10...0.30 mm
11 34 - Valves with springs
Inlet valve clearance Engine cold 0.10...0.17 mm
Valve spring length relaxed 46.21+0.5 mm
−0.5
Exhaust valve clearance Engine cold max 35 °C 0.34...0.41 mm

Inlet valve clearance Engine cold max 35 °C 0.10...0.17 mm
11 40 - Oil supply
Oil pressure at idle speed 1+0.5 bar
−0.2
Engine oil is at regular operating
temperature - at engine 4.5+0.5 bar
speed min 5000 min-1
−0.5


12 - Engine electrical system

12 12 - Ignition lead, spark plugs
Electrode gap of spark plug when new 0.8+0.1 mm
−0.1
Wear limit 1.0 mm

Spark plugs, manufacturer and NGK LMAR8AI-10
designation
12 31 - Alternator with drive and fasteners
Alternator speed for start of charge Idle speed
Alternator current at engine rpm 6000 min 35 A
-1
Alternator - rated current at idle speed 23 A

Gear ratio of alternator 1:1


0780 - EU market exportNV
0739 - Brazil exportNV
0760 - Thailand exportNV
13 - Fuel preparation and control

Alternative fuel grade Normal unleaded (with power loss)
– with EU market exportNV (0780)
maximum 15 % ethanol, E15
91 ROZ/RON
87 AKI
Normal unleaded (power- and
– with Brazil exportNV (0739)
consumption-related restrictions.) min
15 %, max 30 % ethanol, or
E20/E22/E27
91 ROZ/RON – with Thailand exportNV (0760)
87 AKI
Recommended fuel grade Super unleaded maximum 15%
ethanol, E15
95 ROZ/RON
90 AKI
Super unleaded minimum 15%,
maximum 30% ethanol, E27
95 ROZ/RON
90 AKI
13 53 - Injection nozzles and lines
Fuel pressure of the injection system 4+0.5 bar
−0.5


16 - Fuel supply

Usable fuel capacity approx. 30 l
Reserve fuel approx. 4 l
Permitted fuel filling quantity during transportation max 5 l
16 14 - Delivery, preparation and measurement, control unit, fuel pump
Operating pressure of fuel pump approx. 5 bar


17 - Cooling

Cut-in temperature for coolant 118 °C
temperature warning
Cooling system test pressure Test pressure must 1.5 bar
remain
unchanged: min 5 min
Coolant, specified level Engine cold Between MIN and MAX marks on the
expansion tank
Coolant capacity total in coolant circuit 1.5 l

in expansion tank 0.25 l
General consumable (Antifreeze and corrosion inhibitor)
Coolant, frost protection Silicate radiator min −25 °C
protective agent
17 40 - Fan
Cut-in temperature for radiator fan 105 °C


21 - Clutch

Clutch type Multiplate oil-bath clutch, anti-hopping
Clutch actuation Hydraulic
Clutch-fluid level (repairs) with new clutch liner, Mark in reservoir
reservoir horizontal
Hydraulic fluid (Hyspin V10)
21 21 - Clutch with driver plate

Thickness of one lined plate When new 3.0 mm
Wear limit measured 2.85 mm
through friction lining
Backlash of clutch cage 0.003...0.025 mm


23 - Gearbox

Type of transmission Claw-shift 6-speed gearbox with
helical gearing
23 22 - Gears
Gearbox transmission ratios Primary transmission 1.000 (60:60 teeth)
ratio
Transmission input ratio 1.650 (33:20 teeth)
1st gear 2.438 (39:16 teeth)
2nd gear 1.714 (36:21 teeth)
3rd gear 1.296 (35:27 teeth)
4th gear 1.059 (36:34 teeth)
5th gear 0.943 (33:35 teeth)
6th gear 0.848 (28:33 teeth)
Transmission output 1.061 (35:33 teeth)
ratio
23 41 - External gearshift components
Selector-rod length 107.3+0.5 mm
−0.5
Distance between two ball-head
centrelines


0191 - Dynamic ESAOE
31 - Front axle, front-wheel steering

Spring travel, front at wheel 210 mm
Type of front suspension BMW Telelever, with anti-dive top fork
bridge, trailing arm mounted on
engine and telescopic forks, central
spring strut supported by trailing arm
and frame
Fork oil, capacity per fork leg approx. 485 ml
Telescopic fork oil (Telescope fork oil type 1)
Fork oil fill level measured from top 135+2 mm
edge, without fixed fork −2
tube
31 31 - Spring strut
Design of front wheel suspension Central shock absorber complete with
torsion spring and header tank,
electrically adjustable decompression
and compression-stage damping


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

Type of rear suspension Cast aluminium single swinging arm
featuring BMW Motorrad Paralever
Rear axle differential oil SAE 70W-80 / Hypoid Axle G3
Type of final drive Shaft drive with bevel gears
Bevel gears, oil capacity Initial filling 200 ml
Gear oil (Hypoid Axle Oil G3)
Bevel gears, oil capacity Oil change 180 ml
33 54 - Spring strut, mounting parts
Spring travel at rear wheel 220 mm
Type of rear-wheel suspension Central spring strut with coil spring
and reservoir, electrically adjustable
rebound-.stage and compression-
stage damping, electrically adjustable
spring preload
33 74 - Bevel gears, rear
Gear ratio of final drive 2.91 (32/11 teeth)


34 - Brakes

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

Brake-pad material, front Sintered metal
Brake-pad wear limit, front Friction pad only, 1.0 mm
without backing plate.
The wear indicators
(grooves) must be
clearly visible.
Type of front brake Hydraulically operated twin disc brake

with 4-piston radial brake calipers and
floating brake discs
Brake disc lateral runout, front At circumference max 0.15 mm
Brake disc diameter, front 305 mm
Brake disc thickness, front Wear limit min 4 mm
Brake disc thickness, front When new 4.5 mm
Wear limit 4 mm
Play of brake controls On the piston 1.6...2.1 mm
Front brake
34 21 - Rear wheel brakes
Brake-pad material, rear Sintered metal
Type of rear brake Hydraulically actuated disc brake with
2-piston floating caliper and fixed disc
Brake disc lateral runout, rear at outside max 0.35 mm
circumference,
components cooled
Brake disc diameter, rear 276 mm
Brake disc thickness, rear Wear limit min 4.5 mm
Brake disc thickness, rear When new 5 mm
Play of brake controls at piston approx. 1 mm
Rear brake
Brake-pad wear limit, rear Friction pad only, 1.0 mm



35 - Foot operation

35 21 - Footbrake lever, connecting linkage
Blow-by clearance of the footbrake between the frame and 1...1.5 mm
lever the footbrake lever


36 - Wheels and tyres

36 23 - Electronic components
Wheel-speed sensor, rear 0.1...1.6 mm
Distance from sensor ring
Wheel-speed sensor, front 0.1...1.4 mm
Distance from sensor ring
36 30 - Motorcycle wheels
Balance weight for rear wheel max 80 g
Weights have to be affixed with one
half on the left and one half on the
right, in other words centred on the
rim
Permissible rear-wheel imbalance max 45 g
Balance weight for front wheel max 80 g
rim
Permissible front-wheel imbalance max 5 g
36 31 - Wheels with bearings
Rear-wheel type Cross-spoked wheel
Front-wheel type Cross-spoked wheel
Rear wheel rim size 4.50" x 17"
Vertical runout, rear wheel max 1.7 mm
Vertical runout, front wheel max 1.7 mm
Lateral runout, rear wheel max 1.7 mm
Lateral runout, front wheel max 1.7 mm
Front-wheel rim size 3.0" x 19"
36 32 - Tyres
Speed category, front/rear tyres required at V
least 240 km/h
Tyre designation, rear 170/60 - R17
Wheel valve test pressure 4 bar
Recommended tyre combinations An overview of currently approved
tyres is available from your authorised
BMW Motorrad Retailer or on the
Internet at bmw-motorrad.com.
Attention, tyre pressure for spoke 4.0 bar
tension check
Tyre pressure, rear tyre cold 2.9 bar
Tyre pressure, front tyre cold 2.5 bar
Tyre tread depth, front and rear For Germany only min 1.6 mm
Outside Germany Country-specific legal requirements
Load index, rear tyre min. 72
Load index, front tyre min. 60
Tyre designation, front 120/70 - R19


46 - Frame and mounted components

46 51 - Motorcycle frame
Position of the vehicle identification Frame, front right below steering
number head
Frame type Tubular steel frame with supporting
drive unit, steel pipe rear frames
Type plate location Right lower frame tube


0531 - HP batteryOE
61 - General vehicle electrics

61 13 - Plug, terminal
Fuse carrier 1 Slot 1: Instrument 10 A
cluster, anti-theft alarm
(DWA), ignition lock,
diagnostic socket
Slot 2: Left multifunction 7.5 A
switch, tyre pressure
monitoring (RDC)
Fuse holder Fuse 1: Voltage 50 A
regulator
Electrical rating of on-board sockets total for all sockets max 5 A
61 21 - Battery with holder
Battery type Lithium ion battery
Battery rated capacity 10 Ah
Battery rated voltage 12 V


0590 - LED flashing turn indicatorOE
0562 - Additional headlightOE
LED additional headlightOA
63 - Lights

63 10 - Front lights, position lights and side lights
Bulb for parking light LED
63 12 - Headlight
Distance between headlight and 5m
vertical surface
For headlight adjustment
Distance between headlight and 10 m
vertical surface
Bulbs for the low-beam headlight LED
Bulb for high-beam headlight LED
Distance from light/dark limit to upper ESA mode "1-up without 5 cm
edge of low-beam headlight light- cases - Comfort" and
emitting surface vehicle loaded
with 85 kg
63 13 - Flashing turn indicators, front
Bulbs for turn indicators LED
63 17 - Foglights, additional lights
Distance between auxiliary headlight 5m
and vertical surface
Distance between light/dark cut-off Vehicle loaded with 10 cm
and mark at height of centre of 85 kg
auxiliary headlight
63 21 - Rear light cluster
Bulb for tail light/brake light LED
63 23 - Flashing turn indicators, rear
Bulbs for flashing turn indicators, rear LED


65 - Audio, navigation, information systems

65 75 - Anti-theft alarm
Activation time on arming approx. 30 s
Alarm duration approx. 26 s
Battery type CR 123 A
Battery type CR 1632
for remote control


0193 - Keyless RideOE
66 - Cruise control, remote control

66 10 - Electronic closure systems
Range of the Keyless Ride radio- approx. 1 m
operated key
66 12 - Radio-controlled locking system
Battery type CR 2032
For Keyless Ride radio-operated key


Tank bagOA
77 - Optional accessories, motorcycle

77 40 - Luggage system
Maximum permissible speed for max 160 km/h
riding with softbag for rear seat fitted
to the vehicle
Volume of the softbag for rear seat without capacity approx. 14 l
extension
Capacity extension approx. 6 l
Payload of the softbag for rear seat max 5 kg
77 41 - Case, liner
riding with aluminium cases fitted to
the motorcycle
Payload per aluminium case max 10 kg
77 43 - Topcase, liner
riding with aluminium topcase fitted to
the motorcycle
Maximum speed for riding with max 180 km/h
Topcase 2 large, 50 l
Payload of aluminium topcase max 5 kg
Payload of Topcase 2 large, 50 l max 5 kg
77 45 - Tank rucksack
Tank rucksack volume Without extension pack approx. 12 l
– with tank bagOA
Extension pack approx. 4 l
Capacity of the tank rucksack, small approx. 5 l
Payload of tank rucksack max 5 kg

Tightening torques - R 1250 GS Adventure

11 - Engine Value Valid
Coolant drain plug in crankcase
M10 x 1 10 Nm
Coolant filler adapter in crankcase
M10 x 1 5 Nm
Bracket, engine guard to crankcase
M8 x 25 19 Nm
Anti-twist plate (friction bearing) to crankcase
M6 x 25 12 Nm
Assembly of crankcase
M10 x 130 Tightening torque, 25 Nm
Additional angle of rotation, 90°
M6 x 30 10 Nm
M8 x 80 19 Nm
Diaphragm valve to crankcase
M6 x 16 12 Nm
Engine guard on holder
M6 x 20 8 Nm
Oil drain plug to crankcase
M20 x 1.5 42 Nm
Threaded plug (connection for oil pressure measurement) in crankcase
M10 x 1 10 Nm
Threaded plug for locking at TDC in crankcase
M16 x 1.5 30 Nm
Retaining bracket on bearing bracket
M6 x 35 10 Nm
Camshaft bearing cap to cylinder head
M6 x 35 Tightening sequence: tighten
alternately
10 Nm
Oil filler screw in cylinder head cover
M34 x 1.5 8 Nm
Cylinder head to crankcase
M10 x 110 - 10.9 Tightening sequence: tighten in
diagonally opposite sequence
1st tightening torque, 5 Nm
2nd tightening torque, 20 Nm
3rd tightening torque, 40 Nm
M6 x 25 12 Nm

M6 x 95 12 Nm
Cylinder head cover to cylinder head
M6 10 Nm
11 14 - Housing cover
Oil reservoir of front lid
M5 x 16 5 Nm
Crankcase cover to crankcase
M6 x 20 Tightening sequence: See repair
manual
10 Nm
11 15 - Crankcase breather
Breather cover to gearbox cover
M6 x 20 12 Nm
Breather wheel to crankshaft
M10 x 25 41 Nm
11 24 - Conrod with bearings
Conrod bolt
M10 x 1 x 50 - 13.9, Replace screw 1st tightening torque, 5 Nm
Thread and seating face of the screw oiled 2nd tightening torque, 20 Nm
Slacken and then retighten the bolt
1st tightening torque, 5 Nm
11 26 - Starter freewheel, layshaft
Shaft for starter double gear to crankcase
M6 x 80, Replace screw 8 Nm
Thread-locking compound (micro-encapsulated)
Shaft for starter idler gear to crankcase
Left-hand thread, M20 x 1.5 18 Nm
Sleeve (axial stop, freewheel gear) to crankcase
M6 x 50, for re-use 10 Nm
Thread-locking compound (Loctite 243, Medium strength)
Freewheel housing to alternator
M8 x 16 - 12.9 35 Nm
11 31 - Camshaft
Sensor for camshaft sensor to camshaft (clamp)
M5 x 20 - 10.9 8 Nm
Chain tensioner to cylinder
M18 x 1.5 32 Nm
Timing-chain rails to crankcase
M8 19 Nm
Screw for intermediate shaft axle in cylinder head
M6 x 14 8 Nm

Sprocket to intermediate shaft
M6 x 12 10 Nm
Camshaft sprocket to camshaft
Exhaust, right, M10 x 1.25 x 25 - 10.9 65 Nm
other camshafts, M10 x 1.25 x 35 - 10.9 60 Nm
11 41 - Oil pump with strainer and drive
Oil-pump cover to crankcase
M6 x 16 12 Nm
Oil-pump pinion to oil-pump shaft
M6, Replace nut 10 Nm
Thread-locking compound (mechanical)
Oil intake in crankcase
M6 x 20, Replace screws 8 Nm
Threaded plug for oil pressure control valve in crankcase
M24 x 1.5 42 Nm
11 42 - Oil filter and lines
Oil filter to crankcase
Coat seal with engine oil 11 Nm
Oil filter adapter to crankcase
M20 x 1.5 35 Nm
11 51 - Coolant pump with drive
Coolant pump to crankcase
M6 x 40 12 Nm
11 53 - Thermostat and on-engine coolant lines
Coolant adapter to crankcase
M6 x 16 12 Nm
Coolant adapter for thermostat to crankcase
M6 x 16 12 Nm
11 78 - CO adjustment, oxygen sensor
Oxygen sensor to exhaust manifold
M18 x 1.5 45 Nm
Lubricate thread, Lubricant (Optimoly TA)
Oxygen sensor after catalytic converter
M12 x 1.25 25 Nm
Lubricate thread, Lubricant (Optimoly TA)
11 84 - Engine and powerplant protection parts
Engine protection bar to frame/engine
M10 x 45 Tightening sequence: 1. rear
bottom with frame to engine
55 Nm
M8 x 30 Tightening sequence: 2. front top
to frame
19 Nm
M10 x 45 Tightening sequence: 3. front
bottom to engine

55 Nm
Tank guard to bracket
M8 x 40 19 Nm
E.g. bracket of rear engine guard to e.g. crankcase
M8 x 25 19 Nm


12 - Engine electrical system Value Valid
Spark plug to cylinder head
M10 x 1 12 Nm
12 13 - Ignition coil
Ignition-coil cover to cylinder head
M5 x 20 5 Nm
12 31 - Alternator with drive and fasteners
Coil carrier to crankcase
M6 x 20 12 Nm
Rotor to crankshaft
M24 x 1.5 1st tightening torque, 150 Nm
Thread-locking compound (Loctite 270, High strength) slacken completely
Stator to coil carrier
M6 x 40 10 Nm
Thread-locking compound (Loctite 270, High strength)
12 32 - Regulator
Voltage regulator to rear-wheel cover
M5 x 25 5 Nm
12 41 - Starter with fastener
Starter to gearbox cover
M6 x 35 12 Nm
Wiring harness (ground) to starter
M6 x 10 8 Nm
Wiring harness (positive) to starter
12 61 - Oil pressure, oil temperature, oil-level indicators
Oil-level sensor to gearbox cover
Oil temperature sensor to crankcase
M12 x 1.5 14 Nm
12 62 - Coolant temperature
Coolant-temperature sensor to coolant port
M12 x 1.5 15 Nm
12 72 - Transmitter for control unit
Camshaft sensor to cylinder head
M6 x 16 8 Nm
Crankshaft sensor on crankcase
M6 x 14 8 Nm
Knock sensor to cylinder head
M8 x 30 20 Nm


13 - Fuel preparation and control Value Valid
13 63 - Electromechanical switchgear
Switching cam adjuster to cylinder head
M6 x 20 10 Nm
13 64 - Injection valves, start valves
Cover for injection valve to cylinder head
M5 x 20 5 Nm
13 71 - Intake air silencer
Intake air silencer to tank bracket
M6 x 25 8 Nm
Air filter cover to intake air silencer
M5 x 50 Tightening sequence: in diagonally
opposite sequence
3 Nm
13 72 - Air filter
opposite sequence
3 Nm


16 - Fuel supply Value Valid
16 11 - Fuel tank with filler neck
Tank bracket to frame
M6 x 12 8 Nm
Fuel tank to frame
M8 x 45 19 Nm
Fuel filler cap to fuel tank
M5 x 28 4 Nm
M8 x 40 19 Nm
Tank guard to engine protection bar
M8 x 16 19 Nm
16 14 - Delivery, preparation and measurement, control unit, fuel pump
Fuel pump to fuel tank
M5 x 16 Tightening sequence: tighten in
5 Nm
Fuel pump electronics to pump unit
Screw for plastic, 3.5 x 14 0.7 Nm


17 - Cooling Value Valid
17 11 - Radiator with fasteners
Radiator/tank guard bracket to front panel carrier/frame
Special thread for light alloy, 6 x 25 12 Nm
17 13 - Expansion tank
Expansion tank to intake air silencer
Screw for plastic, 5.5 x 16 4 Nm


019A - HP Sports silencerOE
Sports silencerOA
18 - Exhaust system Value Valid

18 51 - Exhaust system parts with mountings
Cover for exhaust-flow control valve to exhaust manifold
Cover to silencer / exhaust manifold
M5 x 10 Tightening sequence: 1.Exhaust
manifold, 2.top silencer, 3.bottom
silencer
5 Nm
Cover on silencer/exhaust manifold
M5 x 10 Tightening sequence: 1. exhaust
manifold, 2. silencer (top),
3. silencer (bottom)
5 Nm
Plastic cover to silencer
Bracket for exhaust manifold to gearbox cover
M8 x 20 19 Nm
Manifold to cylinder head
M8 21 Nm
Mount for servomotor to gearbox cover
M6 x 25 8 Nm
Clamp to silencer and exhaust manifold
19 Nm
Silencer to rear frame
M8 x 35 19 Nm
Clamp to silencer
M5 x 16, Renew screw 8 Nm
Bowden cable to exhaust-flow control valve
M6 5 Nm


21 - Clutch Value Valid
21 21 - Clutch with driver plate
Mounting plate to clutch hub
M6 x 30 10 Nm
lubricate with engine oil
Clutch cage to balancing shaft
M36 x 1.5, Renew nut, thread is free of grease 1st tightening torque, 170 Nm
Thread-locking compound (micro-encapsulated) Slacken the nut, angle of rotation, 90°
Clutch hub to layshaft
M20 x 1.5, Replace nuts and lubricate with engine oil Tightening torque, 150 Nm
Fully slacken nut
Tightening torque, 150 Nm
21 52 - Clutch actuation (hydraulics)
Bleed screw to clutch slave cylinder 5 Nm
Clutch line to clutch lever fitting
M10 x 1 7 Nm
Clutch line to clutch slave cylinder
M10 x 1 7 Nm
Clutch slave cylinder to gearbox cover
M6 x 20 Tightening sequence: Tighten the
screws twice
8 Nm


0222 - Shift assistant ProOE
Shift assistant ProOA
23 - Gearbox Value Valid

23 11 - Housing with cover
Gearbox cover to crankcase
M6 x 25 10 Nm
Shift-mechanism cover to gearbox cover
M6 x 20 10 Nm
23 12 - Bearing in housing, sealing rings
Retaining plate for fixed mount to gearbox cover
Inside, M6 x 16, Replace screw Tightening torque, 8 Nm
Thread-locking compound (micro-encapsulated) Additional angle of rotation, 90°
outer, M6 x 25, Replace screw Tightening torque, 8 Nm
Retaining plate for free bearing to crankcase
Countersunk-head screw, M6 x 16 10 Nm
Retaining plate for free bearing (transmission output shaft) to crankcase
M6 x 18 10 Nm
23 14 - Electrical components
Gearbox potentiometer to gearbox cover
M5 x 14 - 10.9 5 Nm
23 21 - Gearbox shafts
Bearing to countershaft
M20 x 1.5, Replace screw 100 Nm
23 31 - Internal gearshift components
Locking lever on gearbox cover
M6 x 18 Tightening torque, 8 Nm
Retaining plate for selector drum to gearbox cover
M6 x 16, Replace screw Tightening torque, 8 Nm
23 41 - External gearshift components
Shift lever (pinch bolt) to selector shaft
Ball joint to shift rod
Locknut, M6 8 Nm
Ball end to shift lever
M8 19 Nm
Pro shift assistant to selector shaft
M5 x 20, Renew screw and washer 10 Nm

Gearshift lever to frame
M8 x 25 19 Nm
Peg (clamp) to shift lever
M6 x 16 8 Nm


31 - Front axle, front-wheel steering Value Valid

31 42 - Telescopic forks
Stud bolts in fork bridge
M14 x 1.5 130 Nm
or, Thread-locking compound (Loctite 243, Medium strength)
Fork bridge, top, to fork fixed tube
M10 x 1.25, Replace nut 40 Nm
Fork bridge, lower, to slider tube
M8 x 35 Tightening sequence: Tighten

screws six times in alternate
sequence
19 Nm
Clamping screw for quick-release axle in telescopic fork
M8 x 35 19 Nm
Ball joint to leading link
Leading link to engine
M14 x 1.5 120 Nm
Screw plug to seal plug
M4 x 8, Replace O-ring 2.5 Nm
Spring strut, front, to leading link
M10 x 55 - 10.9, Replace screw 56 Nm
Spring strut, front, to frame
ride-height sensor to tank bracket
M5 5 Nm
Actuator rod to ride-height sensor
M6 8 Nm


32 - Steering and wheel alignment Value Valid
32 71 - Motorcycle handlebars
Hand protector to bracket
M5 x 14.5 2 Nm
Handlebar weight to handlebars
M10 x 50 38 Nm
Clamping block (handlebar clamp) to fork bridge
M8 x 35 Tightening sequence: in the
forward direction of travel, tighten
until seated
19 Nm
32 72 - Handlebar lever
Cap to reservoir
M4 x 16 2.5 Nm
Handlebar fitting to handlebar
M6 x 30 Tightening sequence: tighten top
until fully closed
8 Nm
Lever to handlebar fitting
M5, Replace nut Tightening sequence: Tighten the
Thread-locking compound (mechanical) nut, counter-holding the bolt
7 Nm
32 76 - Steering damper
Steering damper to fork bridge
Steering damper to leading link


33 - Rear axle, rear-wheel drive and rear-wheel guidance Value Valid
33 35 - Rear wheel swinging arm with pivot mount, link
Bevel gears to swinging arm
M12 x 1.5, Renew screw 100 Nm
Locknut (floating bearing stud) to frame
M24 x 1.25 145 Nm
Floating bearing stud (swinging arm) to frame
M24 x 1.25 1st tightening torque, 15 Nm
Lubricate thread and bearing seat, Lubricant (Optimoly TA) 2nd tightening torque, 7 Nm
Fixed bearing stud (swinging arm) to frame, left
M27 x 1.25, Replacing fixed-bearing stud 100 Nm
Paralever strut on bevel gears
M10 x 60 - 10.9 56 Nm
M10 x 60 - 10.9, Replace screws 56 Nm
Spring strut to frame
lubricating, Lubricant (Optimoly TA)
Spring strut to swinging arm
Spray guard to spring strut
M4 x 6 3 Nm
33 74 - Bevel gears, rear
Cover to bevel gears, rear
M8 x 30, Replace screws Tightening sequence: tighten in
33 75 - Housing for bevel gears, rear
Oil drain plug in bevel gears
M12 x 1 20 Nm
Oil filler plug to bevel gears
M12 x 1.5 25 Nm


34 - Brakes Value Valid
Brake caliper on telescopic fork
M10 x 65 38 Nm
Brake disc to front wheel
M8 x 27, Replace screw Tightening sequence: tighten by
Thread-locking compound (micro-encapsulated) stages in diagonally opposite
sequence
19 Nm
Sensor ring to front wheel
M5 x 10 5 Nm
Bleed screw, rear, in banjo bolt
M8 10 Nm
Bleeder screw in the banjo bolt
M8 10 Nm
Grub screw (brake pads) in brake caliper 6 Nm
Brake caliper to telescopic fork
M10 x 65 38 Nm
Brake caliper to bevel gears
Screw dome to bevel gears, M8 x 30, Replace screw 28 Nm
Brake disc to wheel flange
M8 x 15.5, Replace screw Tightening sequence: tighten by
sequence
Additional torque, 30 Nm
Bleed screw in rear brake caliper
M10 x 1 14 Nm
34 31 - Footbrake cylinder, tandem brake master cylinder
Brake-fluid reservoir to frame
M6 x 16 6 Nm
Footbrake cylinder with heel deflector to frame
M6 x 20 8 Nm
Locknut to piston rod (footbrake cylinder)
M8 17 Nm
34 32 - Brake lines
Brake line to fork bridge
Brake hose cover to strut
M5 x 12 5 Nm
Brake hose with banjo bolt to components
M10 x 1 24 Nm
34 51 - Mechanical, hydraulic components
ABS pressure modulator on retainer
M6 x 14.5 8 Nm


35 - Foot operation Value Valid
35 21 - Footbrake lever, connecting linkage
Footbrake lever to frame
M8 x 25 19 Nm


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

Wheel-speed sensor to bevel gears
M6 x 16 8 Nm
Wheel-speed sensor to fork leg
M6 x 16 8 Nm
Micro-encapsulated or medium-strength thread-locking
compound
Cable holder for wheel-speed sensor to telescopic forks
M5 x 10 5 Nm
Cable holder / mounting, sensor ring
M5 x 10 5 Nm
Rear wheel to wheel flange
M10 x 1.25 x 40 Tightening sequence: tighten in
60 Nm
Nipple on spoke
M4 1st tightening torque, 1 Nm
Nipple on spoke tightening torque
M4 5 Nm
Nipple on spoke of pre-torquing
M4 3 Nm
Tyre pressure monitoring (RDC) sensor to wheel rim
Renew nut 6 Nm
Thread locking compound for spoke nipples
Grubscrew, M4 2 Nm
Screw lock for spoke nipple
Set screw, M4 2 Nm
Quick-release axle in the telescopic forks
M12 x 20 30 Nm


0680 - Case holder for aluminium caseOE
Case holder for aluminium caseOA
46 - Frame and mounted components Value Valid

46 51 - Motorcycle frame
Rear frame, top, to main frame
Rear frame, bottom, to main frame
Main frame to engine
top front, M12 x 255 - 10.9, Renew screw 100 Nm
top rear, M12 x 215 - 10.9, Renew screw 100 Nm
Bottom, M10 x 45, Renew screw 55 Nm
46 53 - Side stand
Threaded pin (side-stand spring) in frame
M10 x 1.5 38 Nm
Side stand to pivot mount
Side-stand switch to pivot-bearing screw
Luggage carrier to rear frame
M8 19 Nm
Case carrier to rear frame
top front, M8 x 40, Replace screw 19 Nm
top rear, M8 x 25, Replace screw 19 Nm
front, M8 x 20 19 Nm
Case lock to case bottom
M6 x 55 3 Nm

M6 x 25 3 Nm
Cross-member to case carrier
M8 x 20 19 Nm
Topcase lock to topcase bottom
M5 x 14 4 Nm
Replace nut 4 Nm
46 61 - Front-wheel cover
Front-wheel cover, top, to fairing bracket
M5 x 14.5 2 Nm
Front-wheel cover to telescopic forks/fork bridge
M5 x 14.5 2 Nm
46 62 - Rear-wheel cover, number-plate carrier
Tail section to rear frame
front, M8 x 40, Replace screw 19 Nm
rear, M8 x 25, Replace screw 19 Nm
Rear-wheel cover to rear frame
M6 x 14.5 8 Nm
Number-plate carrier to rear frame
M6 x 17.5 8 Nm
Top, M6 x 14.5 8 Nm
Bottom, M6 x 17.5 8 Nm
Spray guard to bevel gears
46 63 - Motorcycle fairing, windscreen
Trim for coil spring to windscreen adjuster
M6 x 16 5 Nm
Left/Right front panel carrier to centre of front panel carrier (front)
Left/Right front panel carrier to centre of front panel carrier (rear)
Front panel carrier, left/right to frame
Front panel carrier, left/right to front panel carrier, centre
Front, M6 x 16, Replace screw 8 Nm
Rear, M6 x 30, Replace screw 8 Nm
Front panel carrier, centre, to frame
M8 x 55 19 Nm

Screw connection of body
M6 x 25 8 Nm
Trim panels
M5 x 14.5, 3 mm collar 2 Nm
Trim panels
M5 x 17.5, 6 mm collar 2 Nm
Stowage compartment inside to tank cover
Screw for plastic, 4 x 10 1 Nm
Cover for fuel tank, centre, to frame
M6 x 25 8 Nm
Trim panels
M5 2 Nm
Slipstream deflector to holder
M5 x 20 2 Nm
Windscreen to windscreen adjuster
without collar, M5 x 12 4 Nm
Bracket to windscreen and covers
M5 x 12 without collar, 4 Nm
Linear guide to windscreen adjuster
M5 x 10 4 Nm
Radiator shroud to cover for intake air pipe
M5 x 14.5 1.5 Nm
46 71 - Engine fasteners, footrests
Left heel deflector to frame
M6 x 16 8 Nm
Footrest bracket to rear frame


51 - Trim panels Value Valid
51 16 - Mirrors, covers, ashtrays, stowage compartments
Cover cap to mirror
M3 x 5 1 Nm
Adapter to clamping block
M10 x 14 25 Nm
Mirror (locknut) to adapter
M10 x 1.25 Left-hand thread, 22 Nm
Mirror milled to manual controls
M10 x 50 25 Nm
51 25 - Other fasteners
Ignition/steering lock to fork bridge
Non-removable screw, M8, Replace screw 20 Nm


52 - Seats and seat bench Value Valid
52 53 - Seat
Latch, rear seat, to rear carrier
Screw for plastic, 4 x 10 1 Nm
Seat adjuster to frame
M6 x 14.5 8 Nm


0272 - Preparation for navigation systemOE
Preparation for navigation systemOA
0538 - Cruise controlOE
05AC - ABS ProOE
ABS Pro with riding modes ProOA
61 - General vehicle electrics Value Valid

Wiring harness (earth) to crankcase
M6 x 14.5 8 Nm
Cable duct to crankcase
M6 x 16 8 Nm
Wiring harness (ground) to cylinder head
M6 x 10 8 Nm
Battery-positive connection point to battery carrier
M6 x 14 2 Nm
Fuse for voltage regulator to holder
M5 x 8 - 10.9 3.5 Nm
Wiring harness to battery
M6 x 11 8 Nm
61 31 - Switch, sensor
Operating facility for intelligent emergency call to clamp
M5 x 22 3 Nm
Throttle twistgrip to handlebar
M3.5 x 30 2 Nm
Retaining plate (ride-height sensor) to frame
M6 x 35 8 Nm
Ride-height sensor to bracket
M5 x 10 5 Nm
Oval-head screw for thermoplastic plastic 2 Nm
Multifunction switch to grip unit
Cover to multifunction switch
Ball end (actuator rod) to rear wheel swinging arm
M6, Replace screw 8 Nm
Handlebar grip, left, to handlebar
M3.5 x 30 1 Nm
Multi-controller to grip

Clutch switch to handlebar fitting
Ball end (actuator rod) to ride-height sensor
Nut, M6
Ball end, M6, replace 8 Nm
61 33 - Emergency power siren, horn
Horn to front panel carrier
M8 x 18 - 10.9 19 Nm
61 34 - On-board sockets, cigarette lighter
On-board socket to front panel carrier
M18 x 1 3 Nm
61 35 - Control units, module
Impact sensor to bracket
M6 x 20 6 Nm
Holder for impact sensor to tank holder
M6 x 20 6 Nm
M6 x 12 8 Nm
Angular rate sensor to rear-wheel cover
61 36 - Relay
Wiring harness to starter relay


62 - Instruments Value Valid
62 11 - Instrument panel
Glass cover for instrument panel
Screw for plastic, 3 x 12 0.5 Nm


0202 - Daytime riding lightOE
Daytime riding lightOA
63 - Lights Value Valid

63 12 - Headlight
Headlight to front panel carrier
M6 x 20 5 Nm
Daytime running light to headlight
63 13 - Flashing turn indicators, front
Flashing turn indicator to front panel carrier
M6 x 16 4 Nm
63 17 - Foglights, additional lights
Bracket for auxiliary headlight to connecting piece
M5 x 16 4 Nm
Bracket for auxiliary headlight to tank guard
M6 x 30 8 Nm
Bracket for auxiliary headlight to connecting piece
M5 x 10 4 Nm
Adapter to LED auxiliary headlight
Switch for auxiliary headlight to clamp
M5 x 12 2 Nm
Auxiliary headlight to bracket
M6 x 40 6 Nm
63 23 - Flashing turn indicators, rear
Flashing turn indicator to number-plate carrier
M6 x 20 3 Nm


65 - Audio, navigation, information systems Value Valid

65 90 - navigation system
Left retainer to front panel carrier
M6 x 18 8 Nm
Right retainer to front panel carrier
M6 x 16 8 Nm


66 - Cruise control, remote control Value Valid

66 12 - Radio-controlled locking system
Keyless Ride control unit to handlebar bridge
Non-removable screw, M8 x 26, Replace screws 20 Nm


Sports silencerOA
Option 719OA
HP Milled partsOA
Aluminium cylinder-head cover guardOA
Enduro engine guardOA
FootrestOA
Tank bagOA
Headlight guardOA
Cruise controlOA
77 - Optional accessories, motorcycle Value Valid

77 02 - Maintenance and Technology
Adapter for variable height stand to engine screw connection
M12 100 Nm
Adapter plate to variable height stand
M10 x 70 40 Nm
77 11 - Exhaust system
Heat protection cover to exhaust manifold
M5 x 12 3 Nm
Sports silencer to rear frame
M8 x 35 19 Nm
Sports silencer to exhaust manifold 19 Nm
M8 22 Nm
77 12 - Housing cover, cover, cover panel
Ignition coil cover to cylinder head cover
M6 x 20 10 Nm
Slip pad to HP cylinder head cover
M6 x 20 4 Nm
Cylinder-head cover guard to crankcase
M5 x 12 5 Nm
Cylinder-head cover guard to cylinder head cover
M6 10 Nm
77 14 - Engine guard, crash bars
Pipe clamp with retaining plate to frame tube
M6 x 16 8 Nm
Enduro engine guard to retaining plate
M6 x 16 8 Nm
Enduro engine guard to bracket
M6 x 25 8 Nm
77 15 - Gearbox, mounted parts

Cover for rear axle Machined
Tightening sequence: 1.
10 Nm
Tightening sequence: 2.
15 Nm
77 25 - Frame, footrests, mounted parts
Mount to carrier
M8 x 25 20 Nm
Footrest on clamping block
M6 x 20 / M6 x 12 10 Nm
Peg to footbrake lever
M6 x 20 10 Nm
Peg to gearshift lever
M6 x 20 10 Nm
Clamping block on footrest hinge
M8 x 25 20 Nm
Clamping block to footrest
M8 x 20 20 Nm
Abrasion protection to footrest
M4 x 8 3 Nm
Mirror on handlebars
M10 x 50 25 Nm
Clamping bolt for peg
M6 x 20 10 Nm
77 30 - Mounted parts, trim panels
Cover for hole for grab handle to rear frame
M8 x 25 8 Nm
77 41 - Case, liner
Closure unit to aluminium case
self-tapping screw for plastic 3 Nm
77 42 - Mounted parts, cases
Cap to footrest plate
M4 x 12 1.5 Nm
77 44 - Mounted parts, topcase, luggage carrier
Cover to carrier plate
M5 x 14.5 2 Nm

Carrier plate to rear frame
M8 x 35 19 Nm
M8 x 50 19 Nm
77 45 - Tank rucksack
Front attachment for tank rucksack to frame
M6 x 28 8 Nm
77 49 - Other luggage system
Tightening the adapter plate
M6 x 40 8 Nm
77 51 - Lights
Bracket to cockpit fairing
M5 x 17.5 2 Nm
Bracket, LED auxiliary headlight to front panel carrier
M6 x 30 8 Nm
Spacer studs to headlight guard
M6 x 10 2.5 Nm
Trim for daytime riding light to front panel carrier
M5 x 20 2 Nm
LED auxiliary headlight to bracket
M6 x 40 6 Nm
77 53 - Switches, small items, control unit
Additional switch to clamping block
M5 x 12 2 Nm

Service data - R 1250 GS Adventure


11 - Engine
Running-in speeds Odometer <5000 min-1
reading 0...1000 km
Odometer No full load
reading 0...1000 km
Engine oil, capacity with filter change approx. 4 l
Engine oil, specified level between MIN and MAX mark
1134 - Valves with springs

Inlet valve clearance Engine cold max 35 °C 0.10...0.17 mm
Exhaust valve clearance Engine cold max 35 °C 0.34...0.41 mm
1212 - Ignition lead, spark plugs
Spark plugs, manufacturer and NGK LMAR8AI-10
designation
17 - Cooling
Cooling system test pressure Test pressure must 1.5 bar
remain
Coolant, specified level Engine cold Between MIN and MAX marks on the
expansion tank
21 - Clutch
Clutch-fluid level (repairs) with new clutch liner, Mark in reservoir
reservoir horizontal
33 - Rear axle, rear-wheel drive and rear-wheel guidance

Bevel gears, oil capacity Oil change 180 ml
34 - Brakes
Brake fluid level, front Brake-fluid reservoir It is impermissible for the brake fluid
horizontal, motorcycle level to drop below the MIN mark.
upright

Brake fluid level, rear Brake-fluid reservoir The brake fluid level may not drop
horizontal, motorcycle below the MIN mark.
upright
3411 - Front wheel brakes

Brake disc thickness, front When new 4.5 mm
Wear limit 4 mm
Brake-pad wear limit, front Friction pad only, 1.0 mm
The wear indicators
(grooves) must be
clearly visible.
3421 - Rear wheel brakes

Brake-pad wear limit, rear Friction pad only, 1.0 mm
Brake disc thickness, rear When new 5 mm

3630 - Motorcycle wheels
Permissible front-wheel imbalance max 5 g
Permissible rear-wheel imbalance max 45 g
Balance weight for rear wheel max 80 g
rim
Balance weight for front wheel max 80 g
rim
3631 - Wheels with bearings
Vertical runout, front wheel max 1.7 mm
Lateral runout, front wheel max 1.7 mm
Vertical runout, rear wheel max 1.7 mm
Lateral runout, rear wheel max 1.7 mm
3632 - Tyres
Tyre tread depth, front and rear For Germany only min 1.6 mm
Outside Germany Country-specific legal requirements

Wheel valve test pressure 4 bar
6312 - Headlight
Distance between headlight and 5m
vertical surface
Distance from light/dark limit to upper ESA mode "1-up without 5 cm
edge of low-beam headlight light- cases - Comfort" and
emitting surface vehicle loaded
with 85 kg
Threaded plug for locking at TDC in crankcase
M16 x 1.5 30 Nm
M8 x 25 19 Nm
M20 x 1.5 42 Nm
Engine guard on holder
M6 x 20 8 Nm
M6 10 Nm
M6 x 35 Tightening sequence: tighten
alternately
10 Nm
11 31 - Camshaft
other camshafts, M10 x 1.25 x 35 - 10.9 60 Nm
Sensor for camshaft sensor to camshaft (clamp)
M5 x 20 - 10.9 8 Nm
M18 x 1.5 32 Nm
11 42 - Oil filter and lines
11 84 - Engine and powerplant protection parts
M10 x 45 Tightening sequence: 1. rear
bottom with frame to engine
55 Nm
M8 x 30 Tightening sequence: 2. front top
to frame
19 Nm
M10 x 45 Tightening sequence: 3. front
bottom to engine
55 Nm

M8 x 40 19 Nm
M10 x 1 12 Nm
12 41 - Starter with fastener
M6 x 35 12 Nm
13 71 - Intake air silencer
M6 x 25 8 Nm
opposite sequence
3 Nm
16 11 - Fuel tank with filler neck
Fuel tank to frame
M8 x 45 19 Nm
M8 x 16 19 Nm
17 11 - Radiator with fasteners
17 13 - Expansion tank
18 51 - Exhaust system parts with mountings
M6 x 25 8 Nm
21 52 - Clutch actuation (hydraulics)
Clutch slave cylinder to gearbox cover
M6 x 20 Tightening sequence: Tighten the
screws twice
8 Nm
M10 x 1 7 Nm
M10 x 1 7 Nm
Bleed screw to clutch slave cylinder 5 Nm
31 42 - Telescopic forks

M8 x 35 Tightening sequence: Tighten

screws six times in alternate
sequence
19 Nm
32 71 - Motorcycle handlebars
M10 x 50 38 Nm
M8 x 35 Tightening sequence: in the
forward direction of travel, tighten
until seated
19 Nm
M5 x 14.5 2 Nm
32 72 - Handlebar lever
M6 x 30 Tightening sequence: tighten top
until fully closed
8 Nm
33 75 - Housing for bevel gears, rear
M12 x 1 20 Nm
M12 x 1.5 25 Nm
M8 x 27, Replace screw Tightening sequence: tighten by
sequence
19 Nm
Brake caliper on telescopic fork
M10 x 65 38 Nm
M8 10 Nm
Screw dome to bevel gears, M8 x 30, Replace screw 28 Nm
M10 x 1 14 Nm
Brake disc to wheel flange
M8 x 15.5, Replace screw
Tightening sequence: tighten by
stages in diagonally opposite
sequence
Additional torque, 30 Nm
M12 x 20 30 Nm
M10 x 1.25 x 40 Tightening sequence: tighten in
60 Nm
Nipple on spoke
M4 1st tightening torque, 1 Nm
Grubscrew, M4 2 Nm
Renew nut 6 Nm
46 53 - Side stand
46 62 - Rear-wheel cover, number-plate carrier
M6 x 17.5 8 Nm
Top, M6 x 14.5 8 Nm
Bottom, M6 x 17.5 8 Nm
46 63 - Motorcycle fairing, windscreen

M6 x 25 8 Nm
51 16 - Mirrors, covers, ashtrays, stowage compartments
Mirror (locknut) to adapter
M10 x 1.25 Left-hand thread, 22 Nm
Adapter to clamping block
M10 x 14 25 Nm
Wiring harness (ground) to cylinder head
M6 x 10 8 Nm
M6 x 11 8 Nm
61 31 - Switch, sensor
65 90 - navigation system
M6 x 18 8 Nm
M6 x 16 8 Nm

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

+ 11 00 567
Preparatory work
Removing left engine protection bar
Removing left cover for spark plug
Removing left direct ignition coil
Removing left spark plug
Remove the right protection bar
Removing right cover for spark plug
Removing right direct ignition coil
Removing right spark plug
Core activity
(-) Testing compression
Connect diagnosis adapter M10 with non-return valve (No. 11 7 846) to

hose, tightening until (No. 11 7 842) hand-tight.
In measuring device, select the function "Preset measurements - Pressure -
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 compression pressure on the measuring device.
Technical data
Compression test Good min 14 bar
pressure Normal 10...14 bar
Poor <10 bar
Result:
Compression not OK
Measure:
Pinpoint the cause of the fault.
Possible causes:
Valves leaking
Piston and cylinder leaking
Cylinder-head gasket defective
Follow-up work
Installing left spark plug
Installing left direct ignition coil
Installing left cover for spark plug
Installing left crash bar
Installing right spark plug
Installing right direct ignition coil

Installing right cover for spark plug
Install the right crash bar
Removing battery cover
Connecting BMW Motorrad diagnostic system to vehicle
Performing vehicle test with BMW Motorrad diagnostic system
Disconnecting BMW Motorrad diagnostic system from vehicle
Install the battery cover
Final check of work performed

11 00 045 Testing for pressure loss with BMW Motorrad diagnostic system
+ 11 00 568
Preparatory work
Removing threaded plug from bore for locating pin
Lock the crankshaft in TDC position
Core activity
(-) Checking pressure loss
In measuring device, select the function "Preset measurement - Pressure -

Pressure loss".
Connect a 0-25 bar pressure sensor to the measuring device.
Connect adapter for loss of pressure (No. 11 7 841) to the measuring
device.
Connect the compressor adapter for pressure loss (No. 11 7 841) and set to
the reference pressure.
Secure diagnosis adapter M10 without non-return valve (No. 11 7 843)
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 shutoff tap on adapter for pressure loss (No. 11 7 841) and check
for loss of pressure with the measuring device.
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
Follow-up work

Removing crankshaft locking device
Installing threaded plug in bore for locating pin
Performing vehicle test with BMW Motorrad diagnostic system

11 00 050 Removing/installing engine

+ 11 00 541
Preparatory work
Removing engine guard
Draining engine oil
Removing front seat
Removing fuel-tank cover
Removing left tank guard
Removing right tank guard
Removing left side panel
Removing left air guide
Removing right side panel
Removing right air guide
Removing fuel tank
Disengaging and draining coolant expansion tank
Disengaging left radiator
Disengaging right radiator
Removing right injection valve
Disconnecting the plug connection for the right switching cam adjuster
Disengaging right throttle-valve assembly
Disconnect right knock sensor
Removing left injection valve
Disconnecting the plug connection for the left switching cam adjuster
Disengaging left throttle-valve assembly
Disconnect left knock sensor
Remove the intake air silencer
Disconnecting plug for fuel-pressure sensor
Removing silencer cover
Removing silencer
Release and disconnecting the right oxygen sensor connector
Disengaging servomotor for exhaust-flow control valve
Disengaging bracket for exhaust manifold
Disconnect the plug for left oxygen sensor
Disengaging cable duct

Removing exhaust manifold
Draining coolant
Disengaging selector rod
Disconnecting plug for switch for side stand
Removing side-stand springs
Removing threaded pin for tension springs
Disengaging connector for tank vent valve
Disconnect battery from vehicle
Removing engine control unit
Removing left cover
Releasing starter cable (positive terminal) from starter motor relay
Removing cover for ride-height sensor
Disengaging rear ride-height sensor with bracket
Disengaging alternator cable
Installing engine lifter
Removing spray guard
Removing rear brake caliper
Disengaging Paralever link from bevel gears
Strapping down motorcycle at rear
Disengaging thermostat
Core activity
(-) Remove the engine
Release clamp (1) with pliers (No. 17 5 571).

Disconnect return hose (2).
Unclip ball socket (1) from ball head (2).

Disengage attachment rod (3).
Remove cover caps (1).

Remove bolt (6).
Remove nut (3) and washer (4) .
Remove axle (5) and contact disc (4).
Remove axle (2).
Securing vehicle to crane, if necessary

Install guide (No. 46 0 831) on both sides.
The vehicle can be secured with straps (arrows) to crane (No. 46 5 670) and
moved.
Remove the nut (1).

Remove axle (2).
Remove screws (1).
Protect the components from damage by affixing masking tape (arrow).

Optimoly TA 18 21 9 062 599
Raise the swinging arm with scissor-type lifter (No. 00 1 571).

Turn universal shaft (1) until the splines (arrows) engage.
Push universal shaft (1) all the way on to gearbox output shaft (2).
Lubricate mating face (1) of flexible gaiter (2).
Lubricant
Staburags NBU 30 PTM 07 55 9 056 992
Check that plastic insert (3) is correctly seated at flexible gaiter (2); correct if
necessary.
Install flexible gaiter (2) complete with plastic insert (3), making sure
positioning (arrow) is correct.
Plastic insert (3) engages
Remove adhesive tape (4).
Install the cable tie (arrow).
Lubricate axle (1).
Lubricant
Optimoly TA 18 21 9 062 599
Install axle (1).
Insert axle (1) and nut (2) and tighten hand-tight.

Install axle (3) and insert screw (4) and tighten hand-tight.

Insert screws (1) and tighten until hand-tight.
Install nuts (1), bolts (2) and (3) and nut (4).
Tightening torques
Main frame to engine
top front, M12 x 255 - 10.9, Renew 100 Nm
screw
Thread-locking compound (micro-
encapsulated)
top rear, M12 x 215 - 10.9, Renew 100 Nm
screw
encapsulated)
Bottom, M10 x 45, Renew screw 55 Nm
Install bolt (5).
Tightening torques
M14 x 1.5 120 Nm
Install cover caps (1).

Position jointed rod (1), arm (2) must point to the front.
Clip ball socket (3) into ball head (4).
Connect return hose (2).

Secure clamp (1) with pliers (No. 17 5 571).
Follow-up work
Removing straps
Securing Paralever link
Securing rear brake calliper
Installing spray guard
Removing engine lifter
Installing engine control unit
Securing alternator cable
Securing starter cable (positive terminal) to starter motor relay
Securing rear ride-height sensor with bracket
Installing cover for ride-height sensor
Installing left cover
Connect battery with vehicle
Routing and securing connector for tank vent valve
Securing thermostat
Installing exhaust manifold
Securing bracket for exhaust manifold
Securing servomotor for exhaust-flow control valve
Connect and secure right oxygen sensor connector
Connecting plug for left oxygen sensor
Installing silencer
Install the silencer cover
Securing selector rod
Installing threaded pin for tension springs
Installing side-stand springs
Connecting plug for switch for side stand
Securing cable duct
Checking routing of tank ventilation hose/overflow hose
Connecting plug for fuel-pressure sensor
Install the intake air silencer
Connect left knock sensor
Securing left throttle-valve assembly
Connecting the plug connection for the left switching cam adjuster
Secure the left injection valve
Connect right knock sensor
Securing right throttle-valve assembly
Connecting the plug connection for the right switching cam adjuster
Securing right injection valve
Securing right radiator
Secure the left radiator
Installing fuel tank
Filling cooling system
Securing expansion tank for coolant
Filling expansion tank
Checking coolant level
Installing left air guide
Installing left side panel
Installing right air guide
Installing right side panel
Installing right tank guard
Installing left tank guard
Installing fuel-tank cover
Installing front seat

Checking, if necessary correcting date
Pouring engine oil into engine
Installing engine guard
Calibrating ride-height sensor
Reading fault memory with BMW Motorrad diagnostic system and
resetting adaptation values

11 00 103 Disassembling and assembling engine (engine removed)

+ 11 00 648
NOTICE
The length of the timing chains varies, the left timing chain is the longer timing
chain.
Preparatory work
Securing engine to engine holder
Removing oil-level sensor
Removing engine breather
Installing crankshaft locking device at BDC
Removing camshaft sensor
Removing front crankcase cover
Removing pressure plate
Removing clutch plates
Removing clutch hub
Removing clutch hub plate
Removing gearbox
Installing crankshaft locking device at TDC
Removing clutch cage
Removing balancing weight
Removing breather wheel
Removing coil carrier
Removing magnetic wheel
Removing gearwheel, starter freewheel
Removing left cylinder head cover
Removing left timing-chain tensioner
Removing the left switching cam adjuster
Remove left retaining bracket for axial fixation
Removing left camshaft bearing cap
Removing left camshafts
Removing sprocket for left intermediate shaft
Removing left cylinder head
Removing right cylinder-head cover
Removing right chain tensioner
Removing the right switching cam adjuster of the camshaft
Remove right retaining bracket for axial fixation
Removing right camshaft bearing cap

Removing right camshafts
Removing sprocket for right intermediate shaft
Removing right cylinder head
Removing right timing-chain rails
Removing starter idler gear
Removing starter double gear
Removing right timing chain
Removing left timing-chain rails
Removing left timing chain
Removing cam followers
Removing valves
Removing valve stem seals and spring retainers
Core activity
(-) Removing oil filter
Remove oil filter (1), using oil filter wrench (No. 11 4 650).
Dispose of the oil filter (1) in an environmentally friendly manner.
(-) Removing oil pump
Remove nut (1), driver (2) and pinion (3).
Remove screws (1).

Remove oil pump cover (2), if necessary pry off at the tabs (arrows), using a
suitable tool.

Pull out oil pump (1) complete with rotor and shim on shaft (2) and remove.
Remove outer rotor (3).
(-) Removing coolant pump
Remove screws (1).

Remove coolant pump (2).
(-) Removing left piston pin
By turning the crankshaft, position piston (1) in such a way that gudgeon pin
(2) is visible through bore hole at front.
Information on removing circlip

If opening of circlip (1) lies above recess (arrow) of piston (2), it must be
turned before removal.

Install insert (No. 11 0 933) in puller (No. 11 0 931).
Insert puller (No. 11 0 931) with insert and turn it until insert engages (No.
11 0 933) in opening of circlip.
Turn puller (No. 11 0 931) with circlip by at least 90°.
Remove insert (No. 11 0 933) from puller (No. 11 0 931).
Insert puller (No. 11 0 931) and turn it until the lever engages with an
audible click in the cut-out (arrows).
Remove circlip (1) with puller (No. 11 0 931).

Remove gudgeon pin (1) with mounting tool for gudgeon pins (No. 11 0
932).
(-) Removing crankshaft sensor
Remove bolt (1).

Remove crankshaft sensor (2) with O-ring (3).
(-) Separating halves of engine block
Remove screws (1).
Remove screws (1), (2) and (3).

Remove screws (1).
Remove wing screws (1).

Remove counter support (2).
Remove axles (3) and (4).
ATTENTION
Engine block tilted on removal or installation
Damage to bearing shells
Do not tilt the engine block in the process of removal or installation.
Remove left crankcase half (5).
Remove O-ring (1).
Install axles (1) and (2).

Install bushes (3) and (4) of engine holder (No. 11 0 832).
Install counter support (5).
Install wing screws (6).

(-) Removing oil intake pipe
Remove screws (1).

Remove oil intake pipes, pressure stage (2) and intake stage (3).
(-) Removing diaphragm valve
Remove screws (1).

Remove panels (2).
Remove diaphragms (3).
Remove screws (1).

Using a suitable tool, remove lid (2).
(-) Removing crankshaft
ATTENTION

Cracked connecting rod installed twisted or in reverse order.
Component damage
Mark connecting rod and connecting rod bearing cap during removal and
install according to the marks.
Remove screws (1) and dispose of them correctly.

Remove connecting rod bearing cap (2).
Remove connecting rod (3).
Remove crankshaft (4).
(-) Removing crankshaft bearing shells
Carefully remove main bearing shells (1) and thrust bearing shells (2) at the
positioner (arrow).
(-) Removing balancing shaft
Remove thrust washer (1) and counterbalance shaft (2).
(-) Removing piston
Remove right piston (1) with conrod (2).

Remove left piston (1).
(-) Removing right conrod
Remove circlips (1).

Remove piston pin (2).
Remove conrod (3) from piston (4).
(-) Removing conrod bearing shells
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 conrod bearing shells (1) from conrod (2) and conrod bearing cap
(3), using a suitable tool.
(-) Removing housing sealing plugs

(-) Installing crankshaft
Oil the tyre treads (arrows) of crankshaft (1) and bearing shells (2).
Install crankshaft (1).
Position connecting rod (3) on crankshaft (4).

ATTENTION
Component damage
Install connecting rod bearing cap with bearing shells (2).

Use an electronic torque wrench/angle-of-rotation tightening tool when
tightening.
Workshop equipment
Electronic torsion-angle wrench
Install screws (1).
Tightening torques
Conrod bolt
M10 x 1 x 50 - 13.9, Replace screw 1st tightening torque,
Thread and seating face of the screw 5 Nm
oiled 2nd tightening torque,
20 Nm
Additional angle of
rotation, 150°
Slacken and then
retighten the bolt
1st tightening torque,
5 Nm
2nd tightening torque,
20 Nm

Additional angle of
rotation, 150°
(-) Joining crankcase sections
Install new O-ring (1).

Remove bushes (3) and (4) of engine holder (No. 11 0 832).
Clean the sealing surface (1).

Apply sealing compound (arrow) evenly over clean and grease-free sealing
surface (1).
Sealant
Dow Corning 07 58 0 397 777
ATTENTION
Place left crankcase half (5) in position.

Install screws (1) and tighten until hand-tight.

Install screws (1) (2) and (3) until hand-tight.

tightening.
Workshop equipment
Tighten all screws.
Tightening torques
M10 x 130 Tightening torque,
25 Nm
Additional angle of
rotation, 90°
M8 x 80 19 Nm
M6 x 30 10 Nm

(-) Installing left piston
Positioning piston rings
Place first piston ring (1) in position with the opening up (mark (arrow) points
in forward direction of travel).
Carefully align middle piston ring (2) with pin (3) to ensure that pin (3) is not
damaged in the installation procedure.
Place third piston ring (4) in position with the opening down.
Lubricate the friction face in the cylinder with engine oil.

Slip piston-ring compressor (No. 11 5 731) around piston (1) in such a way
that it just encloses all the piston rings.
Tighten piston-ring compressor (No. 11 5 731).
Carefully slide left piston (1) with the arrow mark (arrow) down (arrow mark
points in forward direction of travel) into the cylinder; if necessary use the
end of the shaft of a hammer to push the piston into position.
(-) Installing left piston pin
Position piston (1) and connecting rod (2) such that they are aligned and
visible through the bore hole at the front.
Install circlip (1) in bush (2) of mounting tool for gudgeon pins (No. 11 0
932).
Slip bush (2) onto mounting tool for gudgeon pins (No. 11 0 932).
Slip gudgeon pin (3) onto mounting tool for gudgeon pins (No. 11 0 932).

Hold assembly tool for piston pins (No. 11 0 932) in position with the
opening of the circlip offset to the recess (arrow).
Insert mounting tool for gudgeon pins (No. 11 0 932) till the limit position,
press lock (1) and pull it out again.
(-) Installing right coolant neck

surface (1).
Sealant
Dow Corning 07 58 0 397 777
Check the O-ring (3) for damage, replace if necessary.

Install coolant nozzle (2) with O-ring (3).
Install bolt (1).
Tightening torques
M6 x 16 12 Nm
(-) Installing coolant neck for coolant thermostat

Install screws (1).
Tightening torques
M6 x 16 12 Nm
(-) Installing crankshaft sensor

Install crankshaft sensor (2) with O-ring (3).
Install bolt (1).
Tightening torques
M6 x 14 8 Nm
(-) Installing housing plugs
Install screw plug (1) with new sealing ring (2).
Tightening torques
M10 x 1 10 Nm
Install screw plug (5) with new sealing ring (6).
Tightening torques
M20 x 1.5 42 Nm
Install oil pressure control valve (4), spring (3) and screw plug (1) with new
sealing ring (2).
Tightening torques
M24 x 1.5 42 Nm
(-) Installing oil filter
Clean the sealing face on the engine block (arrow).

Lubricate sealing ring (1) with engine oil
Install new oil filter (2), using oil filter wrench (No. 11 4 650).
Tightening torques
(-) Installing oil pump

Install outer rotor (1) with small diameter in engine block (2).
Install oil pump (1), while turning oil-pump shaft (2), making sure that straight
pin (3) is engaged in the recess (arrow).
Check
Turn oil-pump shaft (2) and check ease of movement.
Result:
Oil-pump shaft does not turn or is stiff.
Measure:
Remove oil pump and check for assembly error.
Install outer rotor (1).

Make sure that straight pins (2) are installed.
Install oil-pump cover (2).

Install screws (1).
Tightening torques
M6 x 16 12 Nm
Set pinion (1) in position, making sure that the splines (arrow) mesh.

Align oil-pump shaft (2) and pinion (1).
Set driver (3) in position and make sure it engages.
Install new nut (4).
Tightening torques
Thread-locking compound
(mechanical)
(-) Installing coolant pump
Check the O-rings (arrows) for damage; replace if necessary.
Hold coolant pump (2) in position.

Install screws (1).
Tightening torques
M6 x 40 12 Nm
Follow-up work
Installing valve stem seals and spring retainers
Installing valves
Installing cam followers
Installing left timing chain
Installing left timing-chain rails
Installing right timing chain
Installing starter double gear
Installing starter idler gear
Installing right timing chain tensioner rail
Installing gearwheel, starter freewheel
Installing magnetic wheel
Installing timing-chain slide rail

Installing balancing weight
Installing clutch cage for measurement
Measuring tooth backlash, clutch cage
Tightening clutch cage
Installing right cylinder head
Installing sprocket for right intermediate shaft
Installing right timing-chain tensioner
Installing right valve shim
Installing right camshafts
Installing right camshaft bearing cap
Install retaining bracket for right axial fixation
Checking right-side timing
Installing the right switching cam adjuster
Checking valve clearance
Removing right timing-chain tensioner
Installing right timing chain tensioner
Setting left cylinder to firing TDC
Installing left cylinder head
Installing sprocket for left intermediate shaft
Installing left timing-chain tensioner
Installing left valve shim
Install the left camshafts
Installing left camshaft bearing cap
Install left retaining bracket for axial fixation
Checking timing
Installing the left switching cam adjuster
Installing left timing chain tensioner
Installing left cylinder-head cover
Installing right cylinder-head cover
Installing coil carrier
Installing breather wheel
Installing engine breather
Installing gearbox
Installing oil-level sensor
Installing clutch hub plate
Installing clutch hub
Installing clutch plates

Installing pressure plate
Installing front crankcase cover
Installing camshaft sensor
Removing engine from engine holder

11 00 209 Oil change, engine, with filter

+ 11 00 611
NOTICE
Change the oil at operating temperature:
Make sure the temperature is as specified in the repair instructions.
Or, alternatively, check whether the oil/coolant radiator is hot (risk of burning!).
Preparatory work
Core activity
(-) Engine-oil change, with filter
Draining engine oil
Allow the engine to warm up until the fan is running.
CAUTION
Hot exhaust system
Risk of burn injury
Do not touch a hot exhaust system.
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.
Place a suitable tray underneath the engine to catch escaping oil.

Remove oil drain plug (1) with sealing ring (2).
Drain the engine oil and dispose of it in an environmentally friendly manner.
Dispose of sealing ring (2).
Replacing oil filter

Removing oil filter
Information about different oil filters
There are different oil filters:
Oil filter (1), oil filter wrench (No. 11 4 661)
Oil filter (2), oil filter wrench (No. 11 4 650)
Oil filter (1) is removed and replaced with oil filter (2) in the framework of the
running-in check.
Choose the corresponding repair path and oil filter wrench.
Version 1: Removing oil filter in the framework of running-in check


11 00 550 Replacing engine (engine removed)

Core activity
(-) Replacing engine
Remove bolt (1).

Remove mounting C (2).
Remove old engine (3) from engine adapter (No. 00 1 585).
Install new engine (3) in engine adapter (No. 00 1 585).
Install mounting C (2) with bolt (1).
Remove the sealing plugs from the new engine.

Remove transport protection (1) from clutch slave cylinder mount (2).
(-) Transferring shift assistant
Remove screw (1) and washer (2).
Install jacking screw (No. 23 0 831).

Press off shift assistant (1).
Remove jacking screw (No. 23 0 831).

Remove shift assistant (1).

Remove sleeve (2).
Insert new sleeve (1) flush in shift assistant (2), noting the positioning
(arrow).
Hold shift assistant (1) in position.
Install screw (1) and washer (2).
Tightening torques

encapsulated)
(-) Transferring left and right intake stubs
Open clamp (1) using pliers (No. 13 1 512).

Remove air intake stub (2).
Hold intake neck (1) in place on new engine and position it with the lug
(arrow) in the recess.
Close clamp (1) with pliers (No. 13 1 512).
Remount the left air intake in the same way.
(-) Transferring left and right direct ignition coils
Remove direct ignition coil (1) with puller (No. 12 3 621) and transfer to new
engine.

Transfer the right direct ignition coil in the same way.
(-) Transferring breather hoses
Remount the additional air hose (1) on the new engine.

Remount the hose (2) on the new engine.
(-) Transferring bracket for engine guard
After installing the new engine, transfer the brackets for the engine guard.
Remove screws (1).
Remount the bracket (2) on the new engine.
Install screws (1).
Tightening torques
M8 x 25 19 Nm
Remove screws (1).

Remount the bracket (2) on the new engine.
Install screws (1).
Tightening torques
M8 x 25 19 Nm

11 00 551 Replacing power train (engine removed)
NOTICE
chain.
Preparatory work
Removing crankshaft sensor
Removing coolant pump
Removing clutch hub
Removing oil pump
Removing gearbox
Removing left camshaft sprockets
Setting right cylinder to firing TDC
Removing right camshaft sprockets

Removing balancing shaft
Removing coolant neck for coolant thermostat
Removing right coolant neck
Removing propulsion unit from engine holder
Core activity
(-) Securing propulsion unit to engine holder
Set driving mechanism (5) in engine holder (No. 11 0 832) .

Install shafts (4) and (3).
Install counter-holder (2).
Install butterfly screws (1).

surface (1).
Sealant
Dow Corning 07 58 0 397 777

Install bolt (1).
Tightening torques
M6 x 16 12 Nm


Install screws (1).
Tightening torques
M6 x 16 12 Nm
(-) Installing balancing shaft
Before installing the balancing shaft, remove transportation lock of thrust

washer (1).
Make sure that thrust washer (1) is correctly installed in the housing.
Install balancing shaft (1).
(-) Installing left timing chain
Loop timing chain (1) on to crankshaft sprocket (2).

(-) Installing left timing-chain rails
Position tensioning rail (2) with bearing cap screw (1).

Position slide rail (3) with bearing cap screw (1).
Tighten bearing cap screw (1).
Tightening torques
M8 19 Nm
(-) Installing right timing chain
Loop timing chain (1) onto balancing shaft sprocket (2).
(-) Installing right timing chain tensioner rail
Install tensioning rail (2).

Install bearing cap screw (1).
Tightening torques
M8 19 Nm
(-) Installing starter double gear

Clean the threads.

Install starter double gear (1).
Check the O-ring (arrow) for damage; replace if necessary.
Install axle (2).
Install bolt (3) with sealing washer (4).
Tightening torques
encapsulated)
(-) Installing starter idler gear
Install starter idler gear (4).

Check the O-ring for damage; replace if necessary.
Install axle (3).
Install bolt (1) and sealing washer (2).
Tightening torques
encapsulated)
(-) Installing gearwheel, starter freewheel
Lubricate the friction face (arrow) of the gearwheel with engine oil.
Install gear (1) on crankshaft (2).
Clean the threads.

Install bolt (1) with contact disc (2) and sleeve (3).
Tightening torques
Thread-locking compound (Loctite
243, Medium strength)

(-) Installing magnetic wheel
Clean the contact faces (arrows) of magnetic wheel (1) and crankshaft (2).
Cleaner
Brake cleaner 83 19 2 154 780
Make sure that Woodruff key (3) is installed.
Set magnetic wheel (1) in position and make sure that Woodruff key (2) is
aligned with the keyway (arrow).
Install magnetic wheel (1), turning gearwheel (3) for the starter freewheel
counter-clockwise.
Disengage crankshaft lock at locating pin (No. 11 0 822) and engage at TDC
mark.
Clean the threads (arrows).

Apply thread-locking compound to the threads (arrows) of nut (1) and
crankshaft (2).
Loctite 270, High strength 83 19 2 210 337
Install washer (2) and nut (1).
Tightening torques
Rotor to crankshaft
M24 x 1.5
Thread-locking compound (Loctite 1st tightening torque,
270, High strength) 150 Nm
slacken completely
250 Nm
Heat bearing shell (1) and, using a suitable tool, press on until seated.
Technical data
Release/mating 80 °C
temperature
(-) Installing balancing weight
Install balancing weight (1), making sure that Woodruff key (2) and the
keyway (arrow) are aligned.
(-) Assembling oil pump
ATTENTION
Oil-pump components run dry
Component damage
Lubricate all components of the oil pump with engine oil prior to installation.
Lubricate all components of the oil pump with engine oil.

Install spacing washer (1) with small recess (arrow) first on oil-pump shaft
(2).
Insert driver pin (3) into oil-pump shaft (2).
Place inner rotor (4) on oil-pump shaft (2), making sure that driver pin (3) is
engaged in recesses (5).

Check
Result:
Measure:


Install screws (1).
Tightening torques
M6 x 16 12 Nm
Tightening torques
(mechanical)
(-) Installing clutch cage for measurement
Using a marker, put a mark on tooth (1) at the mark (arrow).
Hold clutch cage (1) in position, making sure that keyway (2) is aligned with
Woodruff key (3).
Turn clutch cage (1) with balancing shaft (2) until tooth (3) marked
beforehand and the mark (arrow) on crankshaft gear (4) are in line.

Install new washer (2).

Install old nut (1) with socket (No. 31 5 631) and tighten until hand-tight.
(-) Measuring tooth backlash, clutch cage
NOTICE
Tooth backlash at the clutch case has to be measured in the following cases:
Replacement of clutch cage or engine block.
Replacement of the crankshaft or crankshaft bearings.
Replacement of the counterbalance shaft or counterbalance shaft bearings.
Remove all traces of seal from area for holder (No. 11 0 863).
Install holder (No. 11 0 863) with screws (1) and washers (2).
Install dial gauge (No. 11 0 861) in such a way that the probe (arrow) is
preloaded and engaged centred relative to a tooth flank of gearwheel (3).
Check
Move clutch cage (4) slightly back and forth.
Technical data
Backlash of clutch 0.003...0.025 mm
cage
Result:
Tooth backlash is out of tolerance.
Measure:
Install appropriate clutch cage:
Technical data
Marks on clutch 1 groove / S Small gear (increase
cage / designation in tooth backlash)
2 grooves / M

BMW Motorrad parts Medium-size gear
catalogue (reduce/increase
tooth backlash)
3 grooves / L Large gear (reduce
tooth backlash)
to reduce backlash: clutch cage with higher classification

to increase backlash: clutch cage with lower classification
Replacing clutch cage
Install clutch cage (1) of the next highest or next lowest classification, as
applicable. There are up to three marks (detail) on the gearwheel to
indicate the classification.
Then re-measure tooth backlash.
(-) Tightening clutch cage
Remove old nut (1).

Rapidly install new nut (1) with socket (No. 31 5 631).
NOTICE
The nut has to be tightened to the final torque within one minute of initial
engagement of the threads, because the thread-locking compound starts to
cure rapidly.
Tightening torques
Clutch cage to balancing shaft
M36 x 1.5, Renew nut, thread is free 1st tightening torque,
of grease 170 Nm
Thread-locking compound (micro- Slacken the nut,
encapsulated) angle of rotation, 90°
250 Nm
(-) Installing timing-chain slide rail
Install slide rail (1).

(-) Installing right cylinder head
Make sure that fitting sleeve (1) and cylindrical pin (2) are securely installed.
Install new seal (1).

Hold cylinder head (2) in position, seating slide rail (3) in the tab (arrow).
Install screws (4) with washers (3) and screws (2) and (1).
Tightening torques
M10 x 110 - 10.9 Tightening
sequence: tighten in
diagonally opposite
sequence
5 Nm
20 Nm
3rd tightening torque,
40 Nm
Additional angle of
rotation, 150°
M6 x 25 12 Nm
M6 x 95 12 Nm
(-) Installing sprocket for right intermediate shaft
Insert chain sprocket (2) into timing chain (1).

Install axle (1) with the bore hole (arrow) toward screw (2).
Install bolt (2).
Tightening torques
M6 x 14 8 Nm
(-) Installing right timing-chain tensioner
Adjust timing-chain tensioner (No. 11 1 512) such that the thread (arrow) is
screwed in as far as possible.
Install timing-chain tensioner (No. 11 1 512) with sleeve (No. 11 1 513).
Tighten timing-chain tensioner (No. 11 1 512) until release and click three
more times after release.
(-) Installing right camshaft sprockets
Install the exhaust camshaft sprocket (3) with friction plate (4).
Install the intake camshaft sprocket (1) with friction plate (2).
Retain the camshafts with holding fixture on the right side (No. 11 2 512)
from the set of holding fixtures (No. 11 2 510) .
Ensure that the holding fixture rests fully (arrow) on the crankshaft ends.

Install bolt (1) hand-tight.
The holding fixture is fastened.

Install the bolt (1) with bearing (2) hand-tight.
Tighten screws (1) and (3).
Tightening torques
other camshafts, M10 x 1.25 x 35 - 60 Nm
10.9
Remove bolt (1).

Remove the right holding fixture (No. 11 2 512) from the set of holding
fixtures (No. 11 2 510) .
Unlock locating pin (No. 11 0 822).

Engage a gear and slowly turn the rear wheel to rotate the crankshaft until
camshafts (1) are back at firing TDC.
Locating pin engages.
Use the right holding fixture (No. 11 2 512) from the set of holding fixtures
(No. 11 2 510) to check that the firing TDC position is correct.

(-) Installing the right switching cam adjuster
Ensure that the locking tab (2) is unlocked.

Slide on connector (1).
Ensure that the connector (1) engages audibly.
Push locking tab (2) in direction of arrow (arrow 1).
Ensure that the locking tab (2) engages audibly.
Connect the connector (1) for right switching cam adjuster (2).
Insert the right switching cam adjuster (2).
Install the screws (1) of the right switching cam adjuster (2).
Tightening torques
M6 x 20 10 Nm
(-) Checking valve clearance
Requirement
Right cylinder is at firing TDC.

Check
Measuring valve clearance
Check valve clearance with feeler gauge (1) inserted between cam follower
(2) and cam (3); do not measure at the recess (arrow) of the cam.
Technical data
Inlet valve clearance Engine 0.10...0.17 mm
cold max 35 °
C
Exhaust valve Engine 0.34...0.41 mm
clearance cold max 35 °
C
Result:
Valve clearance is outside specified range.
Measure:
Noting measured results
Note down the measured results on a record sheet.
NOTICE
This graphic is available as a template for printing.
=> 11 34 510, Adjusting right valve clearances (for checking valve clearances)
(Billed as a separate item)
(-) Removing right timing-chain tensioner
Remove timing-chain tensioner (No. 11 1 512) and sleeve (No. 11 1 513).

(-) Installing right timing chain tensioner
Install timing chain tensioner (1) with piston (2) and new sealing ring (3).
Tightening torques
M18 x 1.5 32 Nm
(-) Setting left cylinder to firing TDC
Lock locating pin (No. 11 0 822), turn the crankshaft a little further and
unlock the locating pin.
Turn nut (1) to turn the crankshaft clockwise, until locating pin (No. 11 0 822)
engages at the TDC position.
(-) Installing left cylinder head


Install screws (4) using contact discs (3) and screws (2) and (1).
Tightening torques
diagonally opposite
sequence
5 Nm
20 Nm
40 Nm
Additional angle of
rotation, 150°
M6 x 25 12 Nm
M6 x 95 12 Nm
(-) Installing sprocket for left intermediate shaft

Install bolt (2).
Tightening torques
M6 x 14 8 Nm
(-) Installing left timing-chain tensioner
(-) Installing left camshaft sprockets
Install the exhaust camshaft sprocket (3) with friction plate (4).
Install the intake camshaft sprocket (1) with friction plate (2).
Retain the camshafts with holding fixture on the left side (No. 11 2 511) from
the set of holding fixtures (No. 11 2 510).

Install the bolt (3) with sleeve (4) hand-tight.

Install the bolt (1) with bearing (2) hand-tight.
Tightening torques
10.9
Remove bolt (1).

Remove left holding fixture (No. 11 2 511) from the set of holding fixtures
(No. 11 2 510) .
Unlock locating pin (No. 11 0 822).

Engage a gear and slowly turn the rear wheel to rotate the crankshaft until
camshafts (1) are back at firing TDC.
Locating pin engages.
Use the left holding fixture (No. 11 2 511) from the set of holding fixtures
(No. 11 2 510) to check that the firing TDC position is correct.

(-) Installing the left switching cam adjuster

The connector (1) engages audibly.
Connect the connector (1) for left switching cam adjuster (2).
Fit the left switching cam adjuster (2).
Install the screws (1) of the left switching cam adjuster (2).
Tightening torques
M6 x 20 10 Nm
Requirement
Left cylinder is at firing TDC.

Check
Technical data
cold max 35 °
C
C
Result:
Measure:
NOTICE
=> 11 34 509, Adjusting left valve clearances (for checking valve clearances)
(-) Removing left timing-chain tensioner

(-) Installing left timing chain tensioner
Tightening torques
M18 x 1.5 32 Nm
(-) Installing left cylinder-head cover
Clean the sealing faces.

Clean seals (1) and (2), check for damage and, if necessary, renew them.
Install seal (1) with recess (arrow) facing up.
Install seal (2).
Fit stopper (1) and fold it upwards.
Fit cylinder head cover (1).

Tighten the screws (2).

Tightening torques
M6 10 Nm
(-) Installing right cylinder-head cover

Install seal (1) with recess (arrow) facing down.
Install seal (2).
Position seals (3) and (4).

Tighten screws (1).
Tightening torques
M6 10 Nm
(-) Installing coil carrier
Clean rubber grommet (1) and groove (2) in the engine block.
Apply sealant to the sealing face (arrow) of rubber grommet (1).

Sealant
Dow Corning 07 58 0 397 777
Make sure that reamed sleeves (1) are installed.

Align coil carrier (2) on reamed sleeves (1) and install.
Insert rubber grommet (3) into groove (4).
Install screws (1).
Tightening torques
M6 x 20 12 Nm
(-) Installing breather wheel
Install breather wheel (2).

Install bolt (1).
Tightening torques
M10 x 25 41 Nm
(-) Installing crankshaft locking device at BDC
Unlock locating pin (No. 11 0 822) and install with BDC mark (B).

Technical data
Diameter of holes for TDC hole for 8 mm
locating pin locating pin
(A)
BDC hole for 6 mm
locating pin
(B)
engages in BDC mark.
Check
Turn nut (1) back and forth to turn the crankshaft.
Result:
Crankshaft has clearly perceptible play, i.e. the locating pin is engaged in
TDC mark.
Measure:
Turn the crankshaft 180 degrees clockwise until the locating pin engages
with zero play in the BDC mark.
(-) Installing gearbox
Clean sealing faces (1) on engine block and gearbox cover.

Make sure sealing face (1) is clean and degreased, and uniformly apply
sealant (arrow) to the face.
Sealant
Dow Corning 07 58 0 397 777
Manoeuvre layshaft (1) with gearbox (2) into balancing shaft (3).
Install complete gearbox (2).
Make sure that all gearbox components can be slipped easily into the
corresponding bearing seats in the engine block.

Insert screws (1) and (2) and tighten until hand-tight.

Insert screws (3) to (18) and tighten until hand-tight.
Working clockwise, tighten screws (3) to (9).
Working counter-clockwise, tighten screws (10) to (18).
Tightening torques
M6 x 25 10 Nm
Insert pushrods (1) and (2) into layshaft (3).

The cylindrical thrust piece (arrow) must face out.
(-) Installing engine breather
Check O-ring (1) for damage; replace if necessary.

Lubricate O-ring (1) with engine oil.
Lubricate the friction face (arrow) of shaft sealing ring (2) with engine oil.
Install engine breather cover (2).

Install screws (1).
Tightening torques

M6 x 20 12 Nm
(-) Installing oil-level sensor
Clean the threads.

Check O-ring (1) and renew if required.
Install oil level sensor (2) by threading through pipe (arrow).
Install screws (3).
Tightening torques
encapsulated)
(-) Installing left spark plug
Use spark-plug socket (No. 12 1 220) to install the spark plug (1).
Tightening torques
M10 x 1 12 Nm
Technical data
Spark plugs, NGK LMAR8AI-10
manufacturer and
designation
(-) Installing left direct ignition coil
Install direct ignition coil (1) till limit position.
(-) Installing right spark plug

Tightening torques
M10 x 1 12 Nm
Technical data
manufacturer and
designation
(-) Installing right direct ignition coil

Install screws (1).
Tightening torques
M6 x 40 12 Nm
(-) Installing clutch hub plate
Install new clutch hub plate (1).

(-) Installing clutch hub
Install clutch hub (1).

Insert driver lock (No. 11 0 828) into clutch hub (1) and clutch cage (2).
Install nut (3).
Tightening torques
Clutch hub to layshaft
M20 x 1.5, Replace nuts and Tightening torque,
lubricate with engine oil 150 Nm
Fully slacken nut
Tightening torque,
150 Nm
Remove driver lock (No. 11 0 828).
(-) Installing clutch plates
ATTENTION
Incorrect sequence or positioning on installation of steel plates and
lined plates
Component damage due to increased wear
Install the lined plates and steel plates in the correct sequence and positions
as marked prior to disassembly.
Install spacer (1).

Install release spring (2) with curve toward the inside (arrow).
Install lined plate (3) with large inside diameter.
Install smooth steel plate (4).
Install spotted steel plates (1) and lined plates (2).

(-) Installing pressure plate
Install friction plates (1) and steel plate with spotting (2) with large inside
diameters in pressure plate (3).
ATTENTION
Friction plates installed with offset
Component damage
Only the last friction plate has to be installed offset by one tooth.
Install thrust piece (1) and pressure plate (2), making sure that only last
friction plate (3) is installed with an offset.
Insert springs (3).

Lubricate screws (1).
Set mounting plate (2) in position with screws (1).
Engage screws (1) and tighten alternately and uniformly.
Tightening torques
M6 x 30 10 Nm
Check that pressure plate (1) is correctly installed.

There is no gap (arrow) between pressure plate (1) and lined plate (2).

(-) Installing front crankcase cover
Clean the sealing surface.

Make sure sealing face is clean and degreased, and uniformly apply sealant
(arrow) to the face.
Sealant
Dow Corning 07 58 0 397 777
Position engine housing cover (1).

Tighten screw (1), then tighten screws (2) to (9) and (10) to (16) in clockwise
direction.
Tightening torques
M6 x 20 Tightening
sequence: See
repair manual
10 Nm
Follow-up work
Installing oil filter
Installing crankshaft sensor

11 00 609 Oil change in engine with filter (for maintenance)
NOTICE
Change the oil at operating temperature:
Make sure the temperature is as specified in the repair instructions.
Or, alternatively, check whether the oil/coolant radiator is hot (risk of burning!).
Preparatory work
Core activity
(-) Engine-oil change, with filter
Draining engine oil
Allow the engine to warm up until the fan is running.
CAUTION
Hot exhaust system
Risk of burn injury
ATTENTION
Component damage
Place a suitable tray underneath the engine to catch escaping oil.

Remove oil drain plug (1) with sealing ring (2).
Drain the engine oil and dispose of it in an environmentally friendly manner.
Dispose of sealing ring (2).
Replacing oil filter

Removing oil filter
Remove all oil stains from the exhaust manifold and engine.
Installing oil filter

Lubricate sealing ring (1) with engine oil.

Tightening torques

Install oil drain plug (1) with new sealing ring (2).
Tightening torques
M20 x 1.5 42 Nm
Prepare the correct total quantity of engine oil.
Technical data
Engine oil, capacity with filter approx. 4 l
change
Remove oil filler plug (1) using key from toolkit.

Pour the engine oil into the engine.
Technical data
Engine oil, capacity 3.5 l
Install oil filler plug (1) using the key from the toolkit.
After completing all work and performing a test run/test ride, top up the
engine oil to the (MAX) mark.
Checking engine oil level
ATTENTION
Misinterpretation of oil level reading, because oil level is temperature-
dependent (the higher the temperature, the higher the oil level)
Engine damage
Check the oil level only after a lengthy ride or when the engine is at
operating temperature.

Allow the engine to warm up until the fan starts.
Turn off motor cycle on related reason.
Wait for 5 minutes.
Check the engine oil level and if necessary, correct the level to the
maximum mark.
Technical data
Engine oil, specified level between MIN and
MAX mark
Engine oil
Product recommended by 83 12 2 405 887
BMW Motorrad: ADVANTEC
Ultimate oil, SAE 5W-40,
API SL / JASO MA2
Follow-up work

11 11 514 Replace engine block (engine removed)
NOTICE
chain.
Preparatory work
Removing clutch hub
Removing gearbox
Removing trigger for camshaft sensor

Core activity
(-) Removing oil filter
Remove screws (1).

suitable tool.

Remove screws (1).

(-) Removing left piston pin
By turning the crankshaft, position piston (1) in such a way that gudgeon pin
(2) is visible through bore hole at front.
Information on removing circlip

If opening of circlip (1) lies above recess (arrow) of piston (2), it must be
turned before removal.
Install insert (No. 11 0 933) in puller (No. 11 0 931).

Insert puller (No. 11 0 931) with insert and turn it until insert engages (No.
11 0 933) in opening of circlip.
Turn puller (No. 11 0 931) with circlip by at least 90°.
Remove insert (No. 11 0 933) from puller (No. 11 0 931).
Insert puller (No. 11 0 931) and turn it until the lever engages with an
audible click in the cut-out (arrows).
Remove circlip (1) with puller (No. 11 0 931).
Remove gudgeon pin (1) with mounting tool for gudgeon pins (No. 11 0
932).

Remove screws (1).
Remove screws (1).

ATTENTION

Remove O-ring (1).

(-) Removing oil intake pipe
Remove screws (1).

Remove oil intake pipes, pressure stage (2) and intake stage (3).
(-) Removing diaphragm valve
Remove screws (1).

Remove panels (2).

Remove diaphragms (3).
Remove screws (1).

Using a suitable tool, remove lid (2).
(-) Removing crankshaft

Remove conrod bearing cap (2).
Remove crankshaft (3) with conrods (4).
(-) Removing crankshaft bearing shells
Carefully remove main bearing shells (1) and thrust bearing shells (2) at the
positioner (arrow).
Remove thrust washer (1) and counterbalance shaft (2).

(-) Removing piston
(-) Removing oil-pressure control valve with cover
Remove threaded plug (1) with sealing ring (2), spring (3) and oil pressure
control valve (4).
(-) Removing coolant neck for coolant thermostat
Remove screws (1).

Remove coolant nozzle (2) with O-ring (3).
(-) Removing right coolant neck
Remove bolt (1).

Remove coolant nozzle (2) with O-ring (3).
(-) Replacing engine block
Remove wing bolts (1) and counter support (2).

Remove bushings (3) and (4).
Remove shafts (5) and (6).
Remove old crankcase half (7) from engine holder (No. 11 0 832) and insert
new crankcase half into engine holder (No. 11 0 832).
Install shafts (6) and (5).
Install bushings (4) and (3).
Install counter support (2) and wing bolts (1).
(-) Installing crankshaft bearing shells
NOTICE
Replace the crankshaft bearing shells if the crankshaft is replaced.
NOTICE
The bearing shells in the left and right housing halves are different:
Install bearing shells, left using marks in the left housing half.
Install bearing shells, right using marks on the crankshaft.
Select the required bearing shells with the help of marks on the
crankshaft/left housing half
Technical data
ID marks of crankshaft Colour mark yellow/green/violet
baring on outside
Colour codes of crankshaft Crankcase Bearing shells
bearing shells yellow yellow
Crankcase Bearing shells,
green green
Crankcase Bearing shells
violet violet
Crankshaft Bearing shells
yellow yellow
Crankshaft Bearing shells,
green green
Crankshaft Bearing shells
violet violet
Mark for classification of A: Y (yellow) / G
the crankshaft bearings Mark/colour (green) / V (violet)
to identify the bearing point near oil
shells in the left crankcase pump
in direction of Guide bearing,
travel, front front (three parts)
in direction of Main bearing, rear
travel, rear (single part)
Marks on crankshaft A front: Yellow/green/violet

to identify the bearing Identification dots
shells in the right for right guide
crankcase / the connecting bearing (three
rod bearing shells parts)
B inside: blue/red dots
near
corresponding
crankshaft
journals:
identification
for connecting
rod bearing
C rear: Yellow/green/violet
identification dots
for right main
bearing
(single part)
Install thrust washers (1) with oil grooves (arrows) facing out on guide
bearing (2).
Install oiled main bearing shells (1) and guide bearing shells (2) in left
housing half, making sure that the lugs (arrow) of the bearing shells engage
in the grooves of the housing halves.
Technical data
Mark for classification of A: Y (yellow) / G
the crankshaft bearings Mark/colour (green) / V (violet)
to identify the bearing point near
shells in the left crankcase oil pump
in direction Guide bearing, front
of travel, (three parts)
front
in direction Main bearing, rear
of travel, (single part)
rear
Install oiled main bearing shells (1) and guide bearing shells (2) in right
housing half, making sure that the lugs (arrow) of the bearing shells engage
in the grooves of the housing halves.
Technical data
to identify the bearing Identification dots
shells in the right for right guide
crankcase / the connecting bearing (three
rod bearing shells parts)
B inside: blue/red dots
near
corresponding
crankshaft
journals:
identification
for connecting
rod bearing
identification dots
for right main
bearing
(single part)
(-) Installing diaphragm valve

surface (1).
Sealant
Dow Corning 07 58 0 397 777
Install lid (2).

Install screws (1).
Tightening torques
Diaphragm valve to crankcase
M6 x 16 12 Nm

Position diaphragms (3) and panels (2).

Install screws (1).
(-) Installing oil intake pipe

Install oil intake pipes, intake stage (1) and pressure stage (2).
Install screws (3).
Tightening torques
Oil intake in crankcase
encapsulated)
Insert thrust washer (1).

Install counterbalance shaft (2)
(-) Provisionally installing crankshaft
Oil the friction faces (arrows) of crankshaft (1) and bearing shells (2).

(-) Provisionally joining crankcase sections

ATTENTION

Install screws (1) (2) and (3) till hand-tight.


tightening.
Workshop equipment
Tighten all screws.
Tightening torques
25 Nm
Additional angle of
rotation, 90°
M8 x 80 19 Nm
M6 x 30 10 Nm
(-) Measuring crankshaft bearing axial play
Install measuring jig (No. 00 2 502), (No. 00 2 505), (No. 00 2 506) with dial
gauge (No. 00 2 510).
Check
Move crankshaft (1) axially back and forth and read play from the dial gauge
(No. 00 2 510).
Technical data
Endplay of crankshaft When new 0.075...0.259 mm

Result:
Endplay is out of tolerance.
Measure:
Check bearing shells, crankcase and crankshaft; replace as necessary.
Remove screws (1).
Remove screws (1).

ATTENTION

(-) Installing right piston with conrod


Carefully slide right piston (1) with the arrow mark (arrow) up (arrow mark
(-) Installing crankshaft

Oil the friction faces (arrows) of crankshaft (1) and bearing shells (2).
ATTENTION
Component damage
Install conrod bearing cap with bearing shells (2).

tightening.
Workshop equipment
Install screws (1).
Tightening torques
Conrod bolt
20 Nm
Additional angle of
rotation, 150°
Slacken and then
retighten the bolt
5 Nm
20 Nm
Additional angle of
rotation, 150°



surface (1).
Sealant
Dow Corning 07 58 0 397 777
ATTENTION



tightening.
Workshop equipment
Tighten all screws.
Tightening torques
25 Nm
Additional angle of
rotation, 90°
M8 x 80 19 Nm
M6 x 30 10 Nm


932).


surface (1).
Sealant
Dow Corning 07 58 0 397 777

Install bolt (1).
Tightening torques
M6 x 16 12 Nm

Install screws (1).
Tightening torques
M6 x 16 12 Nm

Install bolt (1).
Tightening torques
M6 x 14 8 Nm
(-) Installing oil-pressure control valve with cover
Install oil pressure control valve (4), spring (3) and screw plug (1) with new
sealing ring (2).
Tightening torques
M24 x 1.5 42 Nm
(-) Installing oil filter

Lubricate sealing ring (1) with engine oil
Tightening torques

Check
Result:

Measure:


Install screws (1).
Tightening torques
M6 x 16 12 Nm
Tightening torques
(mechanical)


Install screws (1).
Tightening torques
M6 x 40 12 Nm
Follow-up work
Installing left timing chain
Installing left timing-chain rails
Installing right timing chain
Installing starter idler gear
Installing balancing weight
Installing right camshaft sprockets

Installing left camshaft sprockets
Install the trigger for camshaft sensor
Installing gearbox

11 12 026 Removing/installing and sealing left cylinder-head cover

+ 11 12 828
Preparatory work
Core activity
(-) Removing left cylinder head cover
Place a suitable tray underneath the cylinder-head cover to catch escaping

oil.
Remove screws (1).
Remove cylinder head cover (2).
Remove seals (3) and (4).
Fold stopper (1) down and remove.

Install seal (1) with recess (arrow) facing up.
Install seal (2).


Install screws (2).
Tightening torques
M6 10 Nm
Follow-up work

11 12 027 Removing/installing and sealing right cylinder-head cover

+ 11 12 827
Preparatory work
Core activity
(-) Removing right cylinder-head cover

oil.
Remove screws (1).

Install seal (2).


Install screws (2).
Tightening torques
M6 10 Nm
Follow-up work

11 12 055 Removing/installing left cylinder head

+ 11 12 805
CAUTION
Working on hot cooling system
Risk of burn injury
Always allow the cooling system to cool down before starting work.
Preparatory work
Removing cover
Removing front seat
Draining coolant
Disconnecting camshaft sensor
Removing silencer
Releasing exhaust manifold
Removing clip from left air intake stub
Core activity
(-) Removing left cylinder head
Disconnect the connector (1) for the left knock sensor (2).

ATTENTION
Disconnection of the connector not in compliance with correct
procedure
Damage to locking tab
Push the connector away from the locking tab, do not lift or bend the locking
tab.
Unlock locking tab (1) in direction of arrow (arrow 1).

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

Disconnect connector (1) for left camshaft adjuster.
Remove screws (1) and (2).

Remove screws (4) with contact discs (3).
Remove cylinder head (1) and seal (2).


Tightening torques
diagonally opposite
sequence
5 Nm
20 Nm
40 Nm
Additional angle of
rotation, 150°
M6 x 25 12 Nm

M6 x 95 12 Nm
Connect connector (1) for knock sensor (2).
Ensure that the release tab (1) is unlocked.

Slide connector (2) in direction of arrow (arrow 1).
Slide connector (2) in direction of arrow (arrow 2) further.
Slide locking tab (1) in direction of arrow (arrow 3).
The locking tab (1) engages audibly.
Connect connector (1) for left camshaft adjuster.

Secure the cable strap (arrow).
Follow-up work
Installing clip on left air intake stub
Securing exhaust header
Connecting camshaft sensor
Installing silencer
Installing lid

11 12 057 Removing/installing right cylinder head

+ 11 12 806
CAUTION
Risk of burn injury
Preparatory work
Removing front seat
Draining coolant
Removing silencer
Removing clip from right air intake stub
Core activity
(-) Removing right cylinder head
Disconnect bypass air hose (1) from cylinder head (2).

Disconnect the connector (1) for knock sensor (2).
ATTENTION
procedure
tab.

connector (2).
Detach line (arrows) .

Disconnect connector (1) for right camshaft adjuster.



Ensure that intake manifold (1) is seated with the lug (arrow) engaged in the
recess.
Tightening torques

diagonally opposite
sequence
5 Nm
20 Nm
40 Nm
Additional angle of
rotation, 150°
M6 x 25 12 Nm
M6 x 95 12 Nm
Connect additional air hose (1) and tank ventilation line (2) with cylinder
head (3), it must be ensured that they are laid correctly.
NOTICE
Pay attention to correct hose installation: Insert additional air hose on right
side, tank ventilation line on the left side (in the direction of travel).

Connect connector (1) for right camshaft adjuster.

Attach line (arrows).

Follow-up work
Installing clip on right air intake stub
Installing silencer

11 12 171 Replacing left cylinder head

+ 11 12 816
CAUTION
Risk of burn injury
Preparatory work
Removing cover
Removing front seat
Draining coolant
Removing silencer
Core activity

ATTENTION
procedure
tab.

connector (2).



(-) Removing cam followers
Remove needle rollers (1).

Remove rocker arm shafts (2).
Remove rocker arms (3).
(-) Removing valves
Remove adjustment plates (1) and place them, correctly sorted, in tray (No.
11 1 844).
Secure mount (No. 11 0 853) to valve spring compressor (No. 11 0 851).

Adjust the compression fixture (No. 11 0 852) on spring cup (1).
Secure thrust cage (No. 11 0 852) to valve spring compressor (No. 11 0
851).
Position the valve spring compressor (No. 11 0 851) on spring cup (1) and
valve (2), press down spring cup (1).
Remove valve shims (3) and remove valve-spring compressor (No. 11 0
851).
Remove valve (2), spring cup (1) and valve spring (4).
(-) Removing valve stem seals and spring retainers
Remove valve stem seal (1) with pliers (No. 11 1 250).

Remove spring cup (2).
(-) Replacing cylinder head
NOTICE
The description is for the left side of the vehicle. The description also applies
analogously to the right side of vehicle.
Remount the line for switching cam adjuster (1) on the new cylinder head
(2).
Check O-rings (4) for damage; renew if necessary.
Install the connector (3) in the cylinder head (2).
The retaining lug (arrow) engages.
Remount the spark plug (1) with the tool (No. 12 1 220) on the new cylinder
head (2).
Tightening torques
M10 x 1 12 Nm
Remove bolt (1).

Remount camshaft sensor (2) with bolt (1) on new cylinder head (3).
Tightening torques
M6 x 16 8 Nm
Remove bolt (1).

Remount knock sensor (2) with bolt (1) on new cylinder head (3).
Tightening torques
M8 x 30 20 Nm
Transfer reusable small items and to the new intake cylinder head.
(-) Installing valve stem seals and spring retainers
Install spring cup (1)

Install valve (2).
Slide assembly sleeve (3) onto valve (2).
Install valve stem seal (4) using drift (No. 11 5 602) till the limit position.
Remove assembly sleeve (3).
(-) Installing valves
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.
Lubricate the components with engine oil.

Adjust the compression fixture (No. 11 0 852) on spring cup (1) and secure it
on the valve spring compressor (No. 11 0 851).
Install valve spring (2) with the mark (arrow) up and install spring cup (1).
Position the valve spring compressor (No. 11 0 851) on spring cup (1), press
down spring cup (1).
Install valve shims (3) and remove valve-spring compressor (No. 11 0 851).
Install adjustment plate (1) from tray (No. 11 1 844), noting the assignment.

(-) Installing cam followers
Install rocker arms (3).

Slightly lubricate rocker arm shaft (2) and install.
Position rocker arm shafts (2) such that needle rollers (1) can be pushed
through the recesses (arrows).
Install needle rollers (1).

recess.

Tightening torques
diagonally opposite
sequence
5 Nm
20 Nm
40 Nm
Additional angle of
rotation, 150°
M6 x 25 12 Nm
M6 x 95 12 Nm


Follow-up work
Checking tooth backlash, left camshaft sprockets
Checking timing
Installing silencer
Installing lid

11 12 173 Replacing right cylinder head

+ 11 12 817
CAUTION
Risk of burn injury
Preparatory work
Removing front seat
Draining coolant
Removing silencer
Core activity

ATTENTION
procedure
tab.

connector (2).




(-) Removing valves
11 1 844).


851).
851).

(-) Replacing right cylinder head
(2).
head (2).
Tightening torques
M10 x 1 12 Nm
Remove bolt (1).


Tightening torques
M8 x 30 20 Nm

Install valve (2).
ATTENTION
correct procedure.
Engine damage
grooves.




recess.

Tightening torques
diagonally opposite
sequence
5 Nm
20 Nm
40 Nm
Additional angle of
rotation, 150°
M6 x 25 12 Nm
M6 x 95 12 Nm
NOTICE


Follow-up work
Check tooth backlash of right camshaft sprocket
Installing silencer


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

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

of travel).

11 12 829 Replace cylinder head, right (check intermediate shaft axle for radial clearance)
CAUTION
Risk of burn injury
NOTICE
The follow-up works are partially included in the position for checking the
radial clearance of intermediate shaft axis. The follow-up works are therefore
only partially included in the flat rate unit.
Preparatory work
Removing cover
Draining coolant
Removing silencer
Core activity
ATTENTION
procedure
tab.

connector (2).




(-) Removing valves
11 1 844).

851).
851).

(-) Replacing right cylinder head

(2).
head (2).
Tightening torques
M10 x 1 12 Nm
Remove bolt (1).

Tightening torques
M8 x 30 20 Nm

Install valve (2).
ATTENTION
correct procedure.

Engine damage
grooves.




recess.
Tightening torques
diagonally opposite
sequence
5 Nm
20 Nm
40 Nm
Additional angle of
rotation, 150°
M6 x 25 12 Nm
M6 x 95 12 Nm

NOTICE


Follow-up work

Installing right injection-valve cover
Installing silencer
Installing lid

11 12 830 Replace cylinder head, left (check intermediate shaft axle for radial clearance)
CAUTION
Risk of burn injury
NOTICE
The follow-up works are partially included in the position for checking the
radial clearance of intermediate shaft axis. The follow-up works are therefore
only partially included in the flat rate unit.
Preparatory work
Removing cover
Draining coolant
Removing silencer
Core activity
ATTENTION
procedure
tab.

connector (2).



(-) Removing valves
11 1 844).


851).
851).

(-) Replacing cylinder head
NOTICE
The description is for the left side of the vehicle. The description also applies
analogously to the right side of vehicle.
(2).

head (2).
Tightening torques
M10 x 1 12 Nm
Remove bolt (1).

Remount camshaft sensor (2) with bolt (1) on new cylinder head (3).
Tightening torques
M6 x 16 8 Nm
Remove bolt (1).

Tightening torques
M8 x 30 20 Nm
Transfer reusable small items and to the new intake cylinder head.

Install valve (2).

ATTENTION
correct procedure.
Engine damage
grooves.




recess.
Tightening torques

diagonally opposite
sequence
5 Nm
20 Nm
40 Nm
Additional angle of
rotation, 150°
M6 x 25 12 Nm
M6 x 95 12 Nm


Follow-up work

Checking timing
Installing left injection-valve cover
Installing silencer
Installing lid

11 14 019 Removing/installing or sealing front engine-block cover

+ 11 14 875
0499 - Low-slungOE
Preparatory work
Draining engine oil
Core activity
(-) Installing rear-wheel stand
If necessary, prepare rear-wheel stand (No. 36 3 980):

Push the locking button and remove retaining pin (No. 36 3 985).
Push axle adapter (No. 36 3 982) into basic stand (No. 36 3 981) and secure
with retaining pin.
Fit adapter shaft (No. 36 3 986) to axle adapter (No. 36 3 982).
If applicable, adjust height of the axle mounting (No. 36 3 982) and secure
with bolt (1).
Working from the left, install the rear-wheel stand in the rear axle.
Push on bushing (No. 36 3 989) and retaining pin (No. 36 3 985) from the
right, while holding the locking button down.
ATTENTION
Vehicle toppling to side
Risk of damage to parts if vehicle topples
Make sure that the vehicle is secured so that it cannot topple sideways.
Hold the motorcycle upright and at the same time press lever (No. 36 3 983)
down.
Lever is flat on the round.
Make sure the motorcycle is upright.
(-) Removing front crankcase cover
Remove screws (1).
Push off engine housing cover (1) with extractor (No. 11 0 833) and remove.
NOTICE
If the crankcase cover and leading link come into contact with each other,
adjust the rear-wheel stand to a higher setting.

Remove extractor (No. 11 0 833) from engine housing cover (1).

Sealant
Dow Corning 07 58 0 397 777
Install engine housing cover (1).
Hand-tighten screws (1) to (16).

direction.
Tightening torques
M6 x 20 Tightening
sequence: See
repair manual
10 Nm
(-) Removing rear-wheel stand
ATTENTION
Extend side stand (1).

Secure the motorcycle to ensure that it cannot topple and slowly lower it
forward.
Place the motorcycle on its side stand (1).
Push the locking button and remove retaining pin (No. 36 3 985) and
bushing (No. 36 3 989) .
Work the auxiliary stand to the left until it is clear of the rear axle.
Follow-up work

11 15 050 Replace engine breather with hose

+ 11 15 550
Preparatory work
Removing battery
Removing front seat
Removing fuel tank
Removing left cover
Removing starter relay
Remove the cover for battery holder
Removing battery carrier
Core activity
(-) Removing engine breather
Open clip (1) with pliers (No. 17 5 571).

Disconnect breather hose (2).
Remove screws (1).

Remove engine breather cover (2).

(-) Removing breather wheel
Remove screw (1).

Remove breather wheel (2).

Install handlebar end plug (1).
Tightening torques
M10 x 25 41 Nm
(-) Installing engine breather

Secure hose (2) with clamp (1) to new breather cover (3).
Check O-ring (4) for damage, replace if necessary; install in new breather
cover (3).
Using a suitable tool, drive in shaft sealing ring (5) until seated.
Lubricate the friction face (arrow) of shaft sealing ring (5) with engine oil.
Install engine breather cover (2).

Install screws (1).
Tightening torques
M6 x 20 12 Nm
Connect breather hose (2).

Secure clip (1) with pliers (No. 17 5 571).
Follow-up work
Installing battery carrier
Installing cover for battery holder
Installing starter relay
Installing battery

11 15 138 Replace the crankcase ventilation hose

+ 11 15 507
Preparatory work
Removing left cover
Removing battery
Removing front seat
Removing fuel tank
Removing cross-member for battery carrier
Core activity
(-) Removing hose for engine breather
Ease battery carrier (1) aside.

Open clips (2) with pliers (No. 17 5 571).
Remove hose (3).
(-) Installing hose for engine breather
Ease battery carrier (1) aside.

Install hose (3).
Close clips (2) with pliers (No. 17 5 571).
Follow-up work
Installing cross-member for battery carrier

Installing battery

11 21 511 Renewing crankshaft (engine removed)
Preparatory work
Removing clutch hub
Removing nut from clutch basket
Removing clutch basket
Removing gearbox

11 24 547 Replacing all conrod bearings (gearbox removed)
Preparatory work
Removing left piston pin
Separating halves of engine block
Removing left conrod
Removing right conrod bearing cap
Core activity
(-) Removing conrod bearing shells
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 conrod bearing shells (1) from conrod (2) and conrod bearing cap
(3), using a suitable tool.
(-) Install the conrod bearing shells
ATTENTION
Old conrod bearing shells not matched to new crankshaft
Engine damage
Renew the conrod bearing shells when replacing the crankshaft.

ATTENTION
Different weight classes of the conrods
Rough engine operation
Make sure that the conrods are of the same weight class.
Take care on marking, namely, colour markings on crank shaft piston rod.
Technical data
Conrod bearing, bore Identification/colour A/red or B/blue
diameter coding on the
connecting rod foot
Conrod bearing, bore Identification/colour A/red or B/blue

diameter coding on the
connecting rod foot

to identify the bearing Identification for dots
shells in the right right guide bearing
crankcase / the connecting (three parts)
rod bearing shells B inside: near blue/red dots
corresponding
crankshaft
journals:
identification for
connecting rod
bearing
identification for dots
right main bearing
(single part)
Select the required bearing shell using the colour markings on the
crankshaft / connecting rod.
Technical data
Colour codes, conrod red/violet/blue dots
bearings
Assignment,
conrod/conrod cap
Colour codes, conrod Connecting Bearing shell red

bearings rod hole red/

Assignment, crankshaft
conrod/conrod cap journal red
Connecting Bearing shell blue
rod hole
blue/
crankshaft
journal blue
Connecting Bearing shell violet
rod hole
blue/
crankshaft
journal red
Connecting Bearing shell violet
rod hole red/
crankshaft
journal blue
If a connecting rod will be renewed, care is taken that it is the same weight
class:
Technical data
ID mark for conrod weight Labelling on 0 ... 4
classes the big end
(on 4th
position)
ID mark for conrod weight Connecting 542.0...547.9 g

classes rod weight
class 0:
colour
points 2 x
white
Connecting 548.0...553.9 g
rod weight
class 1:
colour
points 2 x
blue
rod weight
class 2:
colour
points 3 x
white
rod weight
class 3:
colour
points 3 x
yellow
rod weight
class 4:
colour point
1 x blue
Lubricate connecting rod bearing (1) with engine oil.

Insert conrod bearing shell (1) be flush in conrod (2), noting the installed
position of the half-moon groove in the conrod (arrows).
Press conrod bearing shell (1) flush into conrod (2) and install.
Lubricate connecting rod bearing (1) with engine oil.

Install conrod bearing shell (1) in conrod bearing cap (2), noting the installed
position of the half-moon groove in the bearing cap (arrows).
Press conrod bearing shell (1) into conrod bearing cap (2) and install.
Follow-up work
Installing right conrod bearing cap
Installing left connecting rod
Checking position of crankshaft relative to clutch cage
Joining crankcase sections
Installing left piston pin

Installing coolant pump

11 25 513 Replacing all pistons (gearbox removed)
Preparatory work
Removing left piston pin
Separating halves of engine block
Core activity
(-) Removing piston
ATTENTION
Component damage

Remove conrod bearing cap (2).

(-) Removing right conrod

Remove piston pin (2).
Remove conrod (3) from piston (4).
(-) Installing right connecting rod
NOTICE
If connecting rods are renewed, check the weight class (Electronic Parts
Catalogue)
Install connecting rods only of the same weight class.
Install the circlip (1).

Position the right piston (2) in such a way that arrow (arrow) is on top (the
arrow points in the direction of travel).
Insert the right connecting rod (3) with crescent-shaped grooves (4) to the
right.
Install gudgeon pin (5).

(-) Installing right piston with conrod


Carefully slide right piston (1) with the arrow mark (arrow) up (arrow mark
ATTENTION
Component damage
Install conrod bearing cap (2).

tightening.
Workshop equipment
Install screws (1).

Tightening torques
Conrod bolt
20 Nm
Additional angle of
rotation, 150°
Slacken and then
retighten the bolt
5 Nm
20 Nm
Additional angle of
rotation, 150°
(-) Checking position of crankshaft relative to clutch cage
Make sure that the marks (arrows) of crankshaft (1) and clutch cage (2) are
aligned.



surface (1).
Sealant
Dow Corning 07 58 0 397 777
ATTENTION



tightening.
Workshop equipment
Tighten all screws.
Tightening torques
25 Nm
Additional angle of
rotation, 90°
M8 x 80 19 Nm
M6 x 30 10 Nm



932).

Follow-up work
Installing coolant pump

11 26 501 Replacing freewheel for starter (gearbox removed)
Preparatory work
Slacking screws of freewheel housing
Core activity
(-) Removing starter freewheel
Remove screws (1).

Remove freewheel housing (2) and freewheel (3) from rotor (4).
(-) Install the starter freewheel
Install freewheel housing (1) on rotor (2) in such a way that the recess
(arrow) is aligned with the groove (arrow).
Insert freewheel (1) into freewheel housing (2), metal edge (arrow) to the
outside.
Position freewheel housing (2) with freewheel (1) on rotor (3) and bring the
holes into alignment.
Follow-up work

Tightening screws in freewheel housing

11 26 502 Replacing layshaft for starter (gearbox removed)
Preparatory work
Removing timing chain slide rail
Core activity
(-) Removing gearwheel, starter freewheel
Remove screw (1), contact disc (2) and sleeve (3).
Remove gear (1) from crankshaft (2).
(-) Removing starter idler gear
Remove bolt (1) and sealing washer (2).

Remove axle (3).
NOTICE
Shaft of idler gear has a left-hand thread. Turn clockwise to open.
Remove starter idler gear (4).

(-) Removing starter double gear
Remove bolt (1) and sealing washer (2).

Remove axle (3).
Remove starter double gear (4).
(-) Installing starter double gear
Clean the threads.

Install starter double gear (1).
Install axle (2).
Install bolt (3) with sealing washer (4).
Tightening torques
encapsulated)
(-) Installing starter idler gear
Install starter idler gear (4).

Check the O-ring for damage; replace if necessary.
Install axle (3).
Install bolt (1) and sealing washer (2).
Tightening torques

encapsulated)
(-) Installing gearwheel, starter freewheel
Lubricate the friction face (arrow) of the gearwheel with engine oil.
Install gear (1) on crankshaft (2).
Clean the threads.

Install bolt (1) with contact disc (2) and sleeve (3).
Tightening torques
Follow-up work

11 27 513 Removing/installing or replacing balancing shaft (gearbox removed)
Preparatory work
Locking balancing shaft
Remove the right timing chain tensioning rail
Core activity
Remove balancing shaft (1).
Before installing the balancing shaft, check that thrust washer (1) is correctly
installed in the housing.
Install balancing shaft (1) while counter-holding balancing weight (2).

Make sure that Woodruff key (3) and the keyway (arrow) are aligned.

Follow-up work
Installing locating device for right camshafts
Removing lock for balancing shaft
Removing locating device for right camshafts

11 30 503 Adjusting valve timing, right (for adjusting valve clearance)
Core activity
(-) Adjusting right-side ignition timing
Loosen screws (1).

Turn camshafts (2) and (3) until the right holding fixture (No. 11 2 512) can
be removed from the holding fixture set (No. 11 2 510).
Ensure that the right holding fixture (No. 11 2 512), from the holding fixture
set lies (No. 11 2 510) fully (arrow) on the camshaft ends.
Tightening torques
10.9
Remove bolt (1).

Remove right holding fixture (No. 11 2 512) from the holding fixture set (No.
11 2 510).
Secure locating pin (No. 11 0 822) (pull back the pin and engage it).

Insert barring tool (No. 11 0 821) into intermediate wheel (1).
Crank the engine until the camshafts (1) are again at firing TDC.
Unlock locating pin (No. 11 0 822) and bar the engine until the locating pin
engages.
Engine is locked at firing TDC.
Using right holding fixture (No. 11 2 512) from holding fixture set (No. 11 2
510) reset the correct firing TDC position and, if required, the timing.

11 30 504 Adjusting valve timing, left (for adjusting valve clearance)
Preparatory work
Core activity
(-) Adjusting left-side ignition timing
Loosen screws (1).

Turn camshafts (2) and (3) until the left holding fixture (No. 11 2 511) can be
removed from the holding fixture set (No. 11 2 510).
Ensure correct fit (arrow) of left holding fixture (No. 11 2 511) from tool set
(No. 11 2 510).
Tightening torques
10.9
Remove bolt (1).

Remove left holding fixture (No. 11 2 511) from the holding fixture set (No.
11 2 510).

engages.
Using left holding fixture (No. 11 2 511) from holding fixture set (No. 11 2
Follow-up work

11 31 002 Replacing right intermediate shaft

+ 11 31 795
Preparatory work
Core activity
(-) Removing sprocket for right intermediate shaft
Remove bolt (1).

Remove axle (2).
Take timing chain (1) off chain sprocket (2).

Remove the chain sprocket (2).
(-) Replacing intermediate shaft
Clamp sprocket (1) in a vice fitted with protective jaws.

Remove screws (2).
Remove intermediate shaft (3) from sprocket (1).

Rounded side (arrow) of sprocket (1) must face out.

Install intermediate shaft (2) in sprocket (1).
Install screws (3).
Tightening torques
M6 x 12 10 Nm
(-) Installing sprocket for right intermediate shaft
Install bolt (2).
Tightening torques
M6 x 14 8 Nm
Follow-up work

11 31 003 Replacing left intermediate shaft

+ 11 31 796
Preparatory work
Core activity
(-) Removing sprocket for left intermediate shaft
Remove bolt (1).

Remove axle (2).
Take timing chain (1) off chain sprocket (2).

Remove the chain sprocket (2).

Remove screws (2).


Install screws (3).
Tightening torques
M6 x 12 10 Nm
(-) Installing sprocket for left intermediate shaft
Install bolt (2).
Tightening torques
M6 x 14 8 Nm
Follow-up work

11 31 004 Replacing right camshaft sprockets

+ 11 31 797
Preparatory work
Core activity
(-) Removing right camshaft sprockets
Move the intake camshaft (2) to the right until the camshaft sprocket (1) runs
flush left to the intermediate shaft sprocket (3).
Retain the camshafts with right holding fixture (No. 11 2 512), from holding
fixture set (No. 11 2 510).
Ensure that the holding fixture lies fully (arrow) on the ends of the camshaft.
Remove the screw (1) with bearing (2).

Remove bolt (3).

11 31 005 Replacing left camshaft sprockets

+ 11 31 798
Preparatory work
Core activity
(-) Removing the left switching cam adjuster
Remove screws (1) and release left switching cam adjuster (2).
ATTENTION
procedure
tab.

connector (2).
Remove the left switching cam adjuster (1).

Disconnect the connector (2) for left switching cam adjuster (1).


11 31 006 Checking camshaft drive tooth backlash, left

+ 11 31 799
Preparatory work
Core activity
(-) Checking tooth backlash, left camshaft sprockets
Preconditions for checking and measuring tooth backlash:

Engine is cold.
Cylinder of side being measured is at firing TDC.
Check
Move intake camshaft (1) and exhaust camshaft (2) axially back and forth.
Result:
Intake camshaft or exhaust camshaft cannot be moved axially, i.e. there is

no tooth backlash.
Measure:
Replace camshaft sprocket.
Install a camshaft sprocket of the next highest or next lowest classification,
as applicable. Ascertain the classification by comparing the spare part
number on the component with the additional information in the electronic
parts catalogue (ETK). Then re-measure tooth backlash.
Result:
Intake camshaft and exhaust camshaft can be moved axially, i.e. there is
tooth backlash.
Measure:
Measuring tooth backlash, left camshaft sprockets
Insert holder (No. 11 0 864) between gears of intermediate shaft (1) and
exhaust camshaft (2) and secure by means of knurled nut (3).

Install dial gauge (No. 11 0 861) in such a way that the button (arrow) is pre-
loaded and engaged centred relative to a tooth flank (detail) of camshaft
sprocket (1).
Check
Move intake camshaft sprocket (1) slightly back and forth without putting
any effort.
Technical data
Backlash of camshaft 0.003...0.020 mm
sprocket
Result:
Measure:
Replacing camshaft sprocket

as applicable. Ascertain the classification based on the spare part number
on the component in the ETK.
Insert holder (No. 11 0 864) between gears of intermediate shaft (1) and
intake camshaft (2) and secure by means of knurled nut (3).
Install dial gauge (No. 11 0 861) in such a way that the button (arrow) is pre-
loaded and engaged centred relative to a tooth flank (detail) of camshaft
sprocket (1).
Check
Move exhaust camshaft sprocket (1) slightly back and forth without putting
any effort.
Technical data

Backlash of camshaft 0.003...0.020 mm
sprocket
Result:
Measure:
Replacing camshaft sprocket
as applicable. Ascertain the classification based on the spare part number
on the component in the ETK.
Remove the measuring tools.
Follow-up work

11 31 008 Check radial clearance of intermediate shaft axle, left

+ 11 31 608
Preparatory work
Core activity
(-) Check intermediate shaft axle and bearing of the intermediate
shaft
Check
Check tyre tread (arrows) of the intermediate shaft axle (1) for damage.
Result:
Damage like blow-outs, chatter marks can be detected.
Measure:
Perform radial play check with new intermediate shaft axle, renew
intermediate shaft axle.
Check
Check bearing (1) of the intermediate shaft (2) for damage.

Result:
Damage like missing needles, broken housing can be detected
Measure:
Renew intermediate shaft.
Replacing intermediate shaft
Remove screws (2).

Install screws (3).
Tightening torques
M6 x 12 10 Nm
(-) Installing axle for left intermediate shaft
Install axle (1) and retaining screw (2).
(-) Check radial clearance of left intermediate shaft axle
Secure holder (No. 11 0 863) with bolt (1) and contact disc (2) on cylinder
head (3).
Install dial gauge (No. 11 0 861) in such a way that the button (arrow) lies
pre-stressed, in the top centre in the distance (A) on the intermediate shaft
axle (4).
Technical data

Distance from approx. 7 mm
measurement point to
cylinder head
Check
Shuttle intermediate shaft axle (4) in direction of piston and measure
radial clearance.
Technical data
Radial clearance of Specified 0.016...0.060 mm
the intermediate shaft value
axle Wear limit min 0.060 mm
Result:
Radial clearance is within the tolerance.
Measure:
Complete motor vehicle.
Result:
Radial clearance is outside the tolerance.
Measure:
Renew cylinder head.
=> 11 12 830, Replace cylinder head, left (check intermediate shaft axle for
radial clearance) (Billed as a separate item)
(-) Removing axle for left intermediate shaft
Remove retaining screw (2) and axle (1).
Follow-up work
Checking timing

11 31 009 Check radial clearance of intermediate shaft axle, right

+ 11 31 609
Preparatory work
Core activity
(-) Check intermediate shaft axle and bearing of the intermediate
shaft
Check
Check tyre tread (arrows) of the intermediate shaft axle (1) for damage.
Result:
Damage like blow-outs, chatter marks can be detected.
Measure:
Perform radial play check with new intermediate shaft axle, renew
intermediate shaft axle.
Check
Check bearing (1) of the intermediate shaft (2) for damage.

Result:
Damage like missing needles, broken housing can be detected
Measure:
Renew intermediate shaft.
Replacing intermediate shaft
Remove screws (2).

Install screws (3).
Tightening torques
M6 x 12 10 Nm
(-) Installing axle for right intermediate shaft
Install axle (1) and retaining screw (2).
(-) Check radial clearance of right intermediate shaft axle
Secure holder (No. 11 0 863) with bolt (1) and contact disc (2) on cylinder
head (3).
Install dial gauge (No. 11 0 861) in such a way that the button (arrow) lies
pre-stressed, in the top centre in the distance (A) on the intermediate shaft
axle (4).
Technical data

Distance from approx. 7 mm
measurement point to
cylinder head
Check
Shuttle intermediate shaft axle (4) in direction of piston and measure
radial clearance.
Technical data
Radial clearance of Specified 0.016...0.060 mm
the intermediate shaft value
axle Wear limit min 0.060 mm
Result:
Radial clearance is within the tolerance.
Measure:
Complete motor vehicle.
Result:
Radial clearance is outside the tolerance.
Measure:
Renew cylinder head.
=> 11 12 829, Replace cylinder head, right (check intermediate shaft axle for
radial clearance) (Billed as a separate item)
(-) Removing axle for right intermediate shaft
Remove retaining screw (2) and axle (1).
Follow-up work

11 31 095 Removing/installing or replacing timing chain tensioner, left cylinder

+ 11 31 781
Preparatory work
Core activity
(-) Replacing left timing-chain tensioner
Remove timing chain tensioner (1) with spring (2), piston (3) and sealing ring
(4).
Install the new timing chain tensioner (1) with spring (2), piston (3) and new
sealing ring (4).
Tightening torques
M18 x 1.5 32 Nm
Follow-up work

11 31 200 Replacing left camshaft(s)

+ 11 31 792
Preparatory work
Core activity
(-) Slackening threaded fasteners of left camshafts
flush right on the intermediate shaft sprocket (3).
Retain the camshafts with the left holding fixture (No. 11 2 511) from the set
of holding fixtures (No. 11 2 510), ensuring that the camshaft ends fit
correctly (arrow).
Loosen screws (1).

11 31 205 Replacing right camshaft(s)

+ 11 31 793
Preparatory work
Core activity
(-) Slackening threaded fasteners of right camshafts
flush left to the intermediate shaft sprocket (3).
Retain the camshafts with the right holding fixture (No. 11 2 512) from the
set of holding fixtures (No. 11 2 510).
Loosen screws (1).

Remove bolt (1).

Remove right holding fixture (No. 11 2 512) from the set of holding fixtures
(No. 11 2 510).
(-) Removing right camshaft bearing cap
Remove screws (1).

Remove camshaft bearing cap (2) and O-ring (3).
(-) Removing right camshafts
Remove intake camshaft (1).

Remove exhaust camshaft (2).
(-) Replacing right camshafts
Remove screws (1).

Remount the bearing (2), camshaft sprocket (3) and friction plate (4) on the
new intake camshaft (5).
Remount the camshaft sprocket (3) and friction plate (4) on the new exhaust
camshaft (6).
(-) Installing right camshafts
flush left on the intermediate shaft sprocket (3).
Install intake camshaft (1) and exhaust camshaft (2) with the cams (arrows)
facing out.
Position intake camshaft (1) and exhaust camshaft (2) in such a way that
gears (3) engage in intermediate shaft (4).
Check the firing TDC position of the camshafts (1).

The flat sections are parallel to the cylinder head surface.
(-) Installing right camshaft bearing cap

Install the O-ring (3).

Fit the camshaft bearing cap (2).
Install screws (1).
Tightening torques
M6 x 35 Tightening
sequence: tighten
alternately
10 Nm
(-) Adjusting right-side ignition timing
Loosen screws (1).

Turn camshafts (2) and (3) until the right holding fixture (No. 11 2 512) can
be removed from the holding fixture set (No. 11 2 510).
Ensure that the right holding fixture (No. 11 2 512), from the holding fixture
set lies (No. 11 2 510) fully (arrow) on the camshaft ends.
Tightening torques
10.9
Remove bolt (1).

Remove right holding fixture (No. 11 2 512) from the holding fixture set (No.
11 2 510).

engages.
Requirement
Right cylinder is at firing TDC.
Check
Technical data
cold max 35 °
C
C
Result:

Measure:
NOTICE


Tightening torques
M6 x 20 10 Nm
Follow-up work

11 31 513 Replacing right timing chain (gearbox removed)
Preparatory work
Remove the right timing chain tensioning rail
Core activity
(-) Replacing right timing chain
Replace timing chain (1).

Loop timing chain (1) onto balancing shaft sprocket.
Follow-up work

11 31 514 Replacing left timing chain (gearbox removed)
Preparatory work
Core activity
(-) Replacing left timing chain
Replace timing chain (1).

Loop timing chain (1) on to crankshaft sprocket.
Follow-up work

11 31 515 Replacing timing-chain rails (gearbox removed)
Preparatory work
Core activity
(-) Replacing timing-chain rails
Remove bearing cap screw (1).

Remove tensioning rail (2) and slide rail (3).
Install new tensioning rail (2) and slide rail (3).
Install bearing cap screws (1).
Tightening torques
M8 19 Nm
Remove bearing cap screw (1).

Remove tensioning rail (2) and slide rail (3).
Install new tensioning rail (2) and slide rail (3).
Install bearing cap screws (1).
Tightening torques
M8 19 Nm
Follow-up work


11 33 697 Removing/installing or replacing all left rocker arms (camshafts removed)
NOTICE
Rocker arms influence the valve clearance. Check or install after renewal or
change of the valve clearance.
Core activity

Lubricate the rocker arm shafts (1) with engine oil.

Insert rocker arm (2) and secure it with rocker arm axles (1).

11 34 001 Checking valve clearance

+ 11 34 501
Preparatory work
Core activity
Unlock locating pin (No. 11 0 822) and install with TDC mark (arrow).
Technical data
(A)
BDC hole for 6 mm
locating pin
(B)

Turn the engine clockwise until the locating pin engages.
Check
Check the position of camshafts (1).

Result:
Camshafts not at firing TDC; cams do not point out.
Measure:
Slowly turn the engine until locating pin (No. 11 0 822) engages.
Check
Technical data
cold max 35 °
C
C
Result:
Measure:
NOTICE

Technical data
(A)
BDC hole for 6 mm
locating pin
(B)

Turn the engine counter-clockwise until the locating pin engages.
Check
Result:

Measure:
Check
Technical data
cold max 35 °
C
C
Result:

Measure:
NOTICE
Follow-up work

11 34 502 Checking valve clearance (for maintenance)
Preparatory work
Core activity
Technical data
(A)
BDC hole for 6 mm
locating pin
(B)

Turn the engine clockwise until the locating pin engages.
Check

Result:
Measure:
Check
Technical data
cold max 35 °
C
C
Result:
Measure:
NOTICE

Technical data
(A)
BDC hole for 6 mm
locating pin
(B)

Turn the engine counter-clockwise until the locating pin engages.
Check
Result:

Measure:
Check
Technical data
cold max 35 °
C
C
Result:

Measure:
NOTICE
Follow-up work

11 34 509 Adjusting left valve clearances (for checking valve clearances)
Core activity
Remove timing chain tensioner (1) with piston (2) and sealing ring (3).
(-) Installing left timing-chain tensioner
ATTENTION
procedure
tab.

connector (2).

(-) Remove left retaining bracket for axial fixation

Spin the engine in clockwise direction further, so that bolt (2) is removed
using recess (arrow).
Remove screws (1).

Remove retaining bracket for axial fixation (2), thereby taking care of the
guide sleeve (arrow).
(-) Removing left camshaft bearing cap
Remove screws (1).


(-) Removing left camshafts

(-) Adjusting left valve clearance
Raise rocker arm (1).

Remove adjustment plate (2).
Measure thickness of adjustment plate (2) with calliper gauge.
Calculate the thickness of the new shim from the difference between the
specified value and the valve clearance noted down beforehand.
Technical data
cold max 35 °
C
C
Install new adjustment plate (2).
(-) Install the left camshafts
flush right on the intermediate shaft sprocket (3).

facing out.
Check the firing TDC position of the camshafts(1).

(-) Installing left camshaft bearing cap

Install screws (1).
Tightening torques
M6 x 35 Tightening
sequence: tighten
alternately
10 Nm
(-) Install left retaining bracket for axial fixation

Spin the engine clockwise until the screw (2) can be removed through the
recess (arrow).
Position retaining bracket for axial fixation (1) noting the guide sleeve
(arrow).
Install screws (2).
Tightening torques
Retaining bracket on bearing bracket
M6 x 35 10 Nm
(-) Checking timing
Check
Using left holding fixture (No. 11 2 511), from holding fixture set (No. 11 2
510), check the correct firing TDC position.
Result:
Locking device cannot be pushed into position.

Measure:
Adjust the valve timing of the cylinder in question.
=> 11 30 504, Adjusting valve timing, left (for adjusting valve clearance) (Billed
as a separate item)


Tightening torques
M6 x 20 10 Nm
(-) Installing left timing chain tensioner

Tightening torques
M18 x 1.5 32 Nm
Recheck valve clearance by way of verification.

11 34 510 Adjusting right valve clearances (for checking valve clearances)
Core activity
(-) Removing right chain tensioner
Remove timing chain tensioner (1) with piston (2) and sealing ring (3).
(-) Installing right timing-chain tensioner
(-) Removing the right switching cam adjuster of the camshaft
Remove the screws (1) and release the right switching cam adjuster of the
camshaft (2).
ATTENTION
procedure
tab.

connector (2).
Remove the right switching cam adjuster of the camshaft (1).

Disconnect the connector (2) for the right switching cam adjuster of the
camshaft (1).
(-) Removing right camshaft bearing cap
Remove screws (1).

(-) Removing right camshafts

(-) Adjusting right valve clearance

Measure thickness of adjustment plate (2) with calliper gauge.
Calculate the thickness of the new shim from the difference between the
specified value and the valve clearance noted down beforehand.
Technical data
cold max 35 °
C
C
Install new adjustment plate (2).
(-) Installing right camshafts
flush left on the intermediate shaft sprocket (3).
facing out.
Check the firing TDC position of the camshafts (1).

(-) Installing right camshaft bearing cap

Install screws (1).
Tightening torques
M6 x 35 Tightening
sequence: tighten
alternately
10 Nm
(-) Checking right-side timing
Check
510) check the correct firing TDC position.
Result:
Locking device cannot be pushed into position.

Measure:
Adjust the valve timing of the cylinder in question.
=> 11 30 503, Adjusting valve timing, right (for adjusting valve clearance)
(-) Removing right timing-chain tensioner
(-) Installing right timing chain tensioner
Tightening torques
M18 x 1.5 32 Nm


Tightening torques
M6 x 20 10 Nm
Recheck valve clearance by way of verification.

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


851).
851).
(-) Remove the valve stem seal and spring retainer

(-) Installing valve stem seal and spring retainer

Install valve (2).

(-) Installing valve
ATTENTION
correct procedure.
Engine damage
grooves.

Install the adjustment plate (2).

Fold out the rocker arm (1).

11 34 800 Replace valve stem seals (cylinder head removed)
Core activity
(-) Removing valves

11 1 844).

851).
851).


Install valve (2).

ATTENTION
correct procedure.
Engine damage
grooves.

Install adjustment plate (2) from tray (No. 11 1 844), noting the sorting
sequence.
Fold out the rocker arm (1).

11 36 001 Replacing switching cams adjuster, left

+ 11 36 501
Preparatory work
Core activity
ATTENTION
procedure
tab.

connector (2).


Tightening torques
M6 x 20 10 Nm
Follow-up work

11 36 002 Replacing switching cams adjuster, right

+ 11 36 502
Preparatory work
Core activity
(-) Removing the right switching cam adjuster of the camshaft
Remove the screws (1) and release the right switching cam adjuster of the
camshaft (2).
ATTENTION
procedure
tab.

connector (2).
Remove the right switching cam adjuster of the camshaft (1).

Disconnect the connector (2) for the right switching cam adjuster of the
camshaft (1).

Tightening torques
M6 x 20 10 Nm
Follow-up work

11 41 000 Removing/installing or replacing oil pump

+ 11 41 651
0499 - Low-slungOE
Preparatory work
Draining engine oil
Installing rear-wheel stand
Removing clutch hub
Core activity
Remove screws (1).

suitable tool.

(-) Assembling oil pump
ATTENTION
Oil-pump components run dry
Component damage
Lubricate all components of the oil pump with engine oil prior to installation.
Lubricate all components of the oil pump with engine oil.

Install spacing washer (1) with small recess (arrow) first on oil-pump shaft
(2).
Insert driver pin (3) into oil-pump shaft (2).
Place inner rotor (4) on oil-pump shaft (2), making sure that driver pin (3) is
engaged in recesses (5).

Check
Result:
Measure:


Install screws (1).
Tightening torques
M6 x 16 12 Nm

Tightening torques
(mechanical)
Follow-up work
Installing clutch cage
Removing rear-wheel stand

11 41 004 Measuring engine oil pressure

+ 11 41 817
CAUTION
Hot exhaust system
Risk of burn injury
Core activity
(-) Removing oil temperature sensor

Disconnect connector (1) for oil-temperature sensor.
Remove oil temperature sensor (2) with sealing ring (3).
(-) 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 4 608) with sealing ring (1) in the engine block.
Install pressure gauge (No. 11 4 601) with hose (No. 11 4 602).
Check
Start the engine.

Check oil pressure across the entire engine rpm range.
Technical data
Oil pressure at idle speed 1+0.5 bar
−0.2
Engine oil is at
regular operating - at engine 4.5+0.5 bar
temperature speed min 5000 min −0.5
-1
Result:
Oil pressure is lower than specified.

Measure:

Identify and rectify the cause of the fault.
(-) Installing oil temperature sensor
Install oil temperature sensor (2) with new sealing ring (3).
Tightening torques
M12 x 1.5 14 Nm
Connect connector (1) for oil temperature sensor.

Follow-up work

11 41 310 Replacing oil-pressure control valve

+ 11 41 810
Preparatory work
Removing silencer
Core activity
(-) Removing oil pressure control valve
Place a suitable oil tray in position.

Remove threaded plug (1) with sealing ring (2), spring (3) and oil pressure
control valve (4).
(-) Installing oil pressure control valve
Replace sealing ring (2).

Install oil pressure control valve (4), spring (3), screw plug (1) with sealing
ring (2).
Tightening torques
M24 x 1.5 42 Nm
Follow-up work
Installing silencer

11 43 010 Replacing oil level indicator

+ 11 43 510
Preparatory work
Draining engine oil
Disconnect the connector for monitoring oxygen sensor
Removing silencer
Disengaging Bowden cables for exhaust-flow control valve
Disconnecting plug for right oxygen sensor
Removing servomotor for exhaust-flow control valve
Core activity
(-) Removing circlip
Remove circlip (1).
(-) Function, milling cutter
Milling cutter (No. 11 0 961):

Guide (1)
Milling head (2)
(-) Milling out rubber seal

ATTENTION


Component damage
Centre milling cutter (No. 11 0 961) by means of the guide (arrow) on oil-
level check (1).
Gripping the milling (No. 11 0 961) with one hand to guide it, press it firmly
into position.
Uniformly mill rubber seal (1).
The metal housing becomes visible all round.
(-) Function, scraper
Scraper (No. 11 0 951) is for right-hand use.

Hook (1) for removing the remains of the rubber seal
Cutter (2) for trimming off projecting remains of the rubber seal
(-) Removing remains of rubber seal
CAUTION
Splintering oil sight glass
Danger of injury
Wear safety goggles.
ATTENTION
Component damage

When using scraper (No. 11 0 951) do not attempt a prying action,

because this can break the blade of the tool.
Remove remains of rubber seal (1) between sight glass (2) and metal
housing (3) all round completely. To do so, work scraper (No. 11 0 951)
with a turning action clockwise.
(-) Method of operation, puller
Puller (No. 11 0 962), sleeve (No. 11 0 954), thrust piece (No. 11 0 955),
sleeve (No. 11 0 956), thrust nut (1).
(-) Removing engine-oil level indicator
ATTENTION
Excessive load on puller tool
Damage to puller tool
Remove all rubber sealing residues before using the puller tool.
Screw sleeve (No. 11 0 954) on to puller (No. 11 0 962) and centre it on oil-
level indicator (1).
Continue tightening sleeve (No. 11 0 954) to expand puller (No. 11 0 962)
under metal housing (2).
Metal housing (2) bulges out (arrow).
Fully tighten sleeve (No. 11 0 954) by hand.
Install thrust piece (No. 11 0 955) in such a way that the projection (arrow) is
seated in the recess of the expanded puller (No. 11 0 962).

Install nut (1) with washer (2) and tighten.
Metal housing (3) is held firmly by the puller and the thrust piece.
The puller is supported by the projections (arrow).
Slip sleeve (No. 11 0 956) into position and turn it until it is seated correctly
on the engine block.
Install thrust nut (1).
Remove the oil-level indicator by tightening thrust nut (1).
(-) Installing engine-oil level indicator
Clean oil-level indicator (1) and sealing face (2) in the engine block. Use a
scraper to remove heavy deposits of foreign matter, taking care not to
scrape into the base metal.
Position oil-level indicator (1) on drift (No. 11 0 963) with extension (No. 00 5
511) and handle (No. 00 5 500).
Apply sealant to oil-level indicator (1).
Sealant
Dow Corning 07 58 0 397 777
ATTENTION
Use of drift not in compliance with correct procedure
Damage to oil sight glass
Do not tilt the drift in the process of installation.
Position oil-level indicator (1) square to the bore and without allowing it to tilt,
install it with drift (No. 11 0 963) until seated.
(-) Install circlip
Install circlip (1).

If applicable, remove excess sealant.

Follow-up work
Installing servomotor for exhaust-flow control valve
Connecting plug for right oxygen sensor
Disconnecting the connector for monitoring oxygen sensor
Engaging Bowden cables for exhaust-flow control valve
Installing silencer

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

+ 11 51 563
0499 - Low-slungOE
CAUTION
Risk of burn injury
Preparatory work
Draining engine oil
=> Draining coolant, refilling/bleeding system (Description in

item: 17 00 504, Billed as a separate item)
Core activity
Remove screws (1).


Install screws (1).
Tightening torques

M6 x 40 12 Nm
Follow-up work

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

+ 11 61 578
0796 - Option 719 Billet Pack ClassicOE
0797 - Option 719 Billet Pack StormOE
0799 - HP Billet PackOE
Preparatory work
Removing front seat
Removing fuel tank
Remove the left throttle-valve assembly
Core activity
(-) Removing left knock sensor
Disconnect connector (1).

Remove bolt (2).
Remove knock sensor (3).
(-) Installing left knock sensor
Position knock sensor (3).

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

Follow-up work
Installing left throttle-valve assembly

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

+ 11 61 578
Preparatory work
Removing front seat
Removing fuel tank
Core activity
(-) Removing left air intake stub
Open clamp (1) using pliers (No. 13 1 512).

Remove air intake stub (2).
(-) Installing left air intake stub
Hold intake manifold (1) in place and position it with the lug (arrow) in the
recess.

Close clamp (1) from intake manifold (2) with pliers (No. 13 1 512).
Follow-up work

11 78 002 Replacing the oxygen control sensor, right

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

connector (2).

Release lock (3) and detach connector (2).
Remove the right oxygen sensor (1).
(-) Installing right oxygen sensor

Clean the threads.

Lubricate thread with lubricant.
Install right oxygen sensor (1).
Tightening torques
M18 x 1.5 45 Nm
Lubricate thread, Lubricant (Optimoly
TA)
Connect connector (2) for right oxygen sensor.

Attach connector (2) to exhaust flap servomotor.
Ensure that lock (3) is engaged to exhaust flap servomotor correctly.
Follow-up work

11 78 003 Replacing the oxygen control sensor, left

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

connector (2).
Remove the cable straps (arrows).

Release lock (3) and detach connector (2) from cable duct.
Disconnect connector (2) for left oxygen sensor.
Remove left oxygen sensor (1).
(-) Installing left oxygen sensor

Clean the threads.

Lubricate thread with lubricant.
Install left oxygen sensor (1).
Tightening torques
M18 x 1.5 45 Nm
TA)
Connecting connector (2) for left oxygen sensor.

Attach connector (2) to cable duct.
Ensure that lock (3) is engaged to cable duct.
Close the cable strap (arrows).
Follow-up work

11 78 005 Replacing right oxygen sensor monitoring sensor

+ 11 78 505
CAUTION
Hot exhaust system
Risk of burn injury
Preparatory work
Core activity
(-) Removing monitoring oxygen sensor
ATTENTION
procedure
tab.

connector (2).

Release lock (2) and detach connector for monitoring oxygen sensor from
battery tray.
Disconnect the connector (1) for monitoring oxygen sensor.
Remove monitoring oxygen sensor (1).

(-) Installing monitoring oxygen sensor
Clean the threads.

Lubricate thread.
Install monitoring oxygen sensor (1).
Tightening torques
M12 x 1.25 25 Nm
TA)

Connect the connector (1) for monitoring oxygen sensor.

Attach connector (1) to battery tray.
Ensure that lock (2) is engaged to battery tray.
Follow-up work


11 84 001 Replacing left crash bar

+ 11 84 501
Core activity
(-) Removing left engine protection bar
Release line (1) from holder (2).
Remove bolt (1).

Remove the engine protection bar (5).
(-) Replacing left engine protection bar
Remount holder (1) on the new engine protection bar (2) or renew it in case
of damage.
(-) Installing left crash bar
Fit engine protection bar (1).

Position screws (2), (3) and (4) and tighten in the given sequence.
Tightening torques

M10 x 45 Tightening
sequence: 1. rear
bottom with frame
to engine
55 Nm
M8 x 30 Tightening
sequence: 2. front
top to frame
19 Nm
M10 x 45 Tightening
sequence: 3. front
bottom to engine
55 Nm
Install bolt (5).
Tightening torques
M8 x 16 19 Nm
Secure line (1) in holder (2).
Follow-up work

11 84 002 Replacing crash bar, right

+ 11 84 502
Core activity
(-) Remove the right protection bar
Remove bolt (1).

(-) Replacing right engine protection bar
Remount holder (1) on the new engine protection bar (2) or renew it in case
of damage.
(-) Install the right crash bar

Position screws (2), (3) and (4) and tighten in the given sequence.
Tightening torques

M10 x 45 Tightening
sequence: 1. rear
bottom with frame
to engine
55 Nm
M8 x 30 Tightening
sequence: 2. front
top to frame
19 Nm
M10 x 45 Tightening
sequence: 3. front
bottom to engine
55 Nm
Install bolt (5).
Tightening torques
M8 x 16 19 Nm
Follow-up work

12 00 014 Performing vehicle test with BMW Motorrad diagnostic system

+ 12 00 516
Preparatory work
Core activity
(-) 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.
Perform all requisite repair work or diagnostic routines, as applicable.
Follow-up work

12 12 011 Renewing all spark plugs

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

Use spark-plug socket (No. 12 1 220) to remove the spark plug (1).
(-) Installing right spark plug
Tightening torques
M10 x 1 12 Nm
Technical data
manufacturer and
designation
(-) Removing left spark plug


(-) Installing left spark plug
Tightening torques
M10 x 1 12 Nm
Technical data
manufacturer and
designation
Follow-up work

12 12 509 Replace all spark plugs (for maintenance)
Core activity
(-) Removing spark plugs

Repeat this procedure to remove the spark plug on the other side.
(-) Installing spark plugs
Tightening torques
M10 x 1 12 Nm
Technical data
manufacturer and
designation
Repeat this procedure to install the spark plug on the other side.

12 13 155 Replacing direct ignition coil

+ 12 13 655
Preparatory work
Removing engine protection bars
Remove the cover for spark plug
Core activity
(-) Removing direct ignition coil
Requirement
Ignition is switched OFF.
ATTENTION
procedure
tab.

connector (2).
Detach line from guide (arrow).

Disconnect the connector (1) for direct ignition coil.
Remove direct ignition coil (2) using drive-out tool (No. 12 3 621).
(-) Installing direct ignition coil
Connect connector (1).

Press locking tab (2) in direction of arrow (1).

Connect connector (2) for direct ignition coil (1).
Attach line to guide (arrow).
Follow-up work
Installing cover for spark plug
Installing engine protection bar

12 31 501 Replacing alternator (gearbox removed)
Core activity
(-) Removing breather wheel
Remove bolt (1).

Remove breather wheel (2).
(-) Removing coil carrier
ATTENTION
Component damage
Remove screws (1).

Using a suitable tool, carefully pry out coil carrier (2) at the marked points
(arrows) and disengage.
Remove coil carrier (2).
(-) Removing stator
Remove cable tie (arrow).

Remove screws (1) and remove stator (2).
(-) Installing crankshaft locking device at TDC
Unlock locating pin (No. 11 0 822) and install with TDC mark (A).

Technical data
(A)
BDC hole for 6 mm
locating pin
(B)
engages at the TDC mark.
(-) Slacking screws of freewheel housing
Slacken screws (1).
(-) Removing magnetic wheel
Heat bearing shell (1) and nut (2).
Technical data
temperature
Remove nut (2) completely from threads of crankshaft (3). This releases
bearing shell (1).
Pull back crankshaft lock at locating pin (No. 11 0 822) and engage lock.

Remove bearing shell (1), nut (2), washer (3) and magnetic wheel (4) with
puller (No. 12 0 531).
(-) Removing starter freewheel
Remove screws (1).

Remove freewheel housing (2) and freewheel (3) from rotor (4).
(-) Install the starter freewheel
Install freewheel housing (1) on rotor (2) in such a way that the recess
(arrow) is aligned with the groove (arrow).
Insert freewheel (1) into freewheel housing (2), metal edge (arrow) to the
outside.

Position freewheel housing (2) with freewheel (1) on rotor (3) and bring the
holes into alignment.
(-) Installing magnetic wheel
Clean the contact faces (arrows) of magnetic wheel (1) and crankshaft (2).
Cleaner
Make sure that Woodruff key (3) is installed.
Set magnetic wheel (1) in position and make sure that Woodruff key (2) is
aligned with the keyway (arrow).
Install magnetic wheel (1), turning gearwheel (3) for the starter freewheel
counter-clockwise.
Disengage crankshaft lock at locating pin (No. 11 0 822) and engage at TDC
mark.
Clean the threads (arrows).

Apply thread-locking compound to the threads (arrows) of nut (1) and
crankshaft (2).

Loctite 270, High strength 83 19 2 210 337
Install washer (2) and nut (1).
Tightening torques
Rotor to crankshaft
M24 x 1.5 1st tightening torque,
Thread-locking compound (Loctite 150 Nm
270, High strength) slacken completely
250 Nm
Heat bearing shell (1) and, using a suitable tool, press on until seated.
Technical data
temperature
(-) Tightening screws in freewheel housing
Tighten screws (1).
Tightening torques
Freewheel housing to alternator
M8 x 16 - 12.9 35 Nm
(-) Installing crankshaft locking device at BDC
Unlock locating pin (No. 11 0 822) and install with BDC mark (B).

Technical data
(A)
BDC hole for 6 mm
locating pin
(B)
engages in BDC mark.
Check
Turn nut (1) back and forth to turn the crankshaft.
Result:
Crankshaft has clearly perceptible play, i.e. the locating pin is engaged in
TDC mark.
Measure:
Turn the crankshaft 180 degrees clockwise until the locating pin engages
with zero play in the BDC mark.
(-) Installing stator
Clean the threads.

Hold stator (2) in position and install screws (1).
Tightening torques
Stator to coil carrier
M6 x 40 10 Nm
270, High strength)
Secure the cable tie (arrow).
(-) Installing coil carrier
Clean rubber grommet (1) and groove (2) in the engine block.
Apply sealant to the sealing face (arrow) of rubber grommet (1).
Sealant
Dow Corning 07 58 0 397 777

Make sure that reamed sleeves (1) are installed.

Align coil carrier (2) on reamed sleeves (1) and install.
Insert rubber grommet (3) into groove (4).
Install screws (1).
Tightening torques
M6 x 20 12 Nm

Install bolt (1).
Tightening torques
M10 x 25 41 Nm

12 32 000 Removing/installing voltage regulator

+ 12 32 500
Preparatory work
Core activity
(-) Removing voltage regulator
Remove screws (1).
Disengage voltage regulator (1) and disconnect plugs (2) and (3).
Remove voltage regulator (1).
(-) Installing voltage regulator
Insert voltage regulator (1) into the vehicle.

Connect plugs (3) and (2).

Hold voltage regulator (2) in position.

Install screws (1).
Follow-up work

12 41 025 Replacing starter

+ 12 41 528
Preparatory work
Core activity
(-) Removing starter
Apply masking tape (1) to working area.

Open protective cap (2) at the tabs (arrows) and remove.
Remove the nut (1).

Release positive wire (2).
Remove screws (1).

Raise battery compartment (2).
Pull off starter motor (3) towards the rear.
Remove starter motor (3) to one side.

Remove bolt (1).
Release ground cable (2).
Remove starter motor (3).

(-) Installing starter

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

Install bolt (2).
Tightening torques
Wiring harness (ground) to starter
M6 x 10 8 Nm
Install the cable strap (arrow).
Raise battery compartment (1).

Install starter motor (2).
Install screws (3), taking care not to trap the cable (arrow).
Tightening torques
M6 x 35 12 Nm
Hold positive wire (2) in position.

Install the nut (1).
Tightening torques

(mechanical)
Connect and close protective cap (2).

The tabs (arrows) snap into position.
Remove the adhesive tape (1).
Follow-up work

12 51 010 Replace wiring harness for engine

+ 12 51 510
0456 - Style HPOE
Additional billing items
31 48 511 Additional work with Dynamic ESA front
Preparatory work
Removing front seat
Removing left cover
Remove right frame guard
Removing battery
Removing fuel tank
Disengaging expansion tank for coolant
Removing fuel distributor
Disengaging left throttle-valve assembly
Removing left intake air pipe
Disengaging right throttle-valve assembly
Removing right intake air pipe
Remove the right tank bracket
Remove the left tank bracket
Disengage front spring strut, top and bottom
Core activity
(-) Removing wiring harness for engine
Disconnecting left direct ignition coil
Requirement
ATTENTION
procedure
tab.

connector (2).

Disconnect plug (2) from direct ignition coil (1) .
Disconnect left knock sensor

ATTENTION
procedure
tab.

connector (2).


Remove bolt (1).

Release cable jumper (2).
Disengage grounding cable (3).

Disconnect connector (1) for camshaft sensor.
ATTENTION
procedure
tab.

connector (2).

Disconnect connector (1) for left oxygen sensor.
Unlock locks (2) and release cable (3) from cable duct.
ATTENTION
procedure
tab.

connector (2).
Unlock and disconnect connector (1) for side support switch.
Disconnecting right direct ignition coil
Requirement
ATTENTION

procedure
tab.

connector (2).

Disconnect plug (2) from direct ignition coil (1) .
Disconnect right knock sensor

ATTENTION
procedure
tab.

connector (2).
Release line from cable routing (arrows).


Remove bolt (1).

Remove cable jumper (2).
Disengage grounding cable (3).
ATTENTION
procedure
tab.

connector (2).

Release lock (3) and detach connector (2) for oxygen sensor on the right (1)
from exhaust flap servomotor.
Disconnect connector (2) for right oxygen sensor (1).

Disconnect connector (1) for transmission potentiometer.


Disconnect the connector (1) for oil-level sensor.
Disengage complete wiring harness from holder (3) and work it up out of the
way.
Disengaging carbon canister
Remove the cable ties (arrows).

Slightly lift carbon canister (1) and disengage pin (2) from holder (3).

Release brake lines (1) and (2) from holder (3).
Release holder (4) with brake lines (1) and (2) from frame (5).
Release holder (1) with brake line (2) from frame (3).
Work through brake lines (2) and (4) below tab (5).


Disconnect connector (1) for the tank vent valve and work it clear.
Release line (2) from cable duct (3).

Release brake line (1) from holder (2).
Disconnect connector (3) or the pressure modulator and work it clear.
Disengage pressure modulator (4) with the holder from the frame, pull it out
and allow it to dangle to one side.

Disconnect connector (1) for coolant temperature sensor.
Remove retaining clips (2) on the left and right.
Lower the vehicle at the front, so that the cable channel (3) can be worked
through underneath trailing arm (4).
Remove bolt (1).

Disconnect plug connection (4).

Remove the cable strap (arrow) and disengage alternator cable (1).
Remove bolt (2).
Remove wiring harness (3) for engine.
(-) Installing wiring harness for engine
Install wiring harness (3) for the engine and route it.
Install bolt (2).
Route alternator cable (1) and secure the cable strap (arrow).

Connect plug connection (4).
Install bolt (1).
Tightening torques
M6 x 14 8 Nm
Work cable channel (3) into position below trailing arm (4).
Install retaining clips (2) on the left and right.
Connect connector (1) for coolant temperature sensor.

Position pressure modulator (4) with the holder in the frame.

Work connector (3) for the pressure modulator into position and connect.
Secure brake line (1) in holder (2).
Install line (2) in cable duct (3).

Work connector (1) for the tank vent valve into position and connect.
Work through brake lines (2) and (4) below tab (5).
Secure holder (1) with brake line (2) in frame (3).
Secure holder (4) with brake lines (1) and (2) in frame (5).
Secure brake lines (1) and (2) in holder (3).

Securing carbon canister

Work the cable ties (arrows) into holder (3).
Hold carbon canister (1) in position and engage pin (2) in holder (3).
Close the cable ties (arrows).
Route wiring harness (3) completely and secure in holder (4).

Connect connector (2) for oil-level sensor.
Connect plug (1) for the potentiometer for the gear indicator.
Connect connector (1) for transmission potentiometer.



Connect connector (2) for right oxygen sensor (1).



Attach line in cable routing (arrows).
Connect right knock sensor


Install grounding cable (3).

Install cable jumper (2).
Install bolt (1).
Connecting right direct ignition coil

Connect plug (2) with direct ignition coil (1).

Position and install grommet (arrow).
Slide connector (1) in the direction of the arrow.


Connect connector (1) for side-stand switch.

Connecting connector (2) for left oxygen sensor.

Route cable (3) in cable duct and engage locks (2) on cable duct.

Connect connector (1) for camshaft sensor.



Connect left knock sensor

Install grounding cable (3).

Install cable jumper (2).
Install bolt (1).

Connecting left direct ignition coil

Connect plug (2) with direct ignition coil (1).

Position and install grommet (arrow).
Follow-up work
Secure front spring strut, top and bottom
Secure the starter relay
Installing left tank bracket
Installing right tank bracket
Installing left intake air pipe
Securing left throttle-valve assembly
Installing right intake air pipe
Securing right throttle-valve assembly
Installing fuel distributor

Installing battery
Installing right frame guard

12 61 010 Replacing oil-temperature sensor

+ 12 61 501
Core activity
(-) Removing oil temperature sensor

Remove oil temperature sensor (2) with sealing ring (3).
(-) Installing oil temperature sensor
Install oil temperature sensor (2) with new sealing ring (3).
Tightening torques
M12 x 1.5 14 Nm

Follow-up work

12 61 066 Replacing oil-level sensor

+ 12 61 566
0456 - Style HPOE
Preparatory work
Removing starter
Core activity
(-) Removing oil-level sensor

Loosen and disconnect connector (1) for oil-level sensor.
Release cable (2) from holder (3) and work it down.
Remove screws (1).

Disengage oil level sensor (2) and ease it out of pipe (3) to remove, catching
the escaping oil while doing so.
(-) Installing oil-level sensor
Clean the threads.

Check O-ring (1) and renew if required.
Install oil level sensor (2) by threading through pipe (3).
Install screws (4).
Tightening torques

encapsulated)
Using a length of wire inserted from the left, work cable (2) up into position
and secure it in holder (3).
Connect and secure connector (1) for oil level sensor.
Follow-up work
Installing starter

12 62 010 Replacing coolant-temperature sensor

+ 12 62 510
CAUTION
Risk of burn injury
Preparatory work
Removing front seat
Removing left cooling-air guide
Removing cover
Draining coolant
Core activity
(-) Removing coolant-temperature sensor

Disconnect plug (1) for the coolant-temperature sensor.
Remove coolant-temperature sensor (1) with sealing ring (2).
(-) Installing coolant-temperature sensor
Install coolant-temperature sensor (1) with sealing ring (2).
Tightening torques
Coolant-temperature sensor to coolant port
M12 x 1.5 15 Nm
Connect plug (1) for the coolant-temperature sensor.

Secure the cable tie (arrow).
Follow-up work
Installing lid
Installing left cooling-air guide

12 72 001 Replacing crankshaft sensor

+ 12 72 501
Preparatory work
Removing front seat
Removing left cooling-air guide
Removing right cooling-air guide
Disengaging carbon canister
Core activity
(-) Removing crankshaft sensor
Remove bolt (1).

Disconnect plug connection (4).
Check O-ring (3) and renew where required.

Lubricate the O-ring (3) with engine oil.
Install crankshaft sensor (2).
Install bolt (1).
Tightening torques
M6 x 14 8 Nm
Follow-up work
Securing carbon canister

Installing right cooling-air duct
Installing left cooling-air guide

12 72 020 Replacing camshaft sensor

+ 12 72 520
Core activity
(-) Removing camshaft sensor

Disconnect connector (1) for camshaft sensor.
Remove bolt (1).

Remove the camshaft sensor (2) with O-ring (3); catch the escaping oil.
(-) Installing camshaft sensor
Check O-ring (3) and replace if required.

Install camshaft sensor (2) with O-ring (3).
Install bolt (1).
Tightening torques
M6 x 16 8 Nm
Connect connector (1) for camshaft sensor.


Follow-up work

13 51 002 Measuring fuel pressure

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

Install coupling receptacle (part number 7 659 120) (4) and plug (part
number 7 700 800) (5).
Tighten clamping screws (2).
ATTENTION
Application of force to close locked quick-action couplings
Leak due to damaged O-rings
Close the quick-action coupling of the fuel line only with the latch
open/pressed.
Press the retainers (arrows).

Connect tester (No. 16 1 500) to fuel hose (1) and female coupling (2).
Start the engine and read the pressure from test instrument (No. 16 1 500).

Technical data
Operating pressure of approx. 5 bar
fuel pump
Stop the engine and switch off the ignition.

Press the retainers (arrows).
Remove tester (No. 16 1 500).
Follow-up work
Securing fuel tank

13 53 050 Removing/installing or replacing fuel distributor

+ 13 53 501
WARNING
Preparatory work
Removing front seat
Removing fuel tank
Core activity
(-) Removing fuel distributor
Release overflow hose (1) and tank ventilation line (2) from holder (3).
Unclip fuel injection line (4) from the holders (arrows).
Release fuel distributor (1) from holder (2).

Disconnect connector (3) for fuel pressure sensor.

(-) Installing fuel distributor
Connect connector (3) for fuel pressure sensor.

Secure fuel distributor (1) in holder (2).
Clip fuel injection line (4) into the holders (arrows).

Secure overflow hose (1) and tank ventilation line (2) in holder (3).
Follow-up work
Installing the left fuel injector
Installing the right fuel injector


13 54 003 Replacing left throttle-valve assembly

+ 13 54 532
Preparatory work
Removing front seat
Removing fuel tank
Core activity
(-) Remove the left throttle-valve assembly
Open clamps (1) and (2) using pliers (No. 13 1 512).
Disconnect connector (1) for the throttle-valve assembly.

Remove throttle-valve assembly (2).
(-) Installing left throttle-valve assembly
Insert throttle valve assembly (1).

Position throttle valve assembly (1) in recess (arrow) of intake manifold (2).
Connect connector (3) for the throttle-valve assembly.
Install cable straps (4).

Close clamps (1) and (2) with pliers (No. 13 1 512).
Follow-up work

13 61 030 Clean the contacts

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

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

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

software)
NOTICE
Before removal, test the control unit with the BMW Motorrad diagnostic
system and make a backup copy of the data.
Preparatory work
Removing front seat
Core activity
(-) Removing engine control unit
Remove screws (1).

Removing the fuse carrier (2).
Push locks (3) slightly to the side and remove engine control unit (4).
Disconnect the connector (5) for engine control unit.
(-) Installing engine control unit
Connect connector (5) for engine control unit.

Position and install engine control unit (4).
Locks (3) engage.
Install fuse carrier (2).
Install screws (1).
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)

13 62 010 Replacing intake-air temperature sensor

+ 13 62 501
Preparatory work
Removing front seat
Removing fuel tank
Core activity
(-) Removing intake-air temperature sensor
Disconnect plug (1) for the intake-air temperature sensor.
Press the retainer (arrow).

Remove intake-air temperature sensor (1).
(-) Installing intake-air temperature sensor

Install intake-air temperature sensor (1).
The locking device (arrow) engages.

Connect plug (1) for the intake-air temperature sensor.
Follow-up work

13 64 165 Renewing one injector

+ 13 64 501
Preparatory work
Removing engine protection bars
Remove the cover for spark plug
Core activity
(-) Removing injection valve
Disconnect the connector (1) for fuel injector.

Remove bolt (2).
Disengage fuel injector with line (3).
Remove clamp (1).

Remove fuel injector (2).
(-) Installing injection valve
Install new O-rings (1).

Install clamp (3), ensuring that fuel injector (2) is not inserted too deep.
Clamp (3) engages in groove (arrow).
Install fuel injector with line (3).

Install bolt (2).
Connect connector (1) for fuel injector.
Follow-up work
Installing cover for spark plug
Installing engine protection bar

13 71 010 Replace intake-air silencer

+ 13 71 510
Preparatory work
Removing front seat
Removing fuel tank
Disengaging left and right intake pipes
Disengaging left intake air pipe
Disengaging right intake air pipe
Core activity
(-) Remove the intake air silencer

Disconnect vent hose (2).
Disconnect the connector (3) for temperature sensor.
Disengage hose (1) to the carbon canister from the clamps (arrows).
Remove screws (1) and contact discs (2).

Release holder (3) with the hose.
Remove intake silencer (4).

(-) Replacing intake air silencer

Remove intake-air temperature sensor (1).
Install intake-air temperature sensor (1) in new intake air silencer (3).
Press the tabs (arrows).

Transfer intake air pipes (1) and (2) to new intake air silencer (3).
(-) Install the intake air silencer
Hold the intake silencer (4) in position, making sure that no hoses or lines
are trapped.
Secure hose and holder (3).
Install screws (1) and contact discs (2).
Tightening torques
M6 x 25 8 Nm
Secure hose (1) to the carbon canister in the clamps (arrows).

Connect connector (3) for temperature sensor.

Connect vent hose (2).
Follow-up work
Securing right intake air pipe
Securing left intake air pipe
Securing left and right intake pipes

13 71 020 Replacing air intake duct

+ 13 71 520
Preparatory work
Removing front seat
Removing tank guard
Removing slipstream deflector
Core activity
(-) Remove the intake air pipe
Remove screw (1).

Press the tabs (arrows).
Work intake air pipe (2) forward to remove.
(-) Installing intake air pipe
Work intake air pipe (2) into position from in front.

Install screw (long collar) (1).
Follow-up work
Installing slipstream deflector
Install the side panel
Installing tank guard

13 72 001 Renewing air cleaner insert

+ 13 72 532
Preparatory work
Removing front seat
Core activity
(-) Replacing air filter element
Remove screws (1).

Remove the cap (2).
Remove air filter insert (1) from frame (2) and dispose of it.
Install a new air filter insert (1) in frame (2).
Position lid (2).

Install screws (1).
Tightening torques
M5 x 50 Tightening
sequence: in
diagonally opposite
sequence
3 Nm
Follow-up work

13 72 505 Replace air filter cartridge (for maintenance)
Preparatory work
Removing front seat
Core activity
(-) Replacing air filter element
Remove screws (1).

Remove the cap (2).
Remove air filter insert (1) from frame (2) and dispose of it.
Install a new air filter insert (1) in frame (2).
Position lid (2).

Install screws (1).
Tightening torques
M5 x 50 Tightening
sequence: in
diagonally opposite
sequence
3 Nm
Follow-up work

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

Remove cover (2).
Remove air filter element (1) from frame (2).
(-) Checking air filter element
Check
Check the air filter element.

Result:
Air filter element is clogged.
Measure:
Clean the air filter element.
Result:
Air filter element evinces cracks.

Measure:
Replace the air filter element.
(-) Installing air filter element
Fit air filter insert (1) in frame (2) and install together.

Position lid (2).

Install screws (1).
Tightening torques
M5 x 50 Tightening
sequence: in
diagonally opposite
sequence
3 Nm
Follow-up work

16 11 029 Replacing right bracket for fuel tank

+ 16 11 746
WARNING
Preparatory work
Removing front seat
Removing fuel tank
Core activity
(-) Removing right bracket for fuel tank
Disengage injection line (1) from holder (2).

Remove screws (3).
Remove bracket (4).
(-) Replacing right tank bracket
Transfer holder (1), buffer (2) and flat nut (3) to new tank bracket (4).

(-) Installing right bracket for fuel tank
Hold bracket (4) in position.

Install screws (3).
Tightening torques
M6 x 12 8 Nm
Secure injection line (1) in holder (2).
Tightening torques
M6 x 25 8 Nm
Follow-up work

16 11 030 Removing/installing fuel tank

+ 16 11 533
WARNING
Preparatory work
Removing front seat
Core activity
(-) Removing fuel tank

Release fuse carrier (1).
Disconnect overflow hose (1).


Disconnect and release plug connection (1) for fuel filler cap.
Release and thread out line (2) for fuel filler cap from holder (3) and intake
silencer (4).

Pull fuel tank (1) slightly to the rear to release it from mounts (2).
Push open lock (1).

Disconnect quick-release coupling (2).
Disconnect the connector (3) for electric fuel pump.
Disconnect the connector (4) for filling level sensor.
Remove fuel tank (1).

When setting down fuel tank (1), take care not to damage fuse carrier (2).
Remove thermal protection (1).

(-) Installing fuel tank
Install thermal protection (1).
Mask off the holders (arrows) for installation.

Position fuel tank (1).
Remove the adhesive tape (arrows).

Lubricate quick-release coupling (2).
Lubricant
Molykote 111 11 00 7 660 832
ATTENTION
Application of force to close locked quick-action couplings
Leak due to damaged O-rings
Close the quick-action coupling of the fuel line only with the latch
open/pressed.
Push open lock (3).

With a little effort, press quick-release coupling (2) into bush (4).
Bush (4) locks audibly.

Connect connector (5) for electric fuel pump.
Connect connector (6) for filling level sensor.
Route the line (2) into holder (3) and secure intake silencer (4) and route it
to the front.
Connect and install plug connection (1) for fuel filler cap.
Connect overflow hose (1).

Firmly press fuel tank (1) into mounts (2).
Install screws (2).

Install screws (3).
Tightening torques
Fuel tank to frame
M8 x 45 19 Nm
Secure fuse carrier (1).

Follow-up work


16 11 032 Replacing left tank guard

+ 16 11 748
63 17 507 Additional work for LED auxiliary headlights
Core activity
(-) Removing left tank guard
Insert a suitable tool (1), for example a smaller screwdriver, in opening (2)
and press the lock (arrow) carefully, downwards.
Pull off the connector (3) for additional headlight towards rear.

Remove tank protection bar (3).
(-) Replacing left tank guard
Remove screw (1).

Transfer auxiliary headlight (2) to new tank guard (3).
Install screw (1), but do not tighten yet.
Transfer bracket (4) to the new tank guard, or replace if damaged.
Remove screw (1).

Clean the threads.
Apply thread-locking compound to screw (1).

Loctite 243, Medium strength 83 19 2 210 339
Transfer adapter (2) to new tank guard (3).

(-) Installing left tank guard
Clean the threads.

Set tank protection bar (3).
Install bolt (2).
Tightening torques
M8 x 40 19 Nm
Install bolt (1).
Tightening torques
M8 x 16 19 Nm
Connect connector (1) for additional headlight.

Follow-up work
Checking alignment of auxiliary headlights

16 11 033 Replacing right tank guard

+ 16 11 749
63 17 507 Additional work for LED auxiliary headlights
Core activity
(-) Removing right tank guard
Insert a suitable tool (1), for example a smaller screwdriver, in opening (2)
and press the lock (arrow) carefully downwards.
Pull off the connector (3) for additional headlight towards rear.

Remove tank protection bar (3).
(-) Replacing right tank guard
Remove screw (1).

Transfer auxiliary headlight (2) to new tank guard (3).
Transfer bracket (4) to the new tank guard, or replace if damaged.
Remove screw (1).

Clean the threads.
Apply thread-locking compound to screw (1).

Transfer adapter (2) to new tank guard (3).

(-) Installing right tank guard
Clean the threads.

Set tank protection bar (3).
Install bolt (2).
Tightening torques
M8 x 40 19 Nm
Install bolt (1).
Tightening torques
M8 x 16 19 Nm

Follow-up work

16 11 034 Replacing right bracket for tank guard

+ 16 11 750
Preparatory work
Removing front seat
Core activity
(-) Replacing right bracket for tank guard
Remove screws (1).

Remove bracket (2).
Transfer flat nut (3) to new bracket (2).
Secure holder (2) with screws (1).
Tightening torques
Follow-up work

16 11 035 Replacing left bracket for tank guard

+ 16 11 751
Preparatory work
Removing front seat
Core activity
(-) Replacing left bracket for tank guard

Remove screws (1).
Remove bracket (2).
Transfer flat nut (3) to new bracket (2).
Hold bracket (2) in position, noting cable (4).
Install screws (1).
Tightening torques
Follow-up work

16 11 204 Replacing seal for fuel filler neck

+ 16 11 704
WARNING
Preparatory work
Removing front seat
Core activity
(-) Removing fuel-tank cap
Disconnect fuel-tank breather hose (1).

Remove screws (1).

Remove fuel filler cap (2) with gasket (3) and retaining ring (4).
(-) Installing fuel-tank cap
Insert retaining ring (1) and gasket (2) with the projection (arrow) up in fuel
filler cap (3).
Hold fuel filler cap (3) in position.
Install screws (4).
Tightening torques
M5 x 28 4 Nm

Connect fuel-tank breather hose (1).
Follow-up work

16 11 213 Renewing fuel tank cover flap

+ 16 11 543
16 11 510 Additional work for replacing cover for fuel tank (Vehicle equipped with Keyless Ride)
WARNING
Preparatory work
Removing front seat
Disengaging left side panel
Removing slipstream deflector, left
Removing top left front-wheel cover
Core activity


Disconnect and remove the plug connection (1) for the fuel filler cap.
Release the cable (2) for the fuel filler cap from the holder (3) and intake
silencer (4) and feed out.
Remove screws (1).

Remove cover (1).

Fuel filler cap (2) is unlocked.
Fully remove the fuel filler cap (1).
Check seal (1) for damage, change if necessary.

Install the seal (1) with the lug (arrow) upwards in the fuel filler cap (2).
Fully install the fuel filler cap (1).

Close fuel filler cap (2) and hold cover (1) in position.
Install screws (1).
Tightening torques
M5 x 28 4 Nm
Route the line (2) into holder (3) and secure intake silencer (4) and route it
to the front.
Connect and install plug connection (1) for fuel filler cap.


Follow-up work
Installing top left front-wheel cover
Installing left slipstream deflector
Securing left side panel

16 11 531 Replacing fuel tank (fuel tank removed)

WARNING
Preparatory work
Draining fuel tank
Core activity
– with Keyless RideOE (0193)
Remove screws (1).
Remove cover (1).

Fuel filler cap (2) is unlocked.
Remove complete fuel filler cap (1).

Remove retaining ring (2).
(-) Removing fuel-pump unit

Remove screws (1).
Remove pressure plate (2).
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.
Remove fuel-pump unit (1) and gasket (2).
(-) Replacing fuel tank
Transfer bushings (1), retaining bridge (2), rubber mount (3) and flat nuts (4)
to the new fuel tank.
Transfer the flat nuts (arrows) and expander grommets (1) to new fuel tank
(2).
Transfer the flat nuts (arrows) and expander grommets (1) to new fuel tank
(2).

(-) Installing fuel-pump unit
Check
Check the sealing face of fuel-pump unit (1) for damage, paying particular
attention to the sealing lip.
Result:
Sealing face is damaged.

Measure:
Replace fuel-pump unit (1).
Check seal (2) for damage; replace if necessary.

Insert gasket (2) and lubricate at contact face with fuel-pump unit (1).
Installation tool
Tyre-fitting paste 81 22 0 433 046
Carefully install fuel-pump unit (1), making sure that seal (2) is correctly
seated.
Gasket (2) is visible round entire circumference.
Hold pressure plate (1) in position while positioning fuel-pump unit (2) in the
recess (arrow).
Install screws (3).


Install seal (1) in fuel filler cap (2).
Hold retaining ring (2) in position.

Install fuel filler cap (1).
Close fuel filler cap (2) and hold cover (1) in position.
Install screws (1).
Tightening torques
M5 x 28 4 Nm
Follow-up work
Filling fuel tank

16 13 001 Replacing carbon canister

+ 16 13 500
Preparatory work
Removing front seat
Removing fuel tank
Disengaging tank vent valve
Core activity
(-) Removing carbon canister
Remove the cable ties (arrows) from the carbon canister.


Pull carbon canister (1) forward at the bottom.
Work hose (2) to the tank vent valve and hose (3) to the fuel filler cap clear.
Remove carbon canister (1).
(-) Replacing carbon canister
Disconnect hoses (1) and (2) from old carbon canister (3).
Connect short hose (1) to port (2) marked PURGE.

Connect long hose (3) to port (4) marked TANK.
(-) Installing carbon canister
Work the cable straps (arrows) into holder (1).

Work carbon canister (1) into position in the vehicle.
Position carbon canister (1) and work hose (2) into position at the fuel filler
cap.
Connect breather hose (1).
Place journal (2) in holder (3) and press down the carbon canister (1).

Follow-up work
Securing tank vent valve

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

+ 16 13 510
Preparatory work
Removing front seat
Core activity
(-) Removing tank vent valve
Disconnect connector (1) for tank vent valve (2).

Disconnect hose (3).
Disengage bracket (1) with the tank vent valve.

Disconnect hose (2) with a suitable tool and remove bracket (1) with the
tank vent valve.
(-) Replacing tank vent valve
Transfer bracket (1) from the old to the new tank vent valve (2).
Make sure that the Woodruff key and the keyway (arrows) are aligned.
Lubricate hose connections of tank vent valve (2).
Installation tool
Silicone spray 83 19 2 208 609

(-) Installing tank vent valve
Work holder (1) with tank vent valve (2) into position in the vehicle.
Using pliers, connect hose (3) to tank vent valve (2).
Install holder (1) with tank vent valve (2).
Connect hose (3).

Connect connector (1) for tank vent valve (2).
Follow-up work

16 13 011 Replacing tank breather line

+ 16 13 501
WARNING
Preparatory work
Removing front seat
Removing fuel tank
Core activity
(-) Disengaging carbon canister

(-) Removing tank breather line
Disconnect the hose (1) from the tank vent valve (2).

Pull the carbon canister (1) forward at the bottom.

Disconnect the tank ventilation line (2) and feed out.
(-) Installing tank breather line
Feed in and connect the tank ventilation line (1).

Insert the carbon canister (2).
Position carbon canister (1) and feed hose (2) upward.
Connect hose (1) to tank vent valve (2).

(-) Securing carbon canister
Work the cable ties (arrows) into holder (3).

Hold carbon canister (1) in position and engage pin (2) in holder (3).
Close the cable ties (arrows).
Follow-up work

16 14 009 Removing/installing fuel-pump unit

+ 16 14 502
WARNING
Preparatory work
Draining fuel tank
Removing front seat
Removing fuel tank
Core activity
Remove screws (1).

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.
Remove fuel-pump unit (1) and gasket (2).
Check

Result:
Measure:

Installation tool
Carefully install fuel-pump unit (1), making sure that seal (2) is correctly
seated.
recess (arrow).
Install screws (3).
Follow-up work
Filling fuel tank


16 14 012 Replacing gasket for fuel-pump unit

+ 16 14 523
WARNING
Preparatory work
Draining fuel tank
Removing front seat
Removing fuel tank
Core activity
Remove screws (1).

Check
Result:
Measure:
Installation tool
Carefully insert fuel-pump unit (1), making sure that gasket (2) is correctly
seated.
recess (arrow).
Install screws (3).
Follow-up work
Filling fuel tank

16 14 513 Replacing fuel-level sensor (fuel-pump unit removed)
Core activity
(-) Removing fuel-level sensor

Disconnect plug (1) for the fuel-level sensor.
Remove screws (2).
Loosen connector (3).
Slightly raise the lug (arrow).

Remove fuel-level sensor (1) from connecting piece (2).
(-) Installing fuel-level sensor
Install fuel-level sensor (1) in connecting piece (2).

The lug (arrow) engages.
Slip connecting piece (3) into position.

Install screws (2).
Connect plug (1) for the fuel-level sensor.


17 00 010 Checking cooling system for leaks (with cooling system tester)
+ 17 00 502
CAUTION
Risk of burn injury
Preparatory work
Removing cover
Removing radiator cap
Core activity
(-) Checking cooling system for leaks
Requirement
Engine cold.
Secure pump (No. 17 0 511) with adapter (No. 17 0 512) and adapter for
tester for cooling system (No. 17 5 520) to coolant filler neck.
Check
Pressure-test the cooling system; the pressure must remain unchanged for
at least 5 minutes.
Technical data
Cooling system Test pressure must 1.5 bar
test pressure remain
Result:
Pressure loss
Measure:
Check for leaks and rectify.
Follow-up work
Install the radiator cap
Installing lid

17 00 020 Checking coolant composition

+ 17 00 503
CAUTION
Risk of burn injury
Preparatory work
Removing cover
Core activity
(-) Check the coolant composition
Check
Remove cap (1).
Check the ability of the coolant to resist freezing temperatures by checking
the antifreeze concentration in expansion tank (2).
Technical data
Coolant, frost Silicate min −25 °C
protection radiator
protective
agent
Result:
Ability to resist freezing temperatures is not ensured.
Measure:
Increase the proportion of antifreeze until ability to resist freezing
temperatures is ensured.
Follow-up work
Installing lid

17 00 035 Draining coolant, refilling/bleeding system

+ 17 00 504
CAUTION
Risk of burn injury
Preparatory work
Removing cover
Core activity
(-) Draining coolant
CAUTION
Risk of burn injury
Removing radiator cap

Remove radiator cap (1).
Remove left drain plug (1) with sealing ring (2).

Drain the coolant into a suitable container.
Install drain plug (1) with new sealing ring (2).
Tightening torques
M10 x 1 10 Nm

Disconnect flow hose (2).
Drain the coolant into a suitable container.

Connect flow hose (1) in such a way that the projection (arrow) engages the
recess.
(-) Emptying expansion tank for coolant
Open lid (1).

Draw off coolant with hose (2).
(-) Filling cooling system

Preparing and priming radiator filler for cooling system
Fill canister (No. 17 5 553) with an adequate quantity of coolant.

Technical data
Coolant capacity total in 1.5 l
coolant circuit
in expansion 0.25 l
tank
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 (No. 17 5 553) on a higher level.

Secure the preassembled radiator filler in position at the motorcycle.
Connect radiator port (No. 17 5 554) to distributor unit (No. 17 5 551) and
radiator filler neck.
Put the end of the drain hose of venturi nozzle (No. 17 5 552) into a suitable
container.
Prepare the compressor.
Technical data

Minimum Pressure min 8 bar
requirement, Delivery rate min 125 l/min
compressor
Evacuating cooling system
ATTENTION
Connecting compressor to distributor unit of filler adapter with
compressed-air valve open
Damage to pressure meter due to pressure peaks
Make sure the valves are closed when you connect the compressor to the
distributor unit.
Connect the compressor to the venturi nozzle (No. 17 5 552).

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

Disconnect the compressor from venturi nozzle (No. 17 5 552).
Observe the needle of the pressure gauge of distributor unit (No. 17 5 551)
for a time and check that the partial vacuum in the cooling system does not
rise to ambient pressure.
Technical data
Requisite vacuum for min −0.8 bar
filling the cooling
system
Slowly open coolant cock (1) until it is fully open.

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

Disconnect the radiator filler from the radiator and remove it from the
vehicle.

Check the coolant level; top up if necessary. (The level of coolant in the
cooling system must be at the bottom edge of the coolant filler neck (arrow).)
General consumable
Antifreeze and corrosion inhibitor 83 51 2 445 463
Install the radiator cap

Install the radiator cap (1).
(-) Filling expansion tank
Fill expansion tank (1) with coolant and close cap (2).
Technical data
Coolant, specified level Engine cold Between MIN and
MAX marks on the
expansion tank
(-) Checking coolant level

Allow the engine to warm up until the fan cuts in.
Allow the engine to cool down.
Check the coolant level; top up if necessary.
Technical data
MAX marks on the
expansion tank
Follow-up work
Installing lid

17 11 010 Removing/installing left radiator without draining/refilling coolant system)

+ 17 11 549
Preparatory work
Removing front seat
Core activity
(-) Removing left radiator
CAUTION
Risk of burn injury
Remove screws (1) and washers (2).

Remove bracket (3).
Disengage radiator (4).
Release clips (1) and (2) with pliers (No. 17 5 571).

Disconnect connecting hose (4).
Remove radiator (5).
(-) Installing left radiator
Connect connecting hose (1) and breather hose (2) in such a way that the
projections (arrows) engage in the recesses.
Secure clips (3) and (4) with pliers (No. 17 5 571).

Hold radiator (4) and bracket (3) in position.

Install screws (1), with washer (2) in the case of the bottom screw.
Tightening torques
Follow-up work

17 11 011 Removing/installing right radiator without draining/refilling coolant system)

+ 17 11 550
Preparatory work
Removing front seat
Core activity
(-) Removing right radiator
CAUTION
Risk of burn injury

Disconnect return hose (3) and bypass hose (4) and drain coolant into the
catchtank.

Disconnect connector (1) for the fan.
Remove bracket (4).
Disengage radiator (5).
Seal off overflow hose (1) with hose clamp (No. 13 3 010).
Ease radiator (3) out slightly.


Remove radiator (3).
(-) Installing right radiator
Connect connecting hose (1) in such a way that the projection (arrow)
engages the recess.
Close clip (2) with pliers (No. 17 5 571).
Connect overflow hose (1) and position it with the mark (arrow) at the land.

Remove hose clamp (No. 13 3 010).

Connect bypass hose (1) and return hose (2) in such a way that the
projections (arrows) engage in the recesses.
Secure clips (1) and (2) with pliers (No. 17 5 571).
Hold radiator (5) and bracket (4) in position.

Install screws (2), with washer (3) in the case of the bottom screw.
Tightening torques
Connect plug (1) for the fan.

Seat vapour discharge hose (1) in the holder (arrow).

Follow-up work

17 11 553 Replace left radiator (radiator removed)
Core activity
(-) Replacing the left radiator
Remount bushes (1) and grommets (2) on new radiator.

Remove screw (3).
Remount flat nut (4) on new radiator.
Remount air duct (5) with bolt (3) on new radiator.

17 11 554 Replace right radiator (radiator removed)
Core activity
(-) Replacing the right radiator
Remount bushes (1) and grommets (2) on new radiator.

Remove screw (3).
Remount flat nut (4) on new radiator.
Remount air duct (5) with bolt (3) on new radiator.
Remove expanding rivet (1).

Remount fan (2) with expanding rivet (1) on new radiator.

17 12 096 Replacing connecting hose for radiators (without draining/refilling coolant system)
+ 17 12 508
CAUTION
Risk of burn injury
Preparatory work
Removing front seat
Core activity
(-) Removing connecting hose for radiators


Work connecting hose (1) to the left to remove.

(-) Installing connecting hose for radiators
Working from the left, install and route connecting hose (1) .
engages the recess.
Position clip (1) and secure with pliers (No. 17 5 571).
engages the recess.
Follow-up work

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

Remove return hose (3).
(-) Install the coolant hose, return
Connect return hose (3) in such a way that the projection (arrow) engages
the recess.
Position clips (1) and (2) and secure with pliers (No. 17 5 571).
Follow-up work

17 12 105 Replacing coolant hose to radiator (without draining/ refilling coolant system)
+ 17 12 605
CAUTION
Risk of burn injury
Preparatory work
Removing front seat
Core activity
(-) Removing coolant hose, flow
Using a suitable tool, open clip (1).

Disconnect coolant flow hose (2) and remove.
(-) Installing coolant hose, flow
Install coolant flow hose (1) and connect with new clip (2).
Follow-up work


17 12 200 Replacing coolant hose from expansion tank

+ 17 12 755
CAUTION
Risk of burn injury
Preparatory work
Removing front seat
Core activity
(-) Removing coolant hose from expansion tank
Remove screw (1).

Disengage expansion tank (2) and manoeuvre it clear.
Disengage clip (1).

Disconnect coolant hose (2), catching escaping coolant by suitable means.
Disengage coolant hose (2) from the holder (arrow).
Disengage clip (1).

Remove coolant hose (2).

(-) Installing coolant hose from expansion tank
Connect coolant hose (2) and secure it in the holder (arrow).

Position clamp (1).
Connect coolant hose (2).

Position clamp (1).
Hold expansion tank (2) in position.

Install screw (1).
Tightening torques
Follow-up work
Filling expansion tank

17 13 001 Replace expansion tank

+ 17 13 501
CAUTION
Risk of burn injury
Preparatory work
Removing front seat
Core activity
(-) Removing expansion tank
NOTICE
The evaporation hose on the expansion tank was dispensed with in mid 2013.
Remove screw (1).

Disengage reservoir (2).

Disconnect overflow hose (2), catching escaping coolant by suitable means.
Disengage overflow hose (2) from the holder (arrow).
Disconnect vapour discharge hose (1).

Remove expansion tank (2).

(-) Installing expansion tank
NOTICE
The evaporation hose on the expansion tank was dispensed with in mid 2013.
Insert expansion tank (2).

Connect vapour discharge hose (1).
Make sure that vapour discharge hose (1) is correctly seated in the holder
(arrow).
Connect overflow hose (2) and secure it in the holder (arrow).

Position expansion tank (2).

Tightening torques
Open lid (1).

Fill expansion tank (2) with coolant.
Technical data
MAX marks on the
expansion tank
Close cover (1).
Follow-up work

17 40 000 Removing/installing or replacing fan

+ 17 40 500
Preparatory work
Removing front seat
Core activity
(-) Removing fan
Disconnect plug (1) for the fan.

Remove body-bound rivet (2).
Work fan (3) down to remove.
(-) Installing fan
Seat fan (1) in the lug (arrow).

Install body-bound rivet (2).
Connect plug (3) for the fan.
Follow-up work

17 65 000 Replacing thermostat for coolant (without draining/ refilling coolant system)
+ 17 65 500
CAUTION
Risk of burn injury
Preparatory work
Disengaging thermostat
Core activity
(-) Removing thermostat
Carefully open the hose clips (arrows).

Disconnect flow hose (1).
Ease thermostat (3) slightly to the left.
Carefully open the hose clip (arrow).

Disconnect bypass hose (1).
Remove thermostat (2).
(-) Installing thermostat
Slip new clip (1) on to bypass hose (2).

Align bypass hose (2) with recess on projection (arrow) and connect.
Close clip (1) with pliers (No. 13 1 500).

Slip hose clamps (1) and (2) on to vent hose (3) and fuel feed line (4).
Align vent hose (3) and fuel feed line( 4) with recesses on lugs (arrows) and
push on.
Close clips (1) and (2) with pliers (No. 13 1 500).
Follow-up work
Securing thermostat

18 51 000 Replacing silencer

+ 18 51 500
Sports silencerOA
CAUTION
Hot exhaust system
Risk of burn injury
Preparatory work
Core activity
(-) Removing silencer
Loosen bolt (1).

Clamp (2) is released.
Remove bolts (1) and shaped washer (2).

Remove silencer (3) and contact disc (4).
(-) Replace the silencer
Transfer flat nuts (1) to new silencer (2).

(-) Installing silencer
NOTICE
To ensure the leaktightness of the exhaust system, the exhaust clamps have
to be lubricated for installation.
It is particularly important to apply lubricant to the vicinity of the joint.
Lightly lubricate the inner face of clamp (1).
Lubricant
Optimoly TA 18 21 9 062 599
Slide the clamp (1) onto the silencer (2).

Push silencer (2) to limit position.
Position washer (3), install shaped washer (4) and screw (5).
Tightening torques
M8 x 35 19 Nm
Tighten screw (1) of clamp (2).
Tightening torques
19 Nm
Follow-up work

18 51 001 Replacing exhaust manifold

+ 18 51 502
CAUTION
Hot exhaust system
Risk of burn injury
Preparatory work
Removing silencer
Core activity
(-) Removing exhaust manifold
Protect the area (arrow) on swinging arm (1) against damage.
Remove nuts (1).

Remove gaskets (2).
Remove exhaust manifold (3).
(-) Replacing exhaust manifold

Remount holder (1) on new exhaust manifold (2).
Remount flat nut (1) on new exhaust manifold (2).

Remount left oxygen sensor (3) on new exhaust manifold (2).
Tightening torques
M18 x 1.5 45 Nm
TA)
Remount right oxygen sensor (4) on new exhaust manifold (2).
Tightening torques
M18 x 1.5 45 Nm
TA)
Remount oxygen sensor monitor (5) on new exhaust manifold (2).
Tightening torques
M12 x 1.25 25 Nm
TA)
(-) Installing exhaust manifold
Pay attention to correct mounting orientation of the seal.
Position new seals (2) on exhaust manifold (3).

Hold exhaust manifold (3) in position.
Install new nuts (1).
Tightening torques
M8 21 Nm
Remove cover (arrow) on swinging arm (1).
Follow-up work
Installing silencer

18 51 002 Replacing gaskets for exhaust manifold on cylinder head

+ 18 51 503
CAUTION
Hot exhaust system
Risk of burn injury
Preparatory work
Removing silencer
Core activity
(-) Replacing gaskets for exhaust manifold
Protect the area (arrow) on swinging arm (1) against scratches.
Remove nuts (1).

Disengage exhaust manifold (3) and support it from below.
Replace seals (2).
Install nuts (1).
Tightening torques

M8 21 Nm
Follow-up work
Installing silencer

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

+ 18 51 510
Core activity
(-) Disengaging Bowden cables for exhaust-flow control valve
Remove screws (1).

Remove cover (2).
Disengage heat shield (1) from Bowden-cable screws (2).

Slacken Bowden-cable screws (2) and locknuts (3).
Disengage the Bowden cables from holder (4).
Disengage return cable (5) and actuating cable (6).
(-) Disconnecting plug for right oxygen sensor
ATTENTION
procedure
tab.

connector (2).


(-) Removing servomotor for exhaust-flow control valve
Allow the connector (1) for oxygen sensor to dangle on one side.
Disconnect connector (2) for the servomotor of the exhaust flap.
Remove screw (3) and contact disc (4).

Pull exhaust flap servomotor (3) off grommets (4) and remove them.
(-) Disassembling servomotor
Remove screws (1).

Remove servomotor (2) with return cable (3) and actuating cable (4).
(-) Replacing actuating cable
Replace actuating cable (1).

(-) Assembling servomotor
Insert return cable (3) and actuating cable (4) into holder (5).
Install servomotor (2) with screws (1).
(-) Installing servomotor for exhaust-flow control valve
Install exhaust flap servomotor (3) in grommets (4).

Install screw (3) and contact disc (4).
Tightening torques
M6 x 25 8 Nm
Connect connector (2) for the exhaust flap servomotor.

Position connector (1) for oxygen sensor.
(-) Connecting plug for right oxygen sensor


(-) Engaging Bowden cables for exhaust-flow control valve
Engage return cable (5) and actuating cable (6).

Secure the Bowden cables in holder (4).
Tighten Bowden-cable screws (2) and locknuts (3).
Pull heat shield (1) over Bowden-cable screws (2).
Place cover (2) in position.

Install screws (1).
Follow-up work

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

+ 18 51 511
Core activity
Remove screws (1).

Remove cover (2).

ATTENTION
procedure
tab.

connector (2).



Remove screws (1).

(-) Replacing return cable
Replace return cable (1).


Tightening torques
M6 x 25 8 Nm





Install screws (1).
Follow-up work

18 51 009 Replacing servomotor for exhaust-flow control valve

+ 18 51 512
Core activity
Remove screws (1).

Remove cover (2).

ATTENTION
procedure
tab.

connector (2).



Remove screws (1).

(-) Replacing servomotor

Transfer actuating cable (1) and return cable (2) to cable pull (3) of new
servomotor.

Tightening torques
M6 x 25 8 Nm





Install screws (1).
Follow-up work

18 51 015 Replacing heat shield for silencer

+ 18 51 518
Core activity
(-) Removing silencer cover

Remove silencer cover (3).
(-) Install the silencer cover
Position silencer cover (3).

Install screws (1) with contact discs (2).
Follow-up work

18 51 017 Replacing rubber mount for exhaust manifold

+ 18 51 520
CAUTION
Hot exhaust system
Risk of burn injury
Preparatory work
Removing silencer
Removing bracket for exhaust manifold
Core activity
(-) Replacing rubber mount for exhaust manifold
Remove rubber mount (1).

Lubricate new rubber mount (1) and insert into holder (2).
Installation tool
Follow-up work
Installing bracket for exhaust manifold
Securing silencer

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

+ 21 21 606
0499 - Low-slungOE
Preparatory work
Draining engine oil
Core activity
(-) Removing pressure plate
Alternately slacken screws (1) and remove.

Remove mounting plate (2).
Remove springs (3).

Remove thrust piece (2).
(-) Removing clutch plates
Remove lined plates (1) and steel plate with spotting (2) with large inside
diameters.

Remove spotted steel plates (1) and lined plates (2).
Remove smooth steel plate (1).

Remove lined plate (2) with large inside diameter.
Remove release spring (3).
Remove spacer (4).
ATTENTION
lined plates
Install spacer (1).


ATTENTION
Component damage
Insert springs (3).


Tightening torques
M6 x 30 10 Nm

The clutch lever can be pulled to the full extent of its travel, plates are
loosened.
Follow-up work

21 21 002 Removing/installing clutch cage

+ 21 21 512
0499 - Low-slungOE
Preparatory work
Draining engine oil
Core activity

Remove springs (3).

ATTENTION
lined plates

Follow-up work

21 21 140 Removing and installing or replacing lined plates

+ 21 21 609
0499 - Low-slungOE
Preparatory work
Draining engine oil
Core activity

Remove springs (3).

Remove lined plates (1) and steel plate with spotting (2) with large inside
diameters.

Remove spotted steel plates (1) and lined plates (2).
Remove smooth steel plate (1).

Remove lined plate (2) with large inside diameter.
Remove release spring (3).
Remove spacer (4).
(-) Lubricating new lined plates
ATTENTION
Installation of the clutch plates dry
Burning of the clutch plates
Immerse new clutch disc package in clean engine oil.
Immerse new lined plates in engine oil.

The friction faces of the lined plates are wetted by oil.
ATTENTION
lined plates

Install spacer (1).
ATTENTION
Component damage
Insert springs (3).


Tightening torques
M6 x 30 10 Nm

loosened.
Follow-up work

21 21 161 Checking tooth backlash of primary drive, adjusting if necessary

+ 21 21 616
0499 - Low-slungOE
Preparatory work
Draining engine oil
Core activity
(-) Measuring tooth backlash, clutch cage
NOTICE
Tooth backlash at the clutch case has to be measured in the following cases:
Replacement of clutch cage or engine block.
Replacement of the crankshaft or crankshaft bearings.
Replacement of the counterbalance shaft or counterbalance shaft bearings.
Remove all traces of seal from area for holder (No. 11 0 863).
Install holder (No. 11 0 863) with screws (1) and washers (2).
Install dial gauge (No. 11 0 861) in such a way that the probe (arrow) is
preloaded and engaged centred relative to a tooth flank of gearwheel (3).
Check
Move clutch cage (4) slightly back and forth.
Technical data
Backlash of clutch 0.003...0.025 mm
cage
Result:
Measure:
Install appropriate clutch cage:

Technical data
Marks on clutch 1 groove / S Small gear (increase
cage / designation in tooth backlash)
BMW Motorrad parts 2 grooves / M Medium-size gear
catalogue (reduce/increase
tooth backlash)
3 grooves / L Large gear (reduce
tooth backlash)
to reduce backlash: clutch cage with higher classification

to increase backlash: clutch cage with lower classification
Replacing clutch cage
Install clutch cage (1) of the next highest or next lowest classification, as
applicable. There are up to three marks (detail) on the gearwheel to
indicate the classification.
Follow-up work

21 51 002 Replacing thrust piece

+ 21 51 729
0499 - Low-slungOE
Preparatory work
Draining engine oil
Core activity

Remove springs (3).


ATTENTION
Component damage
Insert springs (3).

Tightening torques
M6 x 30 10 Nm

loosened.
Follow-up work


21 52 005 Bleeding hydraulic clutch system

+ 21 52 506
0456 - Style HPOE
Preparatory work
Releasing starter
Removing clutch slave cylinder
Core activity
(-) Draining clutch system
Remove screws (1).

Remove reservoir cap (2).
Remove flexible gaiter (3).
ATTENTION
Mixing of oil, brake fluid and clutch fluid
Damage to seals
Use separate syringes and hoses.
Draw off hydraulic fluid (4) with syringe (No. 34 2 551).

Clean the reservoir, diaphragm (3) and reservoir cap (2).
Connect hose (No. 34 2 552) to bleed screw (1).
NOTICE
Missing bleed screws have to be ordered in the electronic parts catalogue and
retrofitted.
Slacken bleed screw (1).

Draw off hydraulic fluid with syringe (No. 34 2 551).
Tighten breather screw (1).
Remove the cable tie (arrow) and hose (No. 34 2 552) with syringe (No. 34 2
551).
(-) Filling clutch system
Fill the clutch-fluid reservoir with hydraulic fluid.
Technical data
Clutch-fluid level (repairs) with new Mark in reservoir
clutch liner,
reservoir
horizontal

Slowly press piston (1) all the way back, taking care that hydraulic fluid does
not splash out of clutch-fluid reservoir (2); cover as necessary.
Wait until piston (1) returns to its initial position.
Repeat the bleeding process until air bubbles cease to rise in the clutch-fluid
reservoir.
Motorcycle upright, handlebars turned all the way to the right.

Repeatedly short-pull clutch lever (1) to expel air from the clutch system.
No more air bubbles escape.
Follow-up work
Secure the clutch slave cylinder
Filling clutch-fluid reservoir and installing reservoir cap
Securing starter motor

21 52 013 Replacing clutch slave cylinder (without bleeding system)

+ 21 52 513
Preparatory work
=> Bleeding hydraulic clutch system (Description in item: 21
52 506, Billed as a separate item)
Core activity
(-) Removing clutch slave cylinder
Remove union screw (1).

Remove clutch slave cylinder (2).
(-) Reassemble clutch slave cylinder
Install air vent (1) in clutch slave cylinder (2).
Tightening torques
Bleed screw to clutch slave cylinder
5 Nm
Install cap (2).
(-) Installing clutch slave cylinder

Hold clutch line (1) in position at clutch slave cylinder (2).
Tighten down union screw (3).
Tightening torques
M10 x 1 7 Nm
Follow-up work

21 52 014 Replacing clutch line (without bleeding system)

+ 21 52 514
Preparatory work
Removing front seat
Removing fuel tank

Core activity
(-) Removing clutch line
Remove union screw (1) and catch the escaping fluid in a suitable container.
Disconnect clutch line (2).
Remove bracket (1).

Remove screw (1).
Ease cable duct (2) and brake lines (3) up slightly.
Remove the cable ties (arrows)

Feed out clutch line (1) to the bottom.
Removing clutch slave cylinder
Remove union screw (1).

Remove clutch slave cylinder (2).
Remove clutch line.
(-) Install the clutch line
Work clutch line (1) into position.

Installing clutch slave cylinder

Hold clutch line (1) in position at clutch slave cylinder (2).
Tightening torques
M10 x 1 7 Nm
Hold clutch line (1) in position, noting sealing rings (2).

Tightening torques
M10 x 1 7 Nm
Install bracket (1).
Ease cable duct (1) and brake lines (2) up slightly.

Work clutch line (1) down and into position.

Install cable straps (arrows).
Follow-up work

23 00 512 Removing/installing gearbox (engine removed)

Preparatory work
Removing shift assistant
Removing the collar nut of the countershaft, if required
Removing clutch hub
Removing clutch hub plate
Core activity
(-) Removing gearbox
Remove screws (1).
Disengage differential cover (1) with extractor (No. 11 0 833).

Remove extractor (No. 11 0 833) from differential cover (1).
Pull out complete transmission (1).

Tilt transmission (1) and remove pushrods (2) and (3).
(-) Installing gearbox
Clean sealing surfaces (1) on engine housing and differential cover.

surface (1).
Sealant
Dow Corning 07 58 0 397 777
Feed countershaft (1) with transmission (2) into counterbalance shaft (3).
Install complete transmission (2).
Make sure that all gearbox components can be slipped easily into the
corresponding bearing seats in the engine block.
Insert screws (1) and (2) and tighten until hand-tight.

Insert screws (3) to (18) and tighten until hand-tight.
Working clockwise, tighten screws (3) to (9).

Working counter-clockwise, tighten screws (10) to (18).
Tightening torques
M6 x 25 10 Nm
Insert pushrods (1) and (2) into countershaft (3).

The cylindrical thrust piece (arrow) must face out.
Follow-up work
Installing collar nut and clutch hub
Installing shift assistant

23 00 520 Replace gearbox (gearbox removed)
23 12 513 Additional work for replacing retaining plate with transmission mount set, at the engine end
Core activity
(-) Removing shift-mechanism cover
Unclip connector (1) for the gearbox potentiometer.

Remove screws (2).
Remove shift-mechanism cover (3) by pressing at the lugs (arrows).
Remove locking pawl (1) from gearshift linkage cover (2).
(-) Replace transmission
Remount holders (1), (2) and (3) on the new transmission housing (4).
(-) Installing shift-mechanism cover
Ensure that the cylindrical pins (1) and oil throttle (2) are installed.

Clean sealing faces (1) on shift-mechanism cover and gearbox cover.

Sealant
Dow Corning 07 58 0 397 777
Install locking pawl (1) in gearshift linkage cover (2).
Hold shift-mechanism cover (1) in position.

Install screws (2).
Tightening torques
M6 x 20 10 Nm
Clip connector (3) for the gearbox potentiometer into position.

23 11 041 Removing/installing and sealing shift-linkage cover

+ 23 11 604
0456 - Style HPOE
Preparatory work
Draining engine oil
Remove left frame guard
Removing shift assistant
Disengaging potentiometer for gear indicator
Removing silencer
Removing bracket for engine guard
Core activity
(-) Lifting rear wheel swinging arm
Support rear wheel swinging arm (1) in order to relieve the spring strut (2).
Remove screw (3).
Remove screw (1).

Raise rear wheel swinging arm (1) with scissor-type lifter (No. 00 1 571).
Loosen gaiter (1) from rear wheel swinging arm (2) and from differential
cover (3).
Remove screws (1).

Remove gearshift cover (2) and while doing so, push off the removal aid
(arrow).
Make sure that the pawl (1) is installed correctly.

Ensure that the cylindrical pins (arrows) and oil throttle (2) are installed.


Sealant
Dow Corning 07 58 0 397 777
Ensure that the spring (1) is attached correctly in shift-mechanism cover (2)
(arrows).

Install screws (2).
Tightening torques
M6 x 20 10 Nm
Work flexible gaiter (1) forward on to gearbox cover (2).

(-) Lowering rear wheel swinging arm
Lower rear wheel swinging arm (1) with scissor-type lifter (No. 00 1 571).
Clean the threads.

Align spring strut (2) and rear wheel swinging arm (1) and install screw (3).
Tightening torques
encapsulated)
Clean the threads.

Tightening torques

encapsulated)
Follow-up work
Securing cable duct
Installing bracket for engine guard
Installing silencer
Install the potentiometer for gear indicator
Installing shift assistant
Installing left frame guard

23 11 501 Renewing gearbox housing (gearbox removed)
Core activity

Remove screws (2).
(-) Removing shift-fork axles
Remove screws (1).

Disengage retaining plate (2).
Remove shift fork axles (1) and (2).

M6 x 20 10 Nm

23 12 078 Replace shaft sealing ring of output shaft

+ 23 12 620
0456 - Style HPOE
Preparatory work
Remove the rear wheel
Releasing rear wheel-speed sensor
Sealing bore for wheel-speed sensor
Disengaging actuator rod for ride-height sensor from swinging arm
Releasing rear spring strut
Disengaging Paralever link
Remove the complete rear wheel swinging arm
Core activity
(-) Removing shaft sealing ring of output shaft
Remove circlip (1).
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.
Carefully drill the centre of the shaft sealing ring (1) using drill stop (No. 00 8
586).
Technical data
Hole diameter max 3 mm
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 shaft
sealing ring (1).
Remove radial shaft seal (1).
(-) Installing shaft sealing ring of output shaft
Clean seat (1) in the housing.

Only lubricate the inner sealing lips (arrows) of radial shaft seal (2) thinly or
install dry and free of lubricant.
Lubricant
Molykote 111 11 00 7 660 832
Position radial shaft seal (2) with the open side to the inside.
Drive in shaft sealing ring (1) until seated, using gearbox drift (No. 23 0 821).
Mark the installation dimension (A) on the water channel (No. 23 4 791).
Technical data
Short length of radial approx. 6.5 mm
shaft seal/differential
cover
Carefully install the radial shaft seal (1) along with water channel (No. 23 4
791) up to the installation dimension (A).
Follow-up work
Installing complete rear swinging arm
Securing rear spring strut
Securing actuator rod for ride-height sensor to swinging arm
Removing plug from bore for wheel-speed sensor
Securing rear wheel-speed sensor
Install the rear wheel

23 12 111 Replacing shaft sealing ring of selector shaft

+ 23 12 621
Preparatory work
Disengaging shift lever
Core activity
(-) Removing shaft sealing ring of selector shaft
ATTENTION
procedure
Housing damage
Centre the hole.
Carefully drill the centre of the shaft sealing ring (1) using drill stop (No. 00 8
586).
Technical data
sealing ring (1).
Remove shaft sealing ring (1).
(-) Installing shaft sealing ring of selector shaft

Lightly lubricate the sealing lip of shaft sealing ring (2).
Position shaft sealing ring (2) with the opening (arrow) toward the inside.
Follow-up work
Securing selector lever

23 12 640 Replace bearings of all gearbox shafts (gearbox removed)
Core activity

Remove screws (2).
Remove screws (1).



Install screws (2).
Tightening torques
M6 x 20 10 Nm

23 14 006 Removing/installing shift assistant

+ 23 14 509
0456 - Style HPOE
NOTICE
Starting from model year 2017 the gear indicator flashes when the shift
assistant is not learnt in (e.g. after initial operation).
After successful learning in, the fault display goes out.
Preparatory work
Core activity
(-) Removing shift assistant
Affix masking tape to frame (1) (arrow).

Remove bolt (2) and washer (3).
Install jacking screw (No. 23 0 831).

Press off shift assistant (1).
Remove jacking screw (No. 23 0 831).
Unlatch connector (1) for the shift assistant (arrow) and disconnect.
Remove shift assistant (2).
Remove sleeve (3).

(-) Installing shift assistant
(arrow).
Clean the threads of selector shaft (1) with thread cleaning agent (No. 23 0
833).
Connect plug (2) for the shift assistant and lock (arrow).
Hold shift assistant (3) in position.
Press on shift assistant (1) with new bolt (2) and washer (3).
Tighten screw (2) with insertion tool (No. 23 0 832).
Tightening torques
encapsulated)
Remove the adhesive tape (arrow).
Follow-up work

23 14 051 Replacing potentiometer for gear indicator

+ 23 14 507
Core activity
(-) Removing potentiometer for gear indicator
ATTENTION
procedure
tab.

connector (2).
Disconnect connector (1) of potentiometer (2).

Remove screws (3).
Remove potentiometer (2) with O-ring (4).
(-) Install the potentiometer for gear indicator
Slide connector (1) in the direction of the arrow

Install potentiometer (2) with O-ring (4).

Install screws (3).
Tightening torques
Gearbox potentiometer to gearbox cover
M5 x 14 - 10.9 5 Nm
Connect connector (1) with potentiometer (2).

Follow-up work

23 21 510 Replace input shaft (gearbox removed)
Core activity

Remove screws (2).
Remove screws (1).


(-) Removing selector drum
Disengage shift forks (1), (2) and (3).

Push locking lever (4) to one side.
Remove selector drum (5).
Remove retaining plate (6).
(-) Remove the shift forks
Remove shift fork for 5th/4th gears (1).

Remove shift fork for 1st/2nd gears (2).
Remove shift fork for 6th/3rd gears (3).
(-) Removing gearbox shafts
Remove the circlip (1).

Remove thrust washer (2) .
Remove screws (1).

Remove screws (1).

Loosen retaining plate (2).
ATTENTION
Damage to sealing face
leaks
Support sealing surface with wood block.
Press the output shaft (1) out until the gear of the output shaft makes
contact with the gear (arrow) of the intermediate shaft (2).
Heat the differential cover (1) around the bearing seats.
Technical data
temperature
Jointly remove the output shaft (2), intermediate shaft (3), drive shaft (4) and
countershaft (5).
NOTICE
To remove the shaft, hold the transmission on the shafts and hit alternately on
the sealing surface with a soft-head hammer.
(-) Removing bearing of input shaft
Remove circlip (1).

Remove thrust washer (2).

Remove bearing (1) of the input shaft with thrust piece (No. 11 6 503) and
puller/separator (No. 00 7 500).
(-) Replacing input shaft
Replace input shaft (1).
(-) Installing bearing of input shaft
ATTENTION
Installation not in compliance with correct procedure
Damage to roller bearings
When installing, apply pressure to the bearing inner race only.
Install new bearing (1) on input shaft (2) until seated.

Mount suitable thrust washer (2) (thrust washer must be as close as

possible to the lower edge of the annular groove of the circlip (1)).
Install new circlip (1).
Check whether the circlip (1) is correctly mounted:

Circlip is completely engaged in annular groove.
Circlip is rotatable in the annular groove.
Check whether the thrust washer (2) has excessive play (arrow): The
strongest available thrust washer must be installed.
Technical data
Thicknesses of the Steps 0.1 mm 1.5...1.8 mm
thrust washers for
input/intermediate
shaft
(-) Installing gearbox shafts
Clean the threads (1).
Technical data
100 °C

Release/mating
temperature
Install the countershaft (5).

Jointly install the output shaft (2), intermediate shaft (3), input shaft (4).
ATTENTION
Fully press in output shaft (2), while counter-holding it with spacer sleeve
(No. 33 6 613) and grip (No. 00 5 500) ( or suitable pipe) on bearing inner
race of bearing (5).
Clean the threads.
Position the retaining plate (2).
ATTENTION
Component damage
Screws do not reach the specified tightening torque
The hardening of the screw locking agent begins with the screw in of the
thread.
Screws are tightened continuous with the correct tightening torque.
Install new screws (1), but do not tighten them.
Install screws (1) and tighten together with the inner screws.
Tightening torques
Inside, M6 x 16, Replace screw Tightening torque,
Thread-locking compound (micro- 8 Nm
encapsulated) Additional angle of
rotation, 90°
outer, M6 x 25, Replace screw Tightening torque,
rotation, 90°
Workshop equipment
Install thrust washer (2).
(-) Installing shift forks
Install shift fork for 6th/3rd gears (3).

Install shift fork for 1st/2nd gears (2).
Install shift fork for 5th/4th gears (1).
(-) Installing selector drum
NOTICE
Selector drum and gearshift fork must be renewed as a set.
Clean thread (1).

Heat bearing seat (2).
Technical data
temperature

Install selector drum (5) together with retaining plate (6) with identification
"OBEN" on top.
Position shift forks (1), (2) and (3) in the corresponding tracks.
(-) Installing shift-fork axles
NOTICE
The shift fork axles vary in length. Pay attention to correct assignment, else
transmission cannot be installed.
Clean the threads.

Install longer shift-fork axle (1), checking that the recess (arrow) is correctly
positioned.
Install shorter shift-fork axle (2), checking that the recess (arrow) is correctly
positioned.

Hold retaining plate (2) in position.

Install screws (1).
Tightening torques
M6 x 16, Replace screw Tightening torque,
rotation, 90°

Sealant
Dow Corning 07 58 0 397 777


Install screws (2).
Tightening torques
M6 x 20 10 Nm

23 21 530 Replace intermediate shaft (gearbox removed)
Core activity

Remove screws (2).
Remove screws (1).





Remove screws (1).

Remove screws (1).

ATTENTION
leaks
Technical data
temperature
countershaft (5).
NOTICE
(-) Removing bearings of intermediate shaft
Remove circlip (1).

Remove thrust washer (2).

Remove bearing (1) of the intermediate shaft with thrust piece (No. 11 6
503) and puller/separator (No. 00 7 500).
Replace intermediate shaft (1).
(-) Fitting intermediate shaft bearing
Install bearing (1) on intermediate shaft (2) until seated.
Mount suitable thrust washer (2) (thrust washer must be as close as

possible to the lower edge of the annular groove of the circlip (1)).

Check whether the circlip (1) is correctly mounted:

Circlip is completely engaged in annular groove.
Circlip is rotatable in the annular groove.
Check whether the thrust washer (2) has excessive play (arrow): The
strongest available thrust washer must be installed.
Technical data
Thicknesses of the Steps 0.1 mm 1.5...1.8 mm
thrust washers for
input/intermediate
shaft
Technical data
temperature

ATTENTION

Clean the threads.
ATTENTION
Component damage
thread.
Tightening torques
rotation, 90°
rotation, 90°
Workshop equipment


NOTICE
Clean thread (1).

Technical data
temperature

"OBEN" on top.
NOTICE
Clean the threads.

positioned.
positioned.

Install screws (1).
Tightening torques
rotation, 90°

Sealant
Dow Corning 07 58 0 397 777

Install screws (2).
Tightening torques

M6 x 20 10 Nm

23 21 540 Replacing output shaft (gearbox removed)
Core activity

Remove screws (2).
Remove screws (1).




(-) Removing shaft sealing ring of output shaft
Remove circlip (1).

ATTENTION
procedure
Housing damage
Centre the hole.
Carefully drill (2) centre of radial shaft seal using drill stop (No. 00 8 586).
Technical data

sealing ring (2).
Remove shaft sealing ring (2).

Remove screws (1).
Remove screws (1).

ATTENTION
leaks

Technical data
temperature
countershaft (5).
NOTICE
(-) Removing bearing of gearbox output shaft

Heat the differential cover in the area of the bearing seat (arrow).
Technical data
temperature
Remove the bearing (2).
(-) Replacing output shaft
Replace the output shaft (1).
(-) Installing bearing of gearbox output shaft
Heat the differential cover in the area of the bearing seat (arrow).
Technical data
temperature
ATTENTION
Install the bearing (2).

Technical data
temperature

ATTENTION
Clean the threads.
ATTENTION
Component damage
thread.
Tightening torques
rotation, 90°
8 Nm

Thread-locking compound (micro- Additional angle of
encapsulated) rotation, 90°
Workshop equipment

(-) Installing shaft sealing ring of output shaft

Only lubricate the inner sealing lip of radial shaft seal (2) lightly, otherwise
install dry and lubricant-free.
Lubricant
Molykote 111 11 00 7 660 832
Position shaft sealing ring (2) with the opening (arrow) toward the inside.
Mark the installation dimension (A) on the water channel (No. 23 4 791).
Technical data
approx. 6.5 mm

Short length of radial
shaft seal/differential
cover
Carefully install the radial shaft seal (1) along with water channel (No. 23 4
791) up to the installation dimension (A).

NOTICE
Clean thread (1).

Technical data
temperature

"OBEN" on top.
NOTICE
Clean the threads.

positioned.
positioned.

Install screws (1).
Tightening torques
rotation, 90°


Sealant
Dow Corning 07 58 0 397 777

Install screws (2).
Tightening torques
M6 x 20 10 Nm

23 41 300 Removing/installing or replacing gearshift lever

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

Remove shouldered bushing (3).
Disengage gearshift lever (4).
Remove washer (5).
Disengage ball end complete with selector rod (1) from gearshift lever (2).
Remove gearshift lever (2).
(-) Installing gearshift lever
Secure ball end complete with selector rod (1) to gearshift lever (2).
Tightening torques
M8 19 Nm
ATTENTION
Damage of the bearing due to lubricants.
Component damage, stiff movement
Lubricants can damage the coating chemically.
Lubricant bind dirt particles and increase the wear by this.
A PTFE-bearing is maintenance free; do not lubricate the bearing.
Clean shouldered bushing (3) and gearshift lever (4).

Hold gearshift lever (4) in position with washer (5) and shouldered bushing
(3).
Tightening torques
M8 x 25 19 Nm
Follow-up work
Checking and, if necessary, adjusting position of gearshift lever

23 41 310 Adjusting gearshift lever

+ 23 41 510
Core activity
(-) Checking and, if necessary, adjusting position of gearshift
lever
Ensure that customer-specific settings for the seat, for example, are correct.
Have the customer don suitable footwear and assume the usual riding
position on the motorcycle.
Check
Result:
When not touched, the gearshift lever is not on a level with the rider's toe
joint.
Measure:
Installing gearshift lever
Slacken screw (1).
Turn peg (2) to adjust position.
Tighten screw (1).
Tightening torques
Peg (clamp) to shift lever
M6 x 16 8 Nm

Have the customer take the motorcycle for a test ride to check the setting;
readjust if necessary.
NOTICE
A poorly adjusted shift lever has a negative effect on the shiftability of the
gearbox.
Follow-up work

23 41 325 Replacing selector rod on pedals

+ 23 41 555
Core activity
(-) Removing selector rod
Remove retaining clip (1).

Disengage selector rod (2) from ball head (3).

Disengage selector rod (2) from ball head (3) and remove.
(-) Checking length of selector rod
Check
Measure selector rod length (dimension A) between ball head centres.
Technical data
−0.5
Distance between
two ball-head
centrelines
Result:
Selector rod length not to specification.
Measure:
Adjusting selector rod length
Slacken nuts (1).
Adjust selector rod (2) to dimension (A).
Technical data
−0.5
Distance between
two ball-head
centrelines
Position ball heads (3).

Tighten nuts (1).
Tightening torques
Ball joint to shift rod
Locknut, M6 8 Nm
(-) Installing selector rod
Push selector rod (2) on to ball head (3).

Install retaining clip (1).

Follow-up work

23 41 329 Replacing shift lever on selector shaft

+ 23 41 556
Core activity
(-) Disengaging selector rod

(-) Removing shift lever
Remove screw (1).

Disengage shift lever (2) from selector shaft (3) and remove.
(-) Installing shift lever
Clean the threads.

Slide gearshift lever (2) onto gearshift shaft (1), checking the mounting
orientation (arrow).
Mark (arrow) is aligned with shift lever gap.
Install bolt (3).
Tightening torques
Shift lever (pinch bolt) to selector shaft
encapsulated)
(-) Securing selector rod


Follow-up work

Wheels - Suspensions - Brakes
Repair Guide
BMW Motorrad
31 42 026 Replacing bearing for leading link

+ 31 42 906
Preparatory work
Removing front seat
Removing fuel tank
Removing right throttle-valve assembly and air intake stub
Disengaging front ride-height sensor
Disengage bottom front spring strut
Disengaging leading link
Core activity
(-) Removing bearing for leading link
Remove right spacing bushing (1).
Remove left spacing bushing (1).
Removing bearing for left leading link side

Install reaction support (No. 00 8 572) with internal puller (No. 00 8 573) and
support ring (No. 31 4 800).
Remove bearing (1).
Carefully work puller (No. 00 8 400) with appropriate thrust piece (1) into
position.
Remove bushing (2), inner bearing (3) and radial shaft seal (4).
Removing bearing for right leading link side

Remove bearing (1).
Carefully work puller (No. 00 8 400) with appropriate thrust piece (1) into
position.
Remove bushing (2), inner bearing (3) and radial shaft seal (4).
(-) Install the bearing for leading link

Installing bearing for left leading link side

Introduce bearing (1) into the inner bearing seat.
Install spindle with pull-in nut (No. 36 5 551), washer (A) (dia. 42 mm)
without thread (No. 36 5 554), washer (B) (dia. 42 mm) and (C) (dia.
20 mm) with thread (No. 36 5 553).
Pull in bearing (1) until seated.
Remove washer (A) and pull-in nut (No. 36 5 551).
Install bushing (1).

Introduce bearing (2) into the outer bearing seat.
Install washer (A) and pull-in nut (No. 36 5 551).
Remove washers (A), (B), (C) and pull-in nut (No. 36 5 551).
Hold shaft sealing ring (1) in position with the open side (arrow) toward inner
bearing (2).
Pull in shaft sealing ring (1) until seated.
Remove spindle with pull-in nut (No. 36 5 551) and washers (A), (B) and (C).
Installing bearing for right leading link side



Remove washers (A), (B), (C) and pull-in nut (No. 36 5 551).
bearing (2).
Install washer (D) (dia. 47 mm) with thread (No. 36 5 554) and pull-in nut
(No. 36 5 551).
Remove spindle with pull-in nut (No. 36 5 551) and washers (A), (C) and (D).
Install narrow spacing bushing (1) on right.

Install wide spacing bushing (1) on left.
Follow-up work
Securing leading link
Securing front spring strut at bottom
Securing front ride-height sensor
Installing right throttle-valve assembly and air intake stub

31 42 028 Replace upper fork bridge

+ 31 42 528
Preparatory work
Removing BMW badges
Removing handlebars
Core activity
(-) Removing top fork bridge
Use the scissor-type lifter (No. 00 1 571) to raise the vehicle to take the
weight off the front wheel.
Disconnect connector (1) for ring aerial/ignition lock.

Remove cover caps (1) with a plastic wedge to avoid scratching the fork
bridge.
Remove nuts (2), while counter-holding at the hexagon head (arrow).
Pull the slider tubes (3) out of the fork bridge (4).
Remove the bearing journal (1) together with the fork bridge (2).

(-) Removing control unit for Keyless Ride
Drill into non-removable screws (1) until the screw heads come off.
Technical data
Control unit for Pilot hole min 6 mm
Keyless Ride - diameter 4.5 mm
drilling depth for Diameter for 6 mm
drilling out non- drilling out
removable screws fully 8.5 mm
Remove control unit for Keyless Ride (2).
(-) Installing control unit for Keyless Ride
Hold control unit for Keyless Ride (1) in position.

Install non-removable screws (2) with socket wrench insert (No. 51 0 531).
Tightening torques
Non-removable screw, M8 x 26, 20 Nm
Replace screws
encapsulated)
(-) Install the top fork bridge
Clean the threads.

Install bearing journal (1) together with fork bridge (2).
Tightening torques
Stud bolts in fork bridge
M14 x 1.5 130 Nm
encapsulated)
or, Thread-locking compound (Loctite
Slide slider tube (1) into fork bridge (2).

Align the slider tubes (1) so that the screw plug (3) faces out.
Install nuts (4), counter-holding at the hexagon head (arrow) while doing so.
Tightening torques
(mechanical)
Connect connector (1) for the ring aerial/ignition lock.

Follow-up work
Securing handlebars
Installing BMW badges

31 42 029 Replace lower fork bridge

+ 31 42 527
Preparatory work
Removing steering damper
Disengaging front wheel-speed sensor
Removing left brake calliper
Remove the right brake calliper
Removing front wheel
Removing fork legs
Removing bottom front-wheel cover
Core activity
(-) Removing bottom fork bridge
Remove screw (1).

Release brake-hose distributor (2).
Remove cap (1).

Heat nut (2), after adopting suitable measures to protect surrounding
components, as necessary.
Technical data
temperature
Remove nut (2), using socket wrench (No. 31 5 601) and Allen key (No. 31 5
603).
Remove washer (1).

NOTICE
Washer is not installed if the bottom fork bridge was replaced.
Remove fork bridge (2).
(-) Installing bottom fork bridge

Hold fork bridge (1) in position.
Install nut (2), using socket wrench (No. 31 5 601) and Allen key (No. 31 5
603).
Tightening torques
encapsulated)
Install cap (3).
Hold the brake-hose distributor in position and install screw (2).

Install screw (1).
Follow-up work
Installing bottom front-wheel cover
Installing fork legs
Venting fork legs
Install the front wheel
Securing front wheel-speed sensor
Securing steering damper

31 42 041 Replace bearing in upper fork bridge

+ 31 42 541
Preparatory work
Removing BMW badges
Removing handlebars
Removing top fork bridge
Core activity
(-) Replacing bearing

Heat fork bridge (2).
Technical data
temperature
Remove the bearing (3).
Remount bearing journal (1) in the new bearing (2).
Heat fork bridge (1).
Technical data
temperature
Press in bearing (2) with drift (No. 31 5 651) up to the limit position.
Follow-up work
Install the top fork bridge
Securing handlebars

31 42 046 Replace ball joints in upper fork bridge

+ 31 42 846
Preparatory work
Removing BMW badges
Removing handlebars
Removing top fork bridge
Core activity
(-) Removing pot-type joints
Remove sealing boot (1).

Remove circlip (2).
Support bushing (No. 31 5 663) from below.
Working from below, press out pot-type joint (3) with drift (No. 31 5 661).
(-) Installing ball joints
Remove sealing boots (1) and (4) from the new pot-type joint.
Lightly lubricate pot-type joint (3) and install with large bevel (arrow) down.
Working from above, press in pot-type joint (3) with drift (No. 31 5 661).
Use a suitable tool to install sealing boots (1) and (4).
Follow-up work
Install the top fork bridge
Securing handlebars

31 42 341 Removing/installing left fork leg

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

Remove screw (2) and loosen holder (3).
Remove cover cap (1) with a plastic wedge.

Remove nut(2), counter-holding at the hexagon head (arrow).
Support the fork legs (1) from below.

Loosen screws (2).
Remove fork leg (1) downwards.
(-) Installing left fork leg
Clean the threads.

Install fork leg (1) from below and support.
Align fork leg (1) so that the screw plug (2) faces out.
Install nut (3), counter-holding at the hexagon head (arrow) while doing so.
Tightening torques
(mechanical)
Install cover cap (4).
Install quick-release axle (1), to bring slider tubes (2) into alignment.
Install bolt (1).

Position line (2) with holder (3).
Install bolt (4).
Install screws (1).
Tightening torques
M8 x 35 Tightening
sequence: Tighten
screws six times in
alternate sequence
19 Nm
Remove quick-release axle (1) from slider tube (2).

(-) Ventilating left fork leg
Remove screw plug (1).

Dispose of O-ring (2).
Install screw plug (1) with new O-ring (2).
Tightening torques
Follow-up work
Securing right brake calliper
Securing left brake calliper

31 42 342 Removing/installing right fork leg

+ 31 42 842
Preparatory work
Core activity
(-) Removing right fork leg
Remove bolt (1).
Remove cover cap(1) with a plastic wedge.

Remove nut (2) counter-holding at the hexagon head (arrow).

Loosen screws (2).
Remove fork leg (1) downwards.
(-) Install the right fork leg
Clean the threads.

Install fork leg (1) from below and support.
Align fork leg (1) so that screw plug (2) faces out.
Install nut (3), counter-holding at the hexagon head (arrow) while doing so.
Tightening torques
(mechanical)
Install cover cap (4).
Install bolt (1).
Tighten screws (1).
Tightening torques
M8 x 35 Tightening
sequence: Tighten
screws six times in
alternate sequence
19 Nm
Remove quick-release axle (1) from slider tube (2).

(-) Ventilating the right fork leg
Remove screw plug (1).

Dispose of O-ring (2).
Install screw plug (1) with new O-ring (2).
Tightening torques
Follow-up work

31 42 350 Removing/installing fork legs

+ 31 42 849
Preparatory work
Core activity
(-) Removing fork legs
Remove screws (1).

Remove bolt (2).
Remove holder (3).
Remove cover caps (1) with a plastic wedge to avoid scratching the fork
bridge.
Remove nuts (2), while counter-holding at the hexagon head (arrow).

Loosen screws (2).
Pull the fork legs (1) down to remove.
(-) Installing fork legs
Clean the threads.

Install fork legs (1) from below and support.
Align fork leg (1) so that the screw plug (2) faces out.
Install nuts (3), counter-holding at the hexagon head (arrow) while doing so.
Tightening torques
(mechanical)
Install screws (1).

Set the sensor cable with holder (3).
Install bolt (2).
Tighten screws (1).
Tightening torques
M8 x 35 Tightening
sequence: Tighten
screws six times in
alternate sequence
19 Nm
Remove quick-release axle (1).

(-) Venting fork legs
Remove screw plugs (1).

Dispose of O-rings (2).
Install new O-rings (2) for the screw plugs (1).
Tightening torques
Follow-up work

31 42 405 Removing/installing leading link

+ 31 42 888
Preparatory work
Removing front seat
Removing fuel tank
Removing left injection valve cover
Removing right injection valve cover
Removing fuel distributor
Draining coolant
Disengaging left and right throttle-valve assemblies
Drain the front brake system
Releasing pressure modulator
Core activity
(-) Disengaging leading link
Fasten front wheel (1) with the belt (arrow) to engine guard (2).

(-) Securing leading link
Clean the threads.

Lift trailing arm (1).
Position spacer (5), contact disc (4) and steering damper (3).
Install bolt (2).
Tightening torques
encapsulated)
Lubricate axle (3).
Lubricant
Optimoly TA 18 21 9 062 599
Install axle (3).

Install bolt (2).
Tightening torques
M14 x 1.5 120 Nm
Remove the lengths of adhesive tape (arrows).

Clean the threads.
Install nut (2) using socket wrench (No. 31 5 601) and hexagon socket (No.
31 5 603).
Tightening torques
encapsulated)
Install cap (1).
Remove the strap (arrow).

Follow-up work
Securing pressure modulator
Filling and bleeding front brake system
Securing left and right throttle-valve assemblies
Installing fuel distributor
Installing left injection-valve cover
Installing right injection-valve cover

31 42 506 Replace fixed tube (fork leg removed)
NOTICE
During the replacement, any installed reflectors must be re-installed in the
same position.
Core activity
(-) Removing fixed fork tube
Remove protective cap (1).

Remove bleed screw (2) with O-ring (3).
Carefully pull fixed fork tube (4) out of slider tube (5) and catch escaping oil.
ATTENTION
Slackening the threaded fastener in the quick-release axle bore of the
slider tube
Causes permanent leakage of the slider tube
Do not slacken the threaded fastener in the quick-release axle bore of the
slider tube.
Turn slider tube (5) upside down and drain out the oil.
Carefully pry out sealing boot (1).
Remove circlip (2).
Remove radial shaft sealing ring (3) with internal puller (No. 00 8 561),
thread adapter (No. 00 8 564), pull rod (No. 13 5 251) and impact weight
(No. 13 5 253).
(-) Install the fixed tube
Pour the correct quantity of oil into the slider tube (1).
Technical data
Fork oil, capacity per approx. 485 ml
fork leg Telescopic fork oil (Telescope fork oil type 1)
Adjust the filler dipstick (No. 31 6 551) to the correct fork oil filling level.
Technical data
Fork oil fill level measured 135+2 mm
from top −2
edge, without
fixed fork tube
Insert the filler dipstick (No. 31 6 551) (1) in the slider tube and draw off
excess fork oil.
Lightly lubricate new shaft sealing ring.

Lubricant
Molykote 111 11 00 7 660 832
Mind the mounting orientation: the small recess (arrow) points upwards.
Install the support disc (1).

Drive in the shaft sealing ring (2) until seated, using the drift (No. 23 4 660)
and handle (No. 00 5 500) .
Slightly lubricate the inner face of dust boot (1).
Lubricant
Molykote 111 11 00 7 660 832
Install the dust boot (1) on the fixed fork tube (2).
Install the fixed fork tube (1).

Provisionally install the bleed screw (2) with O-ring (3).
Install sealing boot (1) with impact sleeve (No. 31 3 691).


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

Remove bleed screw (2) with O-ring (3).
Carefully pull fixed fork tube (4) out of slider tube (5) and catch escaping oil.
ATTENTION
Slackening the threaded fastener in the quick-release axle bore of the
slider tube
Causes permanent leakage of the slider tube
Do not slacken the threaded fastener in the quick-release axle bore of the
slider tube.
Turn slider tube (5) upside down and drain out the oil.
Carefully pry out sealing boot (1).

Remove circlip (2).
Remove radial shaft sealing ring (3) with internal puller (No. 00 8 561),
thread adapter (No. 00 8 564), pull rod (No. 13 5 251) and impact weight
(No. 13 5 253).
Remove washer (1).

Remove bushing (2) with internal puller (No. 00 8 561), threaded adapter
(No. 00 8 564), pull rod (No. 13 5 251) and impact weight (No. 13 5 253).
Remove tubular spacer (1) and bushing (2).

(-) Assembling fork leg
Install the bush (2) and spacer tubes (1) in the slider tube (3).
Install the bush (1) with the drift (No. 23 4 660) and handle (No. 00 5 500) to
the limit position.
Pour the correct quantity of oil into the slider tube (1).
Technical data
Fork oil, capacity per approx. 485 ml
fork leg Telescopic fork oil (Telescope fork oil type 1)
Adjust the filler dipstick (No. 31 6 551) to the correct fork oil filling level.
Technical data
Fork oil fill level measured 135+2 mm
from top −2
edge, without
fixed fork tube
Insert the filler dipstick (No. 31 6 551) (1) in the slider tube and draw off
excess fork oil.
Lightly lubricate new shaft sealing ring.
Lubricant
Molykote 111 11 00 7 660 832
Slip new shaft sealing ring into position with the small recess (arrow) toward
the sealing boot.

Drive in the shaft sealing ring (1) until seated, using the drift (No. 23 4 660)
and handle (No. 00 5 500) .
Slightly lubricate the inner face of dust boot (1).
Lubricant
Molykote 111 11 00 7 660 832
Install the dust boot (1) on the fixed fork tube (2).
Install the fixed fork tube (1).

Provisionally install the bleed screw (2) with O-ring (3).
Install sealing boot (1) with impact sleeve (No. 31 3 691).

31 42 850 Replacing bearing for semi-trailing arm (semi-trailing arm removed)
Core activity
(-) Removing spacing bushings
Remove spacing bushings (1) and (2).
(-) Removing bearing for leading link
Heat the bearing seat.
Technical data
temperature
Remove bearing (1).

Remove bushing (2).
Remove inner bearing (1) and shaft sealing ring (2) with drift (No. 36 5 530).
Repeat this procedure to remove the bearing on the other side.
(-) Install the bearing for leading link

Installing bearing for left leading link side


bearing (2).
Install washer (A) (dia. 42 mm) without thread (No. 36 5 554) and pull-in nut
(No. 36 5 551).
Installing bearing for right leading link side



bearing (2).
Install washer (D) (dia. 47 mm) without thread (No. 36 5 554) and pull-in nut
(No. 36 5 551).
Remove spindle with pull-in nut (No. 36 5 551) and washers (D), (B) and (C).
(-) Installing spacing bushings
Install wide spacing bushing (1) on left.

Install narrow spacing bushing (2) on right.


31 48 001 Replacing front spring strut

+ 31 48 512
31 48 513 Additional work for replacing front spring strut (with Dynamic ESA)
Preparatory work
Removing front seat
Removing fuel tank
Disengaging leading link
Core activity
(-) Removing front spring strut

Disconnect the connector (1) for ESA spring strut.
Unlock bush (2) and unclip it by working it to the rear.
Slightly raise the motorcycle with scissor-type lifter (No. 00 1 571).

Removing front spring strut

Remove screw (1), if necessary lifting the motorcycle slightly further or
lowering it until spring strut (2) is relieved.
Remove bolt (3).
Slightly raise the motorcycle.
Work spring strut (2) forward to remove.
(-) Installing front spring strut

Installing front spring strut
Clean the threads.
Insert spring strut (2) from the front.
Install bolt (1) loosely.
Lower the motorcycle until screw (3) can be installed.
Install bolts (3) and (1) and tighten.
Tightening torques
Spring strut, front, to leading link
encapsulated)
Spring strut, front, to frame
encapsulated)
Guide in line (1).

Clip in bush (2) from the rear.
Connect connector (3) for the ESA spring strut.

Remove scissor-type lifter (No. 00 1 571).
Follow-up work
Securing leading link

32 71 040 Renewing handlebar

+ 32 71 514
Preparatory work
Remove the left handlebar weight
Removing left grip unit
Releasing clutch lever fitting
Remove the right handlebar weight
Removing right multifunction switch
Removing throttle twistgrip
Release the handbrake lever fitting
Core activity
(-) Removing handlebars
Remove screws (1).

Remove clamping blocks (2).
Remove handlebars (3).
(-) Installing handlebars
Position handlebars (1) with the marks (arrow) at clamping blocks (2).
NOTICE
Positioning at the top marks sets the handlebars ideally for a rider standing on
the pegs for offroad riding.
Hold clamping blocks (1) in position.

At the back side of the clamping blocks (1), an air gap (arrows) emerges.
Tightening torques
M8 x 35 Tightening
sequence: in the

forward direction of
travel, tighten until
seated
19 Nm
Follow-up work
Securing handbrake lever fitting
Installing throttle twistgrip
Installing right multifunction switch
Installing right handlebar weight
Secure the clutch lever fitting
Install the left grip unit
Installing left handlebar weight

32 71 053 Replacing left hand protector

+ 32 71 553
Core activity
(-) Removing left mirror
Remove bolt (1).

Remove cover cap (2).
Remove bolt (1).

Remove mirror (2) with discs (3).
(-) Remove the left handlebar weight
Remove screw (1).

Remove bushing (2).
Remove handlebar weight (3).
(-) Removing left hand protector
Remove hand protector (1).

(-) Disassembling hand protector
Remove screw (1).

Remove bracket (2).
Remove flat nut (3).
(-) Assembling hand protector
Install flat nut (1).

Align bracket (2) with the anti-twist stop (arrows) of hand protector (3).
Install screw (4).
Tightening torques
M5 x 14.5 2 Nm
(-) Installing left hand protector
Place hand protector (1) in position.
(-) Installing left handlebar weight

Install handlebar weight (1).

Insert bushing (2) with screw (3).
Position hand protector (4).
Tighten screw (3), making sure that hand protector (4) does not twist out of
position.
Tightening torques
M10 x 50 38 Nm
(-) Installing left mirror
– with HP Billet PackOE (0799)
or
– with Option 719 Billet Pack StormOE (0797)
or
– with Option 719 Billet Pack ClassicOE (0796)
Position mirror (2) with contact discs (3) and align it.
Install bolt (1).
Tightening torques
M10 x 50 25 Nm
or
or
Position cover cap (2).

Install bolt (1).
Tightening torques
Cover cap to mirror
M3 x 5 1 Nm
Follow-up work

32 71 054 Replacing right hand protector

+ 32 71 554
Core activity
(-) Removing right mirror
Remove bolt (1).

Remove bolt (1).

Remove mirror (2).
(-) Remove the right handlebar weight
Remove screw (1).

Remove bushing (2).
(-) Removing right hand protector

Remove screw (1).

Remove bracket (2).

Install screw (4).
Tightening torques
M5 x 14.5 2 Nm
(-) Installing right hand protector
(-) Installing right handlebar weight


position.
Tightening torques
M10 x 50 38 Nm
(-) Installing right mirror
or
or
Set mirror (2) with discs (3).

Install bolt (1).
Tightening torques
M10 x 50 25 Nm
or
or

Install bolt (1).
Tightening torques
Cover cap to mirror
M3 x 5 1 Nm
Follow-up work

32 71 063 Renewing handlebar weight

+ 32 71 515
Core activity
(-) Remove the handlebar weight
Remove screw (1).

Remove bushing (2).
(-) Installing handlebar weight

position.
Tightening torques
M10 x 50 38 Nm
Follow-up work

32 72 001 Replacing throttle twistgrip

+ 32 72 620
Preparatory work
Removing right multifunction switch
Core activity
(-) Removing throttle twistgrip
Remove screw (1).

Remove throttle twistgrip (2).
(-) Installing throttle twistgrip
Install throttle twistgrip (2).

Install screw (1).
Tightening torques
M3.5 x 30 2 Nm
Follow-up work
Installing right multifunction switch

32 72 064 Replacing handlebar fitting for clutch actuation (without bleeding system)
+ 32 72 664
Preparatory work
Draining clutch-fluid reservoir
Core activity
(-) Removing handlebar fitting for clutch actuation
Remove union screw (1) and catch the escaping fluid in a suitable container.
Disconnect clutch line (2).
Disconnect plug (3) for the clutch switch.
Remove screws (1).

Remove clamping block (2).
Remove handlebar fitting (3).
(-) Replacing handlebar fitting for clutch
Remove screw (1).

Transfer clutch switch (2) to the new handlebar fitting.
The locking tab (arrow) faces up.
Install screw (1).
Tightening torques
(-) Installing handlebar fitting for clutch
Hold clamping block (1) and handlebar fitting (2) in position.

Loosely install screws (3).

Position handlebar fitting (2) at the marks (arrow).
Tighten screws (3).
Tightening torques
M6 x 30 Tightening
sequence: tighten
top until fully closed
8 Nm
Hold clutch line (1) in position, noting sealing rings (2).

Tightening torques
M10 x 1 7 Nm
Connect connector (4) for the clutch switch.
Follow-up work

32 72 070 Replace clutch lever

+ 32 72 627
ATTENTION
Changed free-travel setting (blow-by clearance) due to replacement
of/tampering with the lever mount
Malfunction in clutch system
Make sure that lever mount with pushrod remains with the handbrake fitting.
Preparatory work
Removing left mirror
Removing left hand protector
Core activity
(-) Removing clutch lever
Remove nut (1).

Remove screw (2).
Pull out lever unit (3), noting rubber sleeve (4).
Remove sleeve (1).

Remove lever mount with pushrod (2) and spring (3).
(-) Installing clutch lever
Install spring (3) and lever mount with pushrod (2).

Install sleeve (1) and lubricate.
Lubricant
Teflon spray 83 23 0 154 884

Lubricate screw (1).
Lubricant
Teflon spray 83 23 0 154 884
Insert lever unit (2).

Pushrod (3) engages in piston seat (4).
Rubber sleeve (5) is correctly positioned.
Install screw (1) and nut (6).
Tightening torques
M5, Replace nut Tightening
Thread-locking compound sequence: Tighten
(mechanical) the nut, counter-
holding the bolt
7 Nm
Follow-up work
Installing left hand protector
Installing left mirror

32 72 076 Replacing lever for front-wheel brake

+ 32 72 576
ATTENTION
Malfunction in brake system
Preparatory work
Removing right mirror
Removing right hand protector
Core activity
(-) Removing handbrake lever
Remove nut (1).

Remove screw (2).
Pull out lever unit (3), noting rubber sleeve (4).
Remove sleeve (1).

Remove lever mount with pushrod (2) and spring (3).
(-) Installing handbrake lever

Lubricant
Teflon spray 83 23 0 154 884

Lubricate screw (1).
Lubricant
Teflon spray 83 23 0 154 884

Install screw (1) and nut (6).
Tightening torques
holding the bolt
7 Nm
Follow-up work
Installing right hand protector
Installing right mirror

32 72 078 Replacing brake handlebar fitting for front wheel

+ 32 72 578
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.
Preparatory work
Drain the brake fluid reservoir on handbrake lever fitting
Core activity
(-) Removing brake fitting for front wheel
Remove banjo bolt (1) with sealing rings (2) and catch the escaping fluid in a
suitable container.
Disengage brake line (3).
Remove screws (1).

Remove brake fitting (3).
(-) Installing brake fitting for front wheel
Hold clamping block (1) and brake fitting (2) in position.

Position brake fitting (2) at the marks (arrow).
Tighten screws (3).
Tightening torques
M6 x 30 Tightening
sequence: tighten

8 Nm
Hold brake line (3) in position.

Install banjo bolt (1) with new sealing rings (2).
Tightening torques
M10 x 1 24 Nm
Follow-up work
Filling and bleeding brake fluid reservoir on handlebar fitting

32 72 097 Replacing left handlebar grip

+ 32 72 632
0519 - Heated gripsOE
ATTENTION
Opening of switch unit
Damage to the conductors coated with protective sealing lacquer
Do not separate the top and bottom parts of the switch unit.
Preparatory work
Core activity
(-) Removing left handlebar grip
Disconnect connector (1) for the heated grip.
Push up retainer (1).

Remove handlebar grip (2).

(-) Removing multi-controller
Remove screws (1).

Disengage plug (2) for the heated grip.
Remove multi-controller (3) from grip (4).
(-) Installing multi-controller
Position Multi-Controller (1) on grip (2), making sure that recesses (3) and
retainers (4) engage each other.
Work plug (5) for the heated grip through Multi-Controller (1).
Hold plug (5) for the heated grip in position and install screws (6), noting the
routing of the grip-heating cable (arrow).
Tightening torques
(-) Installing left handlebar grip
Install handlebar grip (1), and at the same time insert plug (2) for the heated
grip.
Retainer (3) engages.
Connect plug (1) for the heated grip.

Lubricate the rubber (arrow) of multifunction switch (2).
Installation tool
Follow-up work

32 76 000 Replacing steering damper

+ 32 76 500
Preparatory work
Core activity
(-) Removing steering damper
Remove nut (1).

Disengage steering damper (2) from fork bridge (3).
Remove screw (1).

Remove steering damper (2) with washer (3) and spacer (4).
(-) Installing steering damper
Clean the threads.

Insert spacer (4), washer (3) and steering damper (2).
Install screw (1).
Tightening torques
encapsulated)
Position steering damper (2) on fork bridge (3).

Install nut (1).
Tightening torques
Steering damper to fork bridge
(mechanical)
Follow-up work

33 35 000 Replacing rear wheel swinging arm

+ 33 35 501
0456 - Style HPOE
ATTENTION
Component damage
Preparatory work
Removing bevel gears
Removing spacing washer
Core activity
(-) Removing rear wheel swinging arm
Remove locknut (1) and remove anti-chafing pad (2).

Remove floating-bearing stud (3).
Heat fixed-bearing stud (1).
Technical data
temperature
Remove fixed-bearing stud (1) and anti-chafing pad (2).

33 35 001 Replacing swinging-arm bearing

+ 33 35 502
0456 - Style HPOE
Preparatory work
Remove the complete rear wheel swinging arm
Removing flexible gaiter between gearbox and rear wheel swinging
arm
Core activity
(-) Replacing swinging-arm bearing
ATTENTION
Component damage
Install reaction support (No. 00 8 572), support ring (No. 36 6 610) and
internal puller 2 1/3 (No. 00 8 574).
Heat the part of the swinging arm surrounding the bearing.
Technical data
temperature
Remove bearing (1).
Install new bearing (1) with drift (No. 33 5 700) until flush.

Install the second bearing in the same way.
Follow-up work
Installing flexible gaiter between gearbox and rear wheel swinging arm
Installing complete rear swinging arm

33 35 010 Replacing flexible gaiter between rear wheel swinging arm and bevel gears
+ 33 35 514
Preparatory work
Core activity
(-) Disengaging bevel gears
Loosen strap (1) and lower bevel gears (2).

Unclip flexible gaiter (3) from bevel gears (2).
Remove bevel pinion (4) from universal shaft (5).
(-) Removing flexible gaiter from swinging arm and bevel bears
Remove flexible gaiter (1) complete with plastic insert (2).
(-) Installing flexible gaiter on swinging arm and bevel bears
Lubricate the mating face (arrow) of flexible gaiter (1).
Lubricant
Install flexible gaiter (1) with plastic insert (2) in the bevel gears.
Plastic insert (2) engages with an audible click.

(-) Securing bevel gears
Lubricate the splines (arrows) of bevel pinion (1) and universal shaft (2).
Lubricant
Optimoly TA 18 21 9 062 599
Slightly raise bevel gears (3).

Engage the splints of bevel pinion (1) and universal shaft (2).
Secure bevel gears (3) with strap (4).
Check that plastic insert (1) is correctly seated at the flexible gaiter; correct if
necessary.
Push plastic insert (1) with flexible gaiter (2) into the swinging arm until
plastic insert (1) and the mating face (arrow) engage correctly in swinging
arm (3).
Follow-up work

33 35 011 Replacing flexible gaiter between gearbox and rear wheel swinging arm
+ 33 35 515
Preparatory work
Disengaging bevel gears
Removing flexible gaiter from swinging arm and bevel bears
Removing universal shaft
Core activity
(-) Removing flexible gaiter between gearbox and rear wheel
swinging arm

(-) Installing flexible gaiter between gearbox and rear wheel

swinging arm
Install diaphragm (1).

Follow-up work
Install the universal shaft
Installing flexible gaiter on swinging arm and bevel bears

Secure the bevel gears

33 35 015 Replacing Paralever link

+ 33 35 520
Preparatory work
Removing brake-hose cover
Core activity
(-) Removing Paralever link
Secure bevel gears (1) with a strap (arrow) so that the unit cannot drop out
of position.
Remove screws (2).
Disengage cable guide (3).
Remove Paralever link (4).
(-) Installing the Paralever link
Clean the threads.

Install the Paralever link (1).
Position the cable routing (2).
Install screws (3).
Tightening torques
M10 x 60 - 10.9 56 Nm
encapsulated)
Remove the strap (arrow).
Follow-up work
Installing brake hose cover

33 35 506 Replacing top Paralever bearing on rear bevel gears (bevel gears removed)
ATTENTION
Component damage
Core activity
(-) Removing pivot bearing of Paralever link in bevel gears
Install the spindle with thrust nut (No. 33 2 531) and support (No. 33 2 532).
Install disc (No. 33 2 535) with the collar (arrow) toward bearing (1) and
align.
Remove bearing (1).
(-) Installing pivot bearing of Paralever link in bevel gears
Install the spindle with thrust nut (No. 33 2 531) and disc (No. 33 2 534) with
the (A) mark toward bearing (1).
Insert washer (2) into disc (No. 33 2 534).
Technical data
Washer thickness 1 mm
Introduce bearing (1) into tapered bushing (No. 33 2 533) and slip the
assembly on to spindle with the smaller opening toward housing (3).
Install disc (No. 33 2 535) with the collar (arrow) toward bearing (1).
Align the preassembled tool.
Install bearing (1).
Lightly lubricate new bearing (1).
Care products
Rubber care product 83 12 0 397 018

33 35 507 Replacing bottom Paralever bearing on rear bevel gears (bevel gears removed)
Preparatory work
Draining oil from bevel gears (bevel gears removed)
Preparing holder
Core activity
(-) Seating bevel gears in retaining fixture
Seat bevel gears (1) in mount (No. 33 6 722).

Align mount (No. 33 6 721) and tighten.
Secure bevel gears (1) in mount (No. 33 6 721) with washer (No. 33 6 726)
and screw (2).
(-) Removing Paralever pivot bearing from rear bevel gears (right
side as viewed in direction of travel)
ATTENTION
Hard or sharp-edged components
Scratches and damage to paintwork
Use a suitable soft cover or mask off the areas at risk.
Install the short spindle with thrust nut (No. 36 5 552), washer dia. 50 mm
(No. 36 5 554) and sleeve (No. 31 1 511).
Install washer with thread dia. 37 mm (No. 36 5 553) from below.
Align the preassembled tool and apply light preload.
Heat housing (1).
Technical data
temperature,
swinging-arm bearing
Remove bearing (2).
(-) Installing Paralever pivot bearing in rear bevel gears (right side
as viewed in direction of travel)
Hold new bearing (1) in position with seal toward housing (2).
Install the short spindle with thrust nut (No. 36 5 552) and washer dia. 37
mm (No. 36 5 554).
Heat housing (2).

Technical data
temperature
Install bearing (1) until seated.
(-) Removing rear bevel gears from retaining fixture
Remove screw (2) and disc (No. 33 6 726).

Remove bevel gears (1) from retaining fixture (No. 33 6 701).
(-) Removing Paralever pivot bearing from rear bevel gears (left
side as viewed in direction of travel)
ATTENTION
Hard or sharp-edged components
Scratches and damage to paintwork
Use a suitable soft cover or mask off the areas at risk.
Remove circlip (1).
Masking off gearbox housing

Mask off the marked face (arrow) of gearbox housing (1).

Install the short spindle with thrust nut (No. 36 5 552), washer dia. 57 mm
(No. 36 5 554) and press-out bushing (No. 31 5 652).
Heat housing (1).
Technical data
temperature
Remove bearing (2).

Removing adhesive tape
Remove the adhesive tape (arrow) from gearbox housing (1).
(-) Installing Paralever pivot bearing in rear bevel gears (left side
as viewed in direction of travel)
Hold new bearing (1) in position.

Install the short spindle with thrust nut (No. 36 5 552) and washer dia. 42
mm (No. 36 5 554).
Heat housing (2).
Technical data
temperature
Install bearing (1) until seated.

Follow-up work
Pouring oil into bevel gears (bevel gears removed)

33 35 519 Replacing bearing in Paralever link (link removed)
Core activity
(-) Removing bearing, Paralever link / frame
Remove bearing (1) with spindle and thrust nut (No. 33 2 531), support (No.
33 2 532) and washer (No. 33 2 535).
(-) Installing bearing, Paralever link / frame
Lightly lubricate bearing (1).
Care products
Install the spindle with thrust nut (No. 33 2 531) and washer (No. 33 2 534).
Mark (A) faces toward the bearing.
Introduce bearing (1) into tapered bushing (No. 33 2 533) and slip both
components onto the spindle.
The small opening (arrow) is toward the link.
Install washer (No. 33 2 535).
The collar (arrow) is toward the bearing.
Install bearing (1) centred in the link.

33 54 000 Replacing rear spring strut

+ 33 54 500
0456 - Style HPOE
0413 - Two-up riding packageOE
33 54 512 Additional work for replacing rear spring strut (with Dynamic ESA)
Preparatory work
Removing rear seat
Removing front seat
Disengage the engine control unit
Removing rear ride-height sensor with bracket
Disengaging cable for ESA spring strut
Removing left heel deflector
Removing right heel deflector
Removing silencer
Raising rear frame
Core activity
(-) Removing rear spring strut
ATTENTION
Component damage
Support rear wheel (1) on assembly aid (No. 36 5 520).

Remove screw (2).
Secure spring strut (4) so that it cannot drop and remove screw (3).
Remove assembly aid (No. 36 5 520) so that rear wheel (1) is lowered with
the rear wheel swinging arm.
Work spring strut (1) to the rear and remove, noting bracket (2).

(-) Installing rear spring strut
Clean the threads.

Work spring strut (1) into place in swinging arm (2) from the rear and hold it
in position, noting bracket (3).
Support rear wheel (1) on assembly aid (No. 36 5 520).

Install screw (3).
Install screw (2).
Tightening torques
encapsulated)
Spring strut to swinging arm
encapsulated)
Remove assembly aid (No. 36 5 520).
Follow-up work
Lowering rear frame
Installing silencer
Installing right heel deflector
Installing left heel deflector
Securing cable for ESA spring strut
Installing rear ride-height sensor with bracket
Securing engine control unit

Installing rear seat

33 73 000 Removing/installing or replacing universal shaft

+ 33 73 500
Preparatory work
Disengaging bevel gears
Removing flexible gaiter from swinging arm and bevel bears
Core activity
(-) Removing universal shaft
Affix masking tape to frame (1) (arrow).

Work flexible gaiter (2) forward to remove.
Using a suitable tool, remove universal shaft (1) from gearbox output shaft
(2).
Lift rear wheel swinging arm (1) and remove universal shaft (2).

(-) Install the universal shaft
Lift rear wheel swinging arm (1) and install universal shaft (2).
Lubricate the splines (arrows) of universal shaft (1) and gearbox output shaft
(2).
Lubricant
Optimoly TA 18 21 9 062 599
Turn universal shaft (1) until the splines (arrows) engage.

Push universal shaft (1) all the way on to gearbox output shaft (2).
Lubricate mating face (1) of flexible gaiter (2).
Lubricant
Check that plastic insert (3) is correctly seated at flexible gaiter (2); correct if
necessary.
Install flexible gaiter (2) complete with plastic insert (3), making sure
positioning (arrow) is correct.
Plastic insert (3) engages
Remove adhesive tape (4).
Follow-up work
Installing flexible gaiter on swinging arm and bevel bears
Secure the bevel gears


33 74 000 Oil change in rear bevel gears

+ 33 74 500
Core activity
(-) Changing oil in bevel gears
NOTICE
Change gearbox oil, warmed to normal operating temperature.
Draining oil in bevel gears

Place a suitable tray underneath the bevel gears to catch escaping oil.
Remove oil filler plug (1) with sealing ring (2).
Remove oil drain plug (1) with O-ring (2).
Drain off all the oil.
Filling bevel gears with oil

Install oil drain plug (1) with O-ring (2).
Tightening torques
M12 x 1 20 Nm
Use syringe (No. 34 2 551) to inject the gear oil slowly into the housing.

Technical data
Bevel gears, oil Oil change 180 ml
capacity Gear oil (Hypoid Axle Oil G3)
Install oil filler plug (1) with new sealing ring (2).
Tightening torques
M12 x 1.5 25 Nm
Follow-up work

33 74 001 Removing/installing rear bevel gears

+ 33 74 501
Preparatory work
Core activity
(-) Removing bevel gears
Removing cover for bevel gears
Drill a pilot hole in the centre of cover (1).
Technical data
Drill diameter 3 mm
Remove cover (1) with pull rod (No. 00 8 581) and adapter (No. 00 8 587).
Remove screw (1) while counter-holding bearing stud (2).

Drive out bearing stud (2) with a suitable tool.
Remove bearing stud (3) and sealing ring (4).

Separate bevel gears (2) from universal shaft (3), disengage strap (4) and
remove bevel gears (2).
When setting down bevel gears always keep the assembly upright, never
lay it flat.
(-) Removing spacing washer

Remove spacing washer (1) with O-ring (2).
(-) Installing spacing washer

ATTENTION
Spacing washer not installed
Jamming of bevel gears at swinging arm
Make sure that the spacing washer is installed correctly.
Check the ease of movement of the bearing.
Install spacer (1) with O-ring (2). Make sure that the flattened side (arrow)
faces inwards.
(-) Installing bevel gears
NOTICE
When repairing, always replace the outer bearing journal (with thread) and
screw.
Re-installation of the parts removed beforehand is not permitted!
Lubricate gearing (Arrows) on bevel gears (1) and Cardan shaft (2).
Lubricant
Optimoly TA 18 21 9 062 599
Check plastic insert (3) for correct fit on gaiter (4) and correct as needed.
Secure bevel gears (1) with tensioning strap (5) and put into position.
Slide gearing (Arrows) on bevel gears (1) and Cardan shaft (2) into each
other.
Slide gaiter (4) with plastic insert (3) into bevel gears (1) until plastic insert
(3) engages with an audible click.
Install new bearing journal (4).
Check sealing ring (3) for damage and renew it if necessary.
Install bearing journal (2) with sealing ring (3).
Install new screw (1) counter-holding at bearing journal (4).
Tightening torques
encapsulated)
Installing cover of bevel gears

Install new cover (1).
Follow-up work
Bedding in brake pads

33 74 002 Replacing rear bevel gears

+ 33 74 507
NOTICE
After replacement of the bevel gears or the housing and after the repairs, e.g.
work on the gear set and bearing, the oil in the bevel gears must be changed
after approx. 1000 km.
Preparatory work
Removing rear brake disc
Core activity
(-) Removing bevel gears
Removing cover for bevel gears
Drill a pilot hole in the centre of cover (1).
Technical data
Drill diameter 3 mm
Remove cover (1) with pull rod (No. 00 8 581) and adapter (No. 00 8 587).
Remove screw (1) while counter-holding bearing stud (2).

Drive out bearing stud (2) with a suitable tool.
Remove bearing stud (3) and sealing ring (4).

Separate bevel gears (2) from universal shaft (3), disengage strap (4) and
remove bevel gears (2).
When setting down bevel gears always keep the assembly upright, never
lay it flat.

(-) Removing spacing washer
Remove spacing washer (1) with O-ring (2).
(-) Replacing bevel gears
Prepare new bevel gears for installation.

Comply with the instructions on the label.
Top up bevel gears.
Technical data
Bevel gears, oil Initial filling 200 ml
capacity Gear oil (Hypoid Axle Oil G3)
(-) Installing spacing washer

ATTENTION
Spacing washer not installed
Jamming of bevel gears at swinging arm
Make sure that the spacing washer is installed correctly.
Check the ease of movement of the bearing.
Install spacer (1) with O-ring (2). Make sure that the flattened side (arrow)
faces inwards.
(-) Installing bevel gears

NOTICE
When repairing, always replace the outer bearing journal (with thread) and
screw.
Re-installation of the parts removed beforehand is not permitted!
Lubricate gearing (Arrows) on bevel gears (1) and Cardan shaft (2).
Lubricant
Optimoly TA 18 21 9 062 599
Check plastic insert (3) for correct fit on gaiter (4) and correct as needed.
Secure bevel gears (1) with tensioning strap (5) and put into position.
Slide gearing (Arrows) on bevel gears (1) and Cardan shaft (2) into each
other.
Slide gaiter (4) with plastic insert (3) into bevel gears (1) until plastic insert
(3) engages with an audible click.
Install new bearing journal (4).
Check sealing ring (3) for damage and renew it if necessary.
Install bearing journal (2) with sealing ring (3).
Install new screw (1) counter-holding at bearing journal (4).
Tightening torques
encapsulated)
Installing cover of bevel gears

Install new cover (1).
Follow-up work
Installing rear brake disc


33 74 003 Replacing radial shaft sealing ring of wheel axle in housing

+ 33 74 508
Preparatory work
Draining oil in bevel gears
Core activity
(-) Removing shaft sealing ring of wheel axle from housing
Using a suitable tool, remove cover (1) from wheel axle (2).
Remove the felt (arrow) from shaft sealing ring (1).

ATTENTION
Pilot hole drilled too deeply in radial shaft seal
Damage to components behind the radial shaft seal
Use drill stop to limit drilling depth.
Drill into shaft sealing ring (1) at the outer edge, using drill stop (No. 00 8
586).
Technical data
Drilling into shaft Drill-bit stop 3 mm
sealing ring Hole diameter 2.5 mm
Remove shaft sealing ring with pull rod (No. 00 8 581), impact weight (No.
00 8 582) and adapter (No. 00 8 587).
Check the bearing for metal particles; clean if necessary.
(-) Installing radial shaft seal of wheel axle in housing
Lightly oil the sealing lip of the shaft sealing ring (1).
Gear oil
Hypoid Axle Oil G3 83 22 2 460 128
Position shaft sealing ring (1) with the felt out (arrow) and use drift (No. 33 1
892) and washer (No. 33 1 894) to install it until fully seated.
Install the cover (1) on the wheel axle (2).
Follow-up work

33 74 004 Replacing breather for rear bevel gears

+ 33 74 509
Core activity
(-) Removing breather from bevel gears
Remove breather (1).
(-) Installing breather for rear bevel gears
Lubricate breather (1) at the sealing face (arrow).
Care products
Install breather (1), turning it to and fro until seated.
Follow-up work

33 74 010 Replacing wheel flange on rear bevel gears

+ 33 74 515
Preparatory work
Core activity
(-) Removing wheel flange
Requirement
Gear is engaged.
Remove circlip (1).

Insert plate (No. 33 2 514) in wheel axle (2).
Position counter-holder (No. 33 2 513) on wheel flange (1) and tighten.
Prepare puller (No. 33 2 512).

NOTICE
Regularly lubricate the sliding surfaces of the puller with the grease provided
with the tool.
ATTENTION
Inner wedge of puller slips forward during pull-off operation
Damage to tool
Centre the puller.
Repeatedly check positioning.
Make sure that puller (No. 33 2 512) is retracted and centre it (arrows)
relative to counter-holder (No. 33 2 513) on plate (No. 33 2 514).
Pretension spindle (1) on puller (No. 33 2 512).
Ease off wheel flange (2) by turning spindle (3) until puller sled (4) and
counter support (No. 33 2 513) make contact (arrow).
(No. 33 2 512) Reposition extractor,positioned fully retracted once again
and is pretensioned with spindle (1) again.
Ease off wheel flange (2) by turning spindle (3) until wheel flange (2) is in
contact with puller (No. 33 2 512).
Back off puller (No. 33 2 512) and remove.
(No. 33 2 514) Reverse contact disc and place on wheel axle (1).
The guide (arrow) is facing out.
Position extractor (No. 33 2 512) in retracted state, centrally on contact
disc (No. 33 2 514).
Pretension spindle (3).
Remove wheel flange (2) by turning spindle (4).
Remove the special tools.
(-) Installing wheel flange
Lay wheel flange (1) on heating plate (2) and heat it; in this process use
thermometer (No. 00 1 900) to measure temperature in several recesses
(arrow) at the wheel screw connection.
Technical data
temperature
Insert installation tool (No. 33 2 517).

CAUTION
Risk of burn injury

Position wheel flange (1) with the recesses (arrow) toward the bevel gears.
The gearing of wheel flange (1) and wheel axle (2) must be in alignment.
Position thrust piece (1) in such a way that it is seated with the guide (arrow)
straight and firm on wheel flange (2).
Working quickly, install wheel flange (2) by tightening thrust nut (3) until the
flange is seated; note that the process can produce a slight amount of swarf.
NOTICE
After installation of a new wheel flange there are slight grinding noises and the
flange does not turn as freely.
This is of no significance and has to do with the bedding-in process of the
primary dirt excluder seal, which is perfectly normal. The symptoms will
disappear after a few kilometres.
Remove all traces of swarf from the groove (arrow).

Install circlip (1), making sure that it slips fully into the groove and is not
under strain.
Circlip (1) can be turned in the groove.
Install cover (1) in wheel axle (2).
Follow-up work


33 74 502 Replacing radial shaft sealing ring for bevel pinion (rear bevel gears removed)
Preparatory work
Preparing holder
Seating bevel gears in retaining fixture
Core activity
(-) Removing shaft sealing ring from bevel pinion
ATTENTION
Drill into centre of shaft sealing ring (1), using drill stop (No. 00 8 586).
Technical data
Remove shaft sealing ring (1) with pull rod (No. 00 8 581), impact weight
(No. 00 8 582) and adapter (No. 00 8 587).
(-) Installing shaft sealing ring of bevel pinion
Position sliding sleeve (No. 33 0 822) on nut (1), making sure that the twelve
-point socket engages correctly.
Lubricate sealing lip of shaft sealing ring (2).
Gear oil
Slip shaft sealing ring (2) with the closed side (arrow) out over sliding sleeve
(No. 33 0 822).
Drive in shaft sealing ring (2) until seated, using drift (No. 33 0 821).
Remove sliding sleeve (No. 33 0 822).
Follow-up work
Removing rear bevel gears from retaining fixture

33 74 503 Replacing radial shaft seal in housing cover (bevel gears removed)
Preparatory work
Removing cover for wheel axle
Preparing holder
Removing retainer for wheel flange
Removing wheel flange
Core activity
(-) Removing shaft sealing ring of wheel axle from housing cover
Remove the felt (arrow) from shaft sealing ring (1).

ATTENTION
Drill into shaft sealing ring (1) at the outer edge, using drill stop (No. 00 8
586).
Technical data
Remove shaft sealing ring (1) with pull rod (No. 00 8 581), impact weight
(No. 00 8 582) and adapter (No. 00 8 587).
(-) Install the shaft sealing ring of wheel axle in housing cover
Lightly lubricate the sealing lip (1).
Gear oil
Install shaft sealing ring (2) with the opening (arrow) down, using drift (No.
11 5 701) and washer (No. 33 0 823) in housing cover (3) until seated.

Follow-up work
Installing wheel flange
Installing retainer for wheel flange
Installing cover for wheel axle

33 74 505 Replacing wheel flange on rear bevel gears (rear bevel gears removed)
Preparatory work
Preparing holder
Removing retainer for wheel flange
Core activity
(-) Removing wheel flange
Insert disc (No. 33 2 514) with the guide (arrow) down into wheel axle (1).
Position counter-holder (No. 33 2 513) on wheel flange (1) and tighten.
ATTENTION
Inner wedge of puller slips forward during pull-off operation
Damage to tool
Centre the puller.
Repeatedly check positioning.
Make sure that puller (No. 33 2 512) is retracted and centre it (arrows)
relative to counter-holder (No. 33 2 513) on plate (No. 33 2 514).
Pretension spindle (1) on puller (No. 33 2 512).
Remove wheel flange (2) by turning spindle (3).
Remove special tools from wheel flange (2).
(-) Removing cover for wheel axle

(-) Installing wheel flange
Lay wheel flange (1) on heating plate (2) and heat it; in this process use
thermometer (No. 00 1 900) to measure temperature in several recesses
(arrow) at the wheel screw connection.
Technical data
temperature
CAUTION
Risk of burn injury
Hold wheel flange (1) in position, making sure that the splines of wheel
flange (1) and wheel axle (2) are aligned.
Position installation tool (No. 33 2 517).
Position thrust piece (1) in such a way that it is seated with the guide (arrow)
straight and firm on wheel flange (2).
Working quickly, install wheel flange (2) by tightening thrust nut (3) until the
flange is seated; note that the process can produce a slight amount of swarf.
NOTICE
After installation of a new wheel flange there are slight grinding noises and the
flange does not turn as freely.
This is of no significance and has to do with the bedding-in process of the
primary dirt excluder seal, which is perfectly normal. The symptoms will
disappear after a few kilometres.
Follow-up work

Installing retainer for wheel flange
Installing cover for wheel axle

34 00 010 Change brake fluid in entire system

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

Draw off brake fluid (4).
Position handlebars in such a way that the brake fluid expansion tank is
horizontal.

ATTENTION
Escaping brake fluid
Component damage
Carefully clean the sealing faces before installing the diaphragm in the brake
-fluid reservoir.
Clean the edge of tank (arrow), gaiter (3) and reservoir cap (2).
Position gaiter (3) and reservoir cap (2).
Install screws (1).
Check
Check brake pressure by operating the brakes.

Result:
Low brake pressure
Measure:
Repeat the brake bleeding procedure without removing the brake pads.
On completion of all work place the vehicle on its side stand and repeatedly
short-pull the brake lever to expel the residual air from the handbrake
cylinder.
(-) Changing brake fluid, rear, and bleeding brake system
WARNING
NOTICE
instructions.
Checking blow-by clearance of the piston rod, adjust if required

Adjust blow-by clearance at piston rod
Use frame to determine if checking/adjusting is necessary:
Older build level (1): frame stop (arrow) present: Check/Adjust.

Newer build level (2): no frame stop (arrow) present: checking/adjusting not
possible.
Insert feeler gauge (1) transverse to the direction of travel between frame (2)
and brake lever (3).
Technical data
Blow-by clearance of between the 1...1.5 mm
the footbrake lever frame and the
footbrake
lever
Pull out piston rod (1) to the limit position.

Adjust piston rod (1) through hexagon head (Arrow) such that bolt can be
inserted (2) without resistance.
Install bolt (2) and contact disc (3).
Install cotter pin (4).
Tighten the lock nut (5).
Tightening torques
M8 17 Nm
Apply thread-locking sealant (1).
ATTENTION
Material damage

rubber components.

Remove lock washer (2).
Remove gaiter (3).
Draw off the brake fluid (4).
Remove dust cap (1).

Connect hose (2) from bleeder unit to bleeder screw (3).
Slightly open the bleeder screw (3).
Push brake calliper (4) against brake disc (5), pressing the brake fluid
through hose (2) while doing so.
The pistons are pushed back.
Close the bleeder screw (3).
Clean brake fluid tank (1).

Top up with fresh brake fluid to the MAX mark (arrow).
Hydraulic fluid
Brake fluid, DOT4
Connect the brake bleeding device.

Slacken bleeder screw (1) slightly.
Keep drawing off brake fluid until the full amount of liquid has flown through
or can be seen by the escape of new brake fluid.
Technical data
Amount of liquid for around three fillings
changing/bleeding of brake fluid
the brake system reservoir
Tighten bleeder screw (1).
Route vent hose (1) up.

Rising air bubbles can be observed in a better way.
Operate footbrake lever till pressure point and open bleeder screw (2) for a
short time.
Press footbrake lever till limit position and close bleeder screw (2).
NOTICE

Always open bleeder screw wide and pull through lever wide in order to
increase the flow rate of the brake fluid.
Operate footbrake lever until a pressure point can be traced and bleed
again.
Repeat the process until no air bubbles (arrow) escape and a clearly
noticeable pressure point is reached with the bleeder screw (2) closed.
Operate the brake several times until the brake pads are bedded.
Install dust cap (1).
Clean the rim of the reservoir (arrow), gaiter (3), lock washer (2) and
reservoir cap (1).
Install the gaiter (3), lock washer (2) and reservoir cap (1).
Check

Result:
Low brake pressure

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

34 00 048 Changing brake fluid, front brakes

+ 34 00 548
Core activity
(-) Changing brake fluid, front, and bleeding brake system
WARNING
NOTICE
instructions.
ATTENTION
Material damage
rubber components.
Remove screws (1).

Position handlebars in such a way that the brake fluid expansion tank is
horizontal.

ATTENTION
Component damage
-fluid reservoir.
Clean the edge of tank (arrow), gaiter (3) and reservoir cap (2).
Install screws (1).
Check

Result:
Low brake pressure
Measure:
cylinder.
Follow-up work

34 00 049 Changing brake fluid, rear brakes

+ 34 00 549
Core activity
(-) Changing brake fluid, rear, and bleeding brake system
WARNING
NOTICE
instructions.

possible.
Technical data
footbrake
lever

Tightening torques

M8 17 Nm
ATTENTION
Material damage
rubber components.

Remove gaiter (3).
Draw off the brake fluid (4).
Remove dust cap (1).
Connect hose (2) from bleeder unit to bleeder screw (3).
Push brake calliper (4) against brake disc (5), pressing the brake fluid
through hose (2) while doing so.
Close the bleeder screw (3).


Hydraulic fluid
Brake fluid, DOT4

Keep drawing off brake fluid until the full amount of liquid has flown through
or can be seen by the escape of new brake fluid.
Technical data

short time.
NOTICE
again.
Install dust cap (1).

reservoir cap (1).
Check

Result:
Low brake pressure
Measure:
Follow-up work

34 00 514 Bleeding rear brake system (for replacing component)

Core activity
(-) Filling and bleeding rear brake system
NOTICE
instructions.
ATTENTION
Material damage
rubber components.

Remove gaiter (3).

WARNING
Hydraulic fluid
Brake fluid, DOT4

Continue bleeding the brake system until fresh brake fluid emerges.
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 14 Nm
ATTENTION
Component damage
-fluid reservoir.
reservoir cap (1) with a lint-free cloth.
Check

Result:
Low brake pressure
Measure:

34 00 515 Bleeding front brake system (for replacing component)
Core activity
(-) Filling and bleeding front brake system
NOTICE
instructions.
ATTENTION
Material damage
rubber components.
Remove screws (1).

Insert reset tool (No. 34 1 531) in left brake calliper (1).

Push back brake piston and tighten.

Insert reset tool (No. 34 1 531) in right brake calliper (1).

Turn the handlebars to a position in which the brake fluid reservoir is

horizontal.
Top up with fresh brake fluid to the upper edge (arrow) of sight glass (1).
Hydraulic fluid
Brake fluid, DOT4
Connect the bleeder unit to bleeder screw (1) on the left brake calliper (2).
Continue bleeding the brake system until brake fluid emerges.
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
M8 10 Nm
Connect bleeder unit with hose (1) to bleeder screw (2).

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.
Continue bleeding the brake system until brake fluid emerges.
Technical data
Tightening torques
M8 10 Nm
Turn the handlebars to a position in which air can rise through the base
valve (3).
Vent the brake system by several small strokes on brake lever (1).
Air bubbles (2) cease to escape from base valve (3).
There is a clearly perceptible pressure point.

horizontal.
Top up brake fluid till the upper edge (arrow) of sight glass (1).
Install front left brake pads

Use reset tool (No. 34 1 531) to force the brake pistons back just far enough
to allow the new pads to be slipped into position.

Lugs (arrow) of the spring (1) must point in the direction of travel.
Check locking pins (2) before installation; replace attachment set as needed:
Damage, such as grooves
Wear
Corrosion
Insert brake pads (1) into brake calliper (3).
Clean and install locking pins (2).
Install brake calliper (5).

Tighten locking pins (2).
Insert fuses (1).
Ensure that fuses (1) are fitted on the groove of the threaded bolts (2).
Position holder (3) for line (4).
Remove masking tape in the area (1).


Position brake calliper (3) with holder (2).
Install screws (1).
Tightening torques
M10 x 65 38 Nm
Attach pipe (1) in holder (2).

Make sure that the routing of line (arrows) is correct.
Install front right brake pads


Wear
Corrosion

Insert fuses (1).

Position brake calliper (1).
Install screws (2).
Tightening torques

M10 x 65 38 Nm
WARNING
Brake pads not lying against the brake disc
Risk of accident due to delayed braking effect.
Before driving, check that the brakes respond without delay.
ATTENTION
Component damage
-fluid reservoir.
Clean the rim of the reservoir (arrow), gaiter (3) and reservoir cap (2) with a
lint-free cloth.
Install screws (1).
Check

Result:
Low brake pressure
Measure:
cylinder.

34 00 583 Draining/filling/bleeding front brake system
NOTICE
instructions.
Core activity
(-) Drain the front brake system
ATTENTION
Material damage
rubber components.
Remove screws (1).


Detach line (1) with holder (2).

Remove screws (1).

Release holder (2) from brake calliper (3).
Loosen brake calliper (3).
Removing front left brake pads

Put masking tape on the wheel rim and cross-spokes in the area (1).
Remove fuses (1).

Release threaded bolt (2).
Fold holder (3) with line (4) to the side.
Release the brake calliper (5).
Remove threaded bolt (1).

Remove brake pads (2) from the brake calliper (3).

Insert reset tool (No. 34 1 531) in left brake calliper (1).

Draw off the excess brake fluid and clean the brake fluid expansion tank (1).

Remove screws (1) from brake calliper (2).
Removing front right brake pads


Remove fuses (1).

Release threaded bolt (2).
Remove threaded bolt (1).

Insert reset tool (No. 34 1 531) in right brake calliper (1).

Draw off the excess brake fluid and clean the brake fluid expansion tank (1).

Remove dust cap (1) on right and left brake calliper.
Connect the bleeder unit to bleeder screw (1) on brake calliper (2).
Draw off brake fluid until it ceases to emerge.
Repeat this procedure with the second brake calliper.
(-) Filling and bleeding front brake system
WARNING


horizontal.
Top up with fresh brake fluid to the upper edge (arrow) of sight glass (1).
Hydraulic fluid
Brake fluid, DOT4
Turn the handlebars to a position in which air can rise through the bottom
valve.
Air bubbles (2) cease to escape from base valve (3).
A slight pressure point can be felt.
Connect bleeder unit with hose (1) to bleeder screw (2).

WARNING
required.
Keep filling brake system until the full amount of liquid has flown through or
can be seen by the escape of new brake fluid.
Technical data

Tightening torques
M8 10 Nm
Perform filling operation at the left brake calliper (2) in the same way using
vacuum, tighten bleeder screw (1).
Operate brake lever several times until a pressure point can be perceived.
Operate brake lever till the pressure point and open bleeder screw (2) for a
short time.
Pull brake lever till the grip and close bleeder screw (2).
NOTICE
Release the brake lever.

Operate brake lever until a pressure point can be traced and bleed again.
ATTENTION
Damage to reset tool
Brake pressure too high
Do not damage reset tool by brake pressure that is too high.
Perform bleeding operation on the right brake calliper (1) in the same way.
The brake fluid tank should be topped up approximately twice during the
bleeding operation.
Place handbrake fitting (1) in such a way that air can rise through the outlet
hole (arrow): Banjo bolt (2) points at a slope to the top.

Turn the handlebars to a position in which air can rise through outlet hole.
Air bubbles (2) cease to escape from outlet hole (3).
There is a clearly perceptible pressure point.

horizontal.
Top up brake fluid till the upper edge (arrow) of sight glass (1).
Remove the piston resetting device and locators left and right from the brake
callipers.
ATTENTION
Component damage
-fluid reservoir.
lint-free cloth.
Install screws (1).
Fit dust cap (1) on right and left brake calliper.

Install front left brake pads

Wear
Corrosion

Insert fuses (1).

Position holder (3) for line (4).

Install screws (1).
Tightening torques
M10 x 65 38 Nm

Install front right brake pads


Wear
Corrosion

Insert fuses (1).


Install screws (2).
Tightening torques
M10 x 65 38 Nm
WARNING
Brake pads not lying against the brake disc
Risk of accident due to delayed braking effect.
Before driving, check that the brakes respond without delay.
Check

Result:
Low brake pressure
Measure:
cylinder.

34 00 584 Draining/filling/bleeding rear brake system

NOTICE
instructions.
Core activity
(-) Draining rear brake circuit
ATTENTION
Material damage
rubber components.

Remove retainer (2).
Press brake caliper (1) against brake disc (2).

Draw off the brake fluid that has flowed back and clean fluid reservoir (1).

Slightly slacken bleed screw (1).
Continue drawing off brake fluid until it ceases to emerge.

(-) Filling and bleeding rear brake system
WARNING

possible.
Technical data
footbrake
lever


Tightening torques
M8 17 Nm

Hydraulic fluid
Brake fluid, DOT4

WARNING
required.
Keep filling brake system until the full amount of liquid has flown through or
can be seen by the escape of new brake fluid.
Technical data

short time.
NOTICE
again.
ATTENTION
Component damage
-fluid reservoir.
reservoir cap (1) with a lint-free cloth.

34 11 001 Measuring front brake-disc run-out

+ 34 11 844
Preparatory work
Core activity
(-) Checking front brake discs for runout
Requirement
No burrs or scoring on brake disc, brake disc thickness above minimum.
Raise the front wheel clear of the ground so that it can turn freely.
Check
Check the mounts of the brake disc.
Components of the rivet-package mounts (cannot be disassembled):
Washer (1)
Spring washers (2)
Thrust washers (3)
Rivet (4)
Result:
Individual components missing, broken or installed in wrong sequence.

Measure:
Brake-disc runout cannot be measured.
Result:
Brake-disc mounts are OK
Measure:
Measuring brake-disc run-out
Raise the front wheel clear of the ground so that it can turn freely.
Install extension (No. 00 2 504) with clamping pieces (No. 00 2 505) and
(No. 00 2 506).
Insert dial gauge (No. 00 2 510) into clamping bush (No. 00 2 506) and
install measuring adapter (No. 34 2 510).
Align the slightly preloaded dial gauge in such a way that the measuring
adapter is in contact with the brake disc close to the outer circumference
(arrow).
Check
Set the dial gauge to "0".

Slowly turn the wheel through at least one complete revolution and
observe the dial gauge reading.
The sum of the positive and negative dial-gauge readings is the total run-
out.
Technical data
Brake disc lateral At max 0.15 mm
runout, front circumference
Result:
Lateral run-out is excessive.
Measure:
Check positioning of the brake disc/wheel rim.
Check the wheel rim for damage.
If necessary, check the brake disc.
See the "Diagnosis tree, braking torque fluctuations" overview for further
information.
Repeat this procedure to measure brake-disc run-out on the other side.
Follow-up work

34 11 002 Replacing front left sealing kit for brake calliper (without bleeding)
+ 34 11 845
CAUTION
Handling harmful operating fluids
Damage to health
Observe safety regulations/safety data sheets, use personal protective
equipment (e.g., gloves, safety goggles) where required.
ATTENTION
Damage to surfaces due to sharp-edged tools
Component damage
Use wooden or plastic tools to remove sealing rings from the brake calliper.
Use plastic or wooden tools to clean the sealing ring grooves.
Preparatory work
Securing the brake lever
Loosening brake line and removing brake calliper on left
Core activity
(-) Removing seals set for brake calliper
Requirement
Thoroughly clean the brake calliper and remove all traces of foreign matter.
Once work has been completed on one side of the brake calliper, the
following operations have to be performed on the other side.
Secure brake piston (1) with cable strap (2).
Position air gun (3) with a suitable rubber adapter (arrow) on the brake line
connection and push the brake pinion (4) out with it.
Perform the following operations on all brake-piston bores:

Remove small sealing ring (1) and large sealing ring (2), taking care not to
damage brake calliper (3).
Clean brake calliper (3) inside.
Cleaner

(-) Installing seals set for brake calliper
ATTENTION
Material damage
rubber components.
Perform the following operations on all brake-piston bores:

Lubricate large sealing ring (1) and small sealing ring (2) with brake fluid.
Install large sealing ring (1).
Install small sealing ring (2) with groove (arrow).
Lubricate brake piston (1) with brake fluid and install, noting sealing rings (2)
and (3).
After installation of all brake pistons, clean brake callipers carefully outside
with water and dry without compressed air.
Cover brake line connection in this process.
Follow-up work
Securing brake line to left brake calliper
Release the brake lever
=> Bleeding front brake system (for replacing component)

(Description in item: 34 00 515, Billed as a separate item)

34 11 008 Replacing front brake pads

+ 34 11 832
NOTICE
The brake fluid level in the brake fluid reservoir rises when new brake pads
are installed. If necessary, lower the brake fluid level before removing the
brake pads, in order to prevent brake fluid from overflowing from the brake-
fluid reservoir. On completion of the work, correct the brake fluid level.
Core activity
(-) Replacing front brake pads
Replace the brake pads in one calliper first, then in the second calliper.
Change the front left brake pads
Remove screws (1).



34 11 060 Replacing front brake caliper (without bleeding brakes)

+ 34 11 560
Preparatory work
Securing the brake lever
Core activity
(-) Removing front brake calliper
Remove bleeder screw (1) with sealing rings (2).

Release brake line (3) and seal it using suitable auxiliary materials.
Remove screws (1).

Fold back holder (2).
Remove the brake calliper (3).
(-) Removing front left brake pads
Remove fuses (1).
Remove (1) locking pins.

Check locking pins (1) for wear/damage and replace, if necessary.

(-) Installing front brake calliper
Position brake line (1) with banjo bolt (2) and new sealing rings (3).
Position brake line (1) on torsional stop (Arrow).
Tighten the banjo bolt (2).
Tightening torques
M10 x 1 24 Nm
Follow-up work
Release the brake lever
=> Bleeding front brake system (for replacing component)


34 11 220 Removing/installing front brake discs

+ 34 11 840
Preparatory work
Core activity
(-) Removing front brake discs
Remove screws (1).

Remove brake disc (2).
Repeat this procedure to remove the brake disc on the other side.
(-) Install the front brake discs
Clean the threads.
NOTICE
During the installation of the brake disc, make sure there is no contamination
or screw locking residue between the wheel rim and brake disc. The contact
surfaces must be level and clean.
Lay brake disc (2) on the wheel rim with the beading (arrow) of the rivets to
the outside.
Install screws (1).
Tightening torques
M8 x 27, Replace screw Tightening
Thread-locking compound (micro- sequence: tighten
encapsulated) by stages in
diagonally opposite
sequence
19 Nm
Repeat this procedure to install the brake disc on the other side.
Follow-up work


34 21 005 Replacing sealing kit for brake calliper (without bleeding)

+ 34 21 505
Preparatory work
Removing rear brake pads
Operating and holding footbrake lever in position
Core activity
(-) Removing rear brake caliper
Disengage brake line (1) from holder (2).

Remove banjo bolt (3) and sealing rings (4), catching traces of escaping
fluid.
Remove screws (1).

Remove brake caliper (3).
(-) Removing seals set for brake calliper
Requirement
Thoroughly clean the brake calliper and remove all traces of foreign matter.
Pull off brake calliper (1) from brake-calliper support (2).
CAUTION
Sudden shooting out of a brake piston

Danger of injury
Secure brake piston, e.g. with wooden part.
Catch brake piston on a padded surface.
Insert wooden strip (1) or similar in brake calliper.

Position air gun (2) with a suitable rubber adapter (arrow) on the brake line
connection and push the brake pinion (3) out with it.
Remove small sealing ring (1) and large sealing ring (2), and in doing so, do
not damage the brake cylinder (arrow).
Clean brake cylinder (arrow).
Cleaner
(-) Installing seals set for brake calliper
Lubricate large sealing rings (2) and small sealing rings (1) (with groove
(arrow)) with provided lubricant.
Install sealing rings (2) and (1).
Install bake piston (1) observing sealing rings (2) and (3).
Install brake piston (4) in the same manner.
Push brake piston back completely and remove emerged lubricant/brake
fluid.
Check gaiters (1) and (2), replace if necessary.

Clean and thinly lubricate bolts (3).

Lubricant
Optimoly TA 18 21 9 062 599
Slide brake calliper (4) onto brake-calliper support (5).

Make sure gaiters (1) and (2) are sealing correctly.
(-) Installing rear brake calliper
Clean the threads.

Position cable routing (2).
Install new screws (1).
Tightening torques
Screw dome to bevel gears, M8 x 30, 28 Nm
Replace screw
encapsulated)
Tightening torques
M10 x 1 24 Nm
Follow-up work
Disengaging footbrake lever
Installing rear brake pads
=> Bleeding rear brake system (for replacing component)


34 21 031 Measuring rear brake-disc run-out

+ 34 21 774
Preparatory work
Core activity
(-) Measuring brake-disc runout
Install dial gauge (No. 36 3 610) in dial-gauge holder (No. 34 2 524) and
install slip-on adapter (No. 36 3 612).
Install the dial-gauge holder with screw (1).
Align the slightly preloaded dial gauge in such a way that the measuring
adapter is in contact with the brake disc close to the outer circumference
(arrow).
Check
Set the dial gauge to "0".

Turn the wheel flange slowly 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 outside max 0.35 mm
runout, rear circumference,
components
cooled
Result:
Lateral runout excessive.
Measure:
Check positioning of the brake disc/wheel flange.
Check the wheel flange for damage.
If necessary, check the brake disc.
See the "Diagnosis tree, braking torque fluctuations" overview for further
information.
Follow-up work

34 21 060 Replacing rear brake caliper (without bleeding brakes)

+ 34 21 560
Preparatory work
=> Draining/filling/bleeding rear brake system (Description in
Removing rear brake pads
Core activity
(-) Removing rear brake caliper

fluid.
Remove screws (1).

Remove brake caliper (3).
(-) Replacing rear brake caliper
ATTENTION
Material damage
rubber components.
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 calliper
Clean the threads.

Position cable routing (2).
Install new screws (1).
Tightening torques
Screw dome to bevel gears, M8 x 30, 28 Nm
Replace screw
encapsulated)
Tightening torques
M10 x 1 24 Nm
Follow-up work
Installing rear brake pads

34 21 200 Replacing rear brake pads

+ 34 21 769
NOTICE
The brake fluid level in the brake fluid reservoir rises when new brake pads
are installed. If necessary, lower the brake fluid level before removing the
brake pads, in order to prevent brake fluid from overflowing from the brake-
fluid reservoir. On completion of the work, correct the brake fluid level.
Core activity
(-) Removing rear brake pads
Press brake caliper (1) against brake disc (2).

Remove split pins (1).

Work retaining pin (2) out toward the wheel side.
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.
Remove brake pads (3).
(-) Installing rear brake pads
Insert brake pads (1) in such a way that at the forward (arrow) they are fully
seated in clamp (2).
Check locking pin (2) before installation; replace attachment set as needed:
Wear

34 31 002 Replacing footbrake cylinder (without bleeding brakes)

+ 34 31 502
Preparatory work
Removing right heel deflector
Core activity
(-) Removing footbrake cylinder
Remove split pin (1).

Remove pin (2) and washer (3).
suitable container.
Release clip (4).
Disconnect post-flow hose (5), catch escaping residual fluid in a suitable
manner.
Remove footbrake cylinder (6).
(-) Installing footbrake cylinder
Position brake line (1) at the anti-twist stop (arrow).

Hold brake line (1) in position with banjo bolt (2) and new sealing rings (3).
Tighten banjo bolt (2).
Tightening torques
M10 x 1 24 Nm
Connect post-flow hose (4).

Secure clip (5).
(-) Installing right heel deflector
Hold heel deflector (2) in position.

Install screws (1).

Tightening torques
Footbrake cylinder with heel deflector to frame
M6 x 20 8 Nm
(-) Adjust blow-by clearance at piston rod

possible.
Technical data
footbrake
lever

Tightening torques
M8 17 Nm

Follow-up work

34 32 040 Replacing front brake line to pressure modulator (without bleeding brakes)
+ 34 32 640
ATTENTION
Material damage
rubber components.
Preparatory work
=> Draining/filling/bleeding front brake system (Description
in item: 34 00 583, Billed as a separate item)
Removing front seat
Removing fuel tank
Core activity
(-) Removing front brake line to pressure modulator
Remove bracket (1).

suitable container.

Open holder (1).

suitable container.
Remove brake pipe (4).
(-) Installing front brake line to pressure modulator
Tightening torques
M10 x 1 24 Nm

Install cable tie (5).
Tightening torques
M10 x 1 24 Nm
Follow-up work


34 32 044 Replacing front brake line from pressure modulator (without bleeding brakes)
+ 34 32 644
ATTENTION
Material damage
rubber components.
Preparatory work
Removing front seat
Removing fuel tank
Core activity
(-) Removing front brake line from pressure modulator
Remove banjo bolts (1) with sealing rings (2) and catch the escaping fluid by
suitable means.
Disengage brake line (3) from the holder (arrow).

Remove screw (1).

Open holder (2).
Disengage brake line (3) from the holders (arrows).
suitable container.
Work brake line (3) forward to remove.
(-) Installing front brake line from pressure modulator
Work brake line (1) into position from the front.

Tightening torques
M10 x 1 24 Nm

Route brake line (3) and install screw (1).
Tightening torques
Brake line to fork bridge
encapsulated)
Secure brake line (3) in holders (2) and (arrows).
Hold brake lines (1) and (2) in position with banjo bolts (3) and new sealing
rings (4).
Position brake lines (1) and (2) at the anti-twist stop (arrow).
Tighten banjo bolts (3).
Tightening torques
M10 x 1 24 Nm
Follow-up work


34 32 050 Replacing rear brake line to pressure modulator (without bleeding brakes)
+ 34 32 650
0456 - Style HPOE
ATTENTION
Material damage
rubber components.
Preparatory work
Removing front seat
Removing fuel tank
Removing battery
Removing left cover
Core activity
(-) Removing rear brake pipe to pressure modulator
suitable container.
suitable container.

Disengage brake line (1) from holders (2) and (3).
(-) Installing rear brake line to pressure modulator
Manoeuvre brake line (1) into position.

Tightening torques
M10 x 1 24 Nm
Tightening torques
M10 x 1 24 Nm
Secure brake line (1) in holders (2) and (3).


Follow-up work
Installing battery

34 32 051 Replacing rear brake line from pressure modulator (without bleeding brakes)
+ 34 32 651
ATTENTION
Material damage
rubber components.
Preparatory work
Removing front seat
Removing fuel tank
Removing left cover
Core activity
(-) Removing rear brake line from pressure modulator
suitable container.
Disengage brake line (3) from the holder (arrow).

fluid.


Disengage brake line (1) from holders (2), (3) and (4).
Work brake line (1) clear and remove.
(-) Installing rear brake line from pressure modulator
Manoeuvre brake line (1) into position.

Tightening torques
M10 x 1 24 Nm
Tightening torques
M10 x 1 24 Nm
Secure brake line (1) in holders (2), (3) and (4).


Follow-up work

34 51 011 Replacing pressure modulator (without bleeding/testing software/ programming)

+ 34 51 511
ATTENTION
Material damage
rubber components.
Preparatory work

Removing front seat
Removing fuel tank
Disconnecting brake lines from pressure modulator
Disengaging left tank bracket
Core activity
(-) Removing pressure modulator
Release fuel distributor (1) from holder (2).

Disconnect connector (3) for fuel pressure sensor.

Lift the fuel distributor (1).

Release brake line (2) from holder (3).
Pull the bracket (4) with pressure modulator slightly outwards.
Disconnect the connector (5) for the pressure modulator.
Release the connector (1) for the crankshaft sensor from the bracket
(arrows).
Remove cable straps (2).
Remove the pressure modulator and bracket (3).
(-) Replacing pressure modulator
Remove anti-twist stop (1).

Remove screws (2).
Remove pressure modulator (3).
Install new pressure modulator (3) with screws (2).
Tightening torques
ABS pressure modulator on retainer
M6 x 14.5 8 Nm
Install anti-twist stop (1).
(-) Installing pressure modulator
Insert cable strap (arrows) in holder (1).

Insert the pressure modulator and holder (1).

Connect the connector (2) for the pressure modulator.
Fasten the fuel distributor (3) and brake line (4) in the bracket (5).
Install cable strap (6), turning it so that the cable strap lock (arrow) is down.
Secure connector (1) for the crankshaft sensor in the holder (arrows).
Close the cable strap (2).
Follow-up work
Securing left tank bracket
Connect the brake lines to pressure modulator

a separate item)

separate item)

35 21 000 Removing/installing or replacing footbrake lever

+ 35 21 531
Preparatory work
Removing front right footrest
Core activity
(-) Removing footbrake lever
Remove split pin (1).

Remove pin (2) and washer (3).
Disengage spring (1).
Remove screw (1) with washer (2).

Remove footbrake lever (4) and washer (5).
(-) Installing footbrake lever
ATTENTION

Clean shouldered bushing (3) and footbrake lever (4).
Hold footbrake lever (4) in position with shouldered bushing (3) and washer
(5).
Install screw (1) with washer (2).
Tightening torques
M8 x 25 19 Nm
Engage spring (1).

possible.
Technical data
footbrake
lever


Tightening torques
M8 17 Nm
Follow-up work
Installing front right footrest

36 20 510 Replacing RDC control unit (without checking software/programming)

0456 - Style HPOE
NOTICE
Preparatory work
Removing rear seat
Removing front seat
Core activity
(-) Remove the RDC control unit
Remove screws (1).

Remove RDC control unit (2).
Disconnect plug (3) for the RDC control unit.
(-) Install the RDC control unit
Connect plug (3) for the RDC control unit.

Hold RDC control unit (2) in position.
Install screws (1).
Follow-up work

a separate item)

separate item)

36 20 554 Replacing front RDC sensor (tyre removed)

Core activity
(-) Removing RDC sensor
Remove the nut (1).

Remove RDC-sensor (2).
Remove angled valve (3) with sealing ring (4).
(-) Installing RDC sensor
Clean the seat and the threaded bore for the RDC sensor.
Install RDC sensor (1) parallel with the wheel rim such that the plastic part
does not touch the wheel rim.
Insert angled valve (3) with sealing ring (4).

Position RDC sensor (2).
Align angled valve vertically to the wheel rim and install new nut (1).
Tightening torques
Renew nut 6 Nm
encapsulated)
Angled valve rear must face toward the silencer.

Affix RDC label to the wheel rim at sensor height .
Follow-up work

Teaching in RDC sensor at control unit

36 20 555 Replacing rear RDC sensor (tyre removed)

Core activity
Remove the nut (1).

Clean the seat and the threaded bore for the RDC sensor.

Tightening torques
Renew nut 6 Nm
encapsulated)

Follow-up work


36 23 001 Replacing wheel-speed sensor, front

+ 36 23 601
Preparatory work
Removing front seat
Core activity
(-) Removing front wheel-speed sensor
Disconnect plug (1) for the wheel-speed sensor.

Remove female connector with holder (2).
Disengage sensor cable (1) from the holders (arrows).
Remove screw (1).

Remove bracket (2).
Disengage sensor cable (3) from holder (4).

Remove screw (1).

Push front-wheel cover (2) slightly to one side.
Work sensor cable (3) clear.
(-) Replacing front wheel-speed sensor
Transfer holder (1) to female connector (2) of the new wheel-speed sensor.
(-) Installing front wheel-speed sensor
Hold wheel-speed sensor (1) and brake caliper (2) in position.

Set sensor cable (3) with holder (4) in position.
Install holder (4) with screw (5).
Secure sensor cable (3) in holder (6).
Push front-wheel cover (2) slightly to one side.

Work sensor cable (3) up into position.

Install screw (1).
Tightening torques
M5 x 14.5 2 Nm
Secure sensor cable (3) in the holders (arrows).
Secure sensor cable (1) with the holders (arrows).
Install female connector with holder (2).

Connect plug (1) for the wheel-speed sensor.
Follow-up work

36 23 002 Replacing wheel-speed sensor, rear

+ 36 23 602
Preparatory work
Removing left cover
Core activity
(-) Removing rear wheel-speed sensor
Disconnect plug (1) for the wheel-speed sensor.

Unlock sensor-cable female connector (2) and unclip it by working it to the
rear.
Disengage sensor cable (3) from the holders (arrows) and work it to the
rear.
Disengage sensor cable (1) from holders (2) and (arrows).
Remove screw (1).

Remove wheel-speed sensor (2).
(-) Installing rear wheel-speed sensor
Check the sealing ring (arrow) for damage; replace if necessary.

Install wheel-speed sensor (2).
Install screw (1).

Tightening torques
Wheel-speed sensor to bevel gears
M6 x 16 8 Nm
Work sensor cable (1) through toward the front.

Secure sensor cable (1) in holders (2) and (arrows).
Clip sensor-cable female connector (1) into position.

Connect plug (2) for the wheel-speed sensor.
Secure sensor cable (3) in the holders (arrows).
Follow-up work

36 23 003 Replacing sensor ring, front

+ 36 23 603
Preparatory work
Core activity
(-) Removing front sensor ring
Remove screws (1).

Remove sensor ring (2).
(-) Installing front sensor ring
Hold sensor ring (2) in position.

Install screws (1).
Follow-up work

36 30 300 Removing/installing front wheel

+ 36 30 628
Preparatory work
Core activity
(-) Removing front wheel
Use straps to pull the rear of the motorcycle down and secure it in this
position.
Slacken axle clamping screws (1).
Remove bolt (2).
Roll the front wheel forward to remove (4).
(-) Install the front wheel
Make sure that spacer bush (1) is installed with the collar (arrow) toward
the outside.
Clean and lubricate quick-release axle (1).
Lubricant
Optimoly TA 18 21 9 062 599
Hold front wheel (2) in position.

Install quick-release axle (1).


Install screws (2).
Tightening torques
M10 x 65 38 Nm

Install screws (1).
Tightening torques
M10 x 65 38 Nm

Disengage tensioning straps (1) at the rear.

Fold in centre stands (2).
Firmly compress the front forks several times.
Place the motorcycle on its centre stand (2).
Install bolt (1)
Tightening torques

M12 x 20 30 Nm
Tighten clamping bolts (2).
Tightening torques
M8 x 35 19 Nm
Follow-up work

36 30 320 Removing/installing rear wheel

+ 36 30 629
Core activity
(-) Remove the rear wheel
Remove wheel studs (1).

Remove rear wheel (2).
(-) Install the rear wheel
Clean the wheel centring spigot and the contact surfaces of the wheel hub.
Hold rear wheel (2) in position.

Engage all wheel studs (1) on their threads, then tighten uniformly.
Tightening torques
M10 x 1.25 x 40 Tightening
diagonally opposite
sequence
60 Nm
Follow-up work

36 30 508 Balancing front wheel (statically) (wheel removed)
Core activity
(-) Statically balancing front wheel
Level balancing jig (No. 36 3 601) with knurled screws (1) and level gauge
(2).
Insert balancing shaft (No. 36 5 571) in front-wheel bearing and secure it
with tensioner (No. 36 5 572), making sure that front-wheel bearing is lightly
preloaded.
Remove old adhesive weights (3).
Place the front wheel on the balancing jig and allow it to come to rest.
Clean the attachment points for the adhesive weights.
Affix new adhesive weights (3) opposite the heaviest point of the wheel.
Technical data
Permissible front- max 5 g
wheel imbalance
Balance weight for max 80 g
front wheel
Weights have to be
affixed with one half
on the left and one
half on the right, in
other words centred
on the rim
Repeat the balancing procedure as a check.

36 30 518 Balancing rear wheel (statically) (wheel removed)
Core activity
(-) Statically balancing rear wheel
Install balancing adapter (No. 36 5 561) with wheel studs (1).
Align balancer (No. 36 3 601) with knurled screws (1) and level gauge (2).
Introduce balancing shaft (No. 36 5 571) into the rear wheel and secure it
with tensioning device (3).
Place the rear wheel on the balancer and allow it to come to rest.
Affix adhesive weights (4) opposite the heaviest point of the wheel.
Technical data
Permissible rear- max 45 g
wheel imbalance
rear wheel
Weights have to be
on the left and one
other words centred
on the rim

36 30 601 Replacing rim for front wheel (wheel removed)

Core activity
(-) Removing spacing bushing for front wheel
Remove the spacer bush (1).
(-) Removing front sensor ring
Remove screws (1).

Remove sensor ring (2).
(-) Removing front brake discs
Remove screws (1).

Remove brake disc (2).
Repeat this procedure to remove the brake disc on the other side.
(-) Removing front tyre
Pry tyre (1) off opposite (arrow) the valve/tyre pressure monitoring (RDC)
sensor.

Apply the lever to the rim at RDC sticker (2), to prevent the tyre bead from
damaging the RDC sensor.
Remove tyre (1) with commercially available tools.
(-) Checking battery forRDC sensor
Check
Check the battery for RDC sensor (1) with the RDC test tool (No. 61 1 673).
Result:
Battery is too weak.

Measure:
Renew RDC sensor (1).
Remove the nut (1).



Tightening torques
Renew nut 6 Nm
encapsulated)

(-) Installing front tyre
Hold the tyre in position, noting the RDC sensor.
ATTENTION
Component damage
Install the tyre in accordance with the manufacturer's instructions, using

commercially available tools. Make sure that the direction-of-rotation arrows
on tyre and rim point in the same direction.
Manufacturer-specific tyre mark for imbalance must be toward the valve.
Inflate the tyre to test pressure.
Check
Check the valve for leaks.
Technical data
Wheel valve test 4 bar
pressure
Result:
Valve is leaking.
Measure:
Replace the valve insert.
Result:
Valve is leaktight.
Measure:
Correct the tyre pressure.
Technical data
Check the tyre and make sure the line is at a uniform distance from the rim
flange all the way round.
(-) Install the front brake discs
Lay brake disc (2) on the wheel rim with the beading (arrow) of the rivets to
the outside.
Install screws (1).
Tightening torques
M8 x 27, Replace screw Tightening
Thread-locking compound (micro- sequence: tighten
encapsulated) by stages in
diagonally opposite
sequence
19 Nm
Repeat this procedure to install the brake disc on the other side.
(-) Installing front sensor ring
Hold sensor ring (2) in position.

Install screws (1).
(2).
preloaded.
Technical data
wheel imbalance

front wheel
Weights have to be
on the left and one
other words centred
on the rim
(-) Installing spacing bushing for front wheel
Install spacer bush (1) with the collar (arrow) outwards.

36 30 611 Replacing rim for rear wheel (wheel removed)

Core activity
(-) Removing rear tyre
sensor.
Check
Result:
Measure:
Remove the nut (1).



Tightening torques
Renew nut 6 Nm
encapsulated)

(-) Installing rear tyre
ATTENTION
Component damage

Check
Technical data
pressure
Result:
Valve is leaking.
Measure:
Result:
Valve is leaktight.
Measure:
Technical data
Technical data
wheel imbalance
rear wheel
Weights have to be
on the left and one
other words centred
on the rim

36 31 510 Replacing spokes for front wheel (tyre removed)
Core activity
(-) Replacing spokes
NOTICE
Before exchanging the spokes, determine the cause of the spoke break and
check rim for plastic deformation.
The rim should be within the permissible tolerance for side and radial runout or
within a tolerance range with centering capability, whereby the runout should
be distributed to a larger size.
In case of plastic deformations on the rim or runouts in a small area of the rim
circumference, the rim should be replaced for reasons of safety.
In case of more than one loose or damaged spoke, the rim should be replaced
or completely equipped with new spokes by a professional for reasons of
safety.
Slacken grub screw (1).

Remove spoke nipple (2) and spoke (3).
Insert new spoke (3).
Install spoke nipple (2).
Tightening torques
Nipple on spoke
M4 1st tightening torque,
1 Nm
4 Nm
Tighten grubscrew (1).
Tightening torques
Grubscrew, M4 2 Nm
(-) Checking runout of front wheel rim
Align balancing jig (No. 36 3 601) with knurled screws (1) and bubble level
(2).
preloaded.
Push stops (No. 36 5 573) on to balancing shaft (No. 36 5 571) and seat the
front wheel in the balancer.
Move limit positions (No. 36 5 573) against belt pulleys (1) and tighten.

Check
Set dial gauge (No. 00 2 510) with measuring adapter (No. 34 2 510) on the
machined inner face and check lateral runout.
Technical data
Lateral runout, front max 1.7 mm
wheel
Result:
Permissible lateral runout is exceeded.
Measure:
Replace the wheel rim.
Check
machined inner face and check vertical runout.
Technical data
Vertical runout, front max 1.7 mm
wheel
Result:
Permissible vertical runout is exceeded.
Measure:

36 31 511 Replacing spokes for rear wheel (tyre removed)
Core activity
(-) Replacing spokes
NOTICE
Before exchanging the spokes, determine the cause of the spoke break and
check rim for plastic deformation.
The rim should be within the permissible tolerance for side and radial runout or
within a tolerance range with centering capability, whereby the runout should
be distributed to a larger size.
In case of plastic deformations on the rim or runouts in a small area of the rim
circumference, the rim should be replaced for reasons of safety.
In case of more than one loose or damaged spoke, the rim should be replaced
or completely equipped with new spokes by a professional for reasons of
safety.
Slacken grub screw (1).

Remove spoke nipple (2) and spoke (3).
Insert new spoke (3).
Install spoke nipple (2).
Tightening torques
Nipple on spoke
M4 1st tightening torque,
1 Nm
4 Nm
Tighten grubscrew (1).
Tightening torques
Grubscrew, M4 2 Nm
(-) Check the runout of rear wheel rim
(2).
Introduce balancing shaft (No. 36 5 571) into the rear-wheel rim and secure
it with tensioning device (No. 36 5 572).

Push stops (No. 36 5 573) on to balancing shaft (No. 36 5 571) and seat the
rear wheel in the balancer.
Seat stops (No. 36 5 573) against rollers (1) and secure in position.
Check
machined inner face and check lateral runout.
Technical data
Lateral runout, rear max 1.7 mm
wheel
Result:
Permissible lateral runout is exceeded.
Measure:
Check
machined inner face and check vertical runout.
Technical data
Vertical runout, rear max 1.7 mm
wheel
Result:
Permissible vertical runout is exceeded.
Measure:


36 31 851 Renewing front wheel bearing (wheel removed)
Preparatory work
Removing spacing bushing for front wheel
Removing shaft sealing rings
Core activity
(-) Removing wheel bearings
Place support ring (No. 31 6 500) on the wheel hub on the right-hand side of
the wheel and lay the wheel flat.
Install reaction support (No. 00 8 572) and internal puller (No. 00 8 573).
Heat the bearing seat.
Technical data
temperature
Remove wheel bearing (1).

Remove spacing bushing (2).
Heat the left bearing seat.
Technical data
temperature
Drive out the left wheel bearing (1) with drift (No. 11 6 733) from the inside.
Allow the wheel hub to cool down.
Degrease and clean the bearing seats and the spacing bushing.
(-) Installing left wheel bearing
Introduce wheel bearing (1) into the bearing seat.

Pull in wheel bearing (1) until seated.
Remove washer (A) and pull-in nut.
(-) Installing right wheel bearing
Install spacing bushing (2).

Spacing bushing (2) sits flat and square on wheel bearing (1).
Introduce wheel bearing (3) into the bearing seat.
Install washer (A) and pull-in nut.

Pull in wheel bearing (3) until seated against spacing bushing (2).
Follow-up work
Installing shaft sealing rings
Installing spacing bushing for front wheel

36 32 501 Renewing front tyre (wheel removed)

Core activity
(-) Changing front tyre
Removing front tyre
ATTENTION
Component damage
sensor.
Checking battery for front RDC sensor
Check
Result:
Measure:
=> 36 20 554, Replacing front RDC sensor (tyre removed) (Billed as a
separate item)
Installing front tyre

ATTENTION
Component damage


Check
Technical data
pressure
Result:
Valve is leaking.
Measure:
Result:
Valve is leaktight.
Measure:
Technical data
(2).
preloaded.
Technical data
wheel imbalance
front wheel
Weights have to be
on the left and one
other words centred
on the rim

36 32 511 Removing rear tyre (wheel removed)

Core activity
(-) Changing rear tyre
Removing rear tyre
ATTENTION
Component damage
sensor.
Checking battery for rear RDC sensor
Check
Result:
Measure:
=> 36 20 555, Replacing rear RDC sensor (tyre removed) (Billed as a
separate item)
Installing rear tyre

ATTENTION
Component damage


Check
Technical data
pressure
Result:
Valve is leaking.
Measure:
Result:
Valve is leaktight.
Measure:
Technical data
Technical data
wheel imbalance
rear wheel

Weights have to be
on the left and one
other words centred
on the rim

Frames - Fairing
Repair Guide
BMW Motorrad
46 51 004 Replacing the frame guard on the left

+ 46 51 504
0456 - Style HPOE
Core activity
(-) Remove left frame guard
Remove rubber bands (arrows).

Remove frame guard (1).
(-) Installing left frame guard
Pull off the protective films from foam strips (1).
Remove adhesive residues if required and clean contact surface.

ATTENTION
Component damages, component loss
Rubber bands on the frame guard can be opened through boot contact
Turn locks of the rubber bands away from the contact area.
Position frame guard (1) and secure with rubber bands (2).
The locks (arrow) on the rubber bands (2) lie inside or at the bottom.
Follow-up work

46 51 050 Replacing rear frame

+ 46 51 563
0456 - Style HPOE
46 54 514 Additional work with case carrier
Preparatory work
Removing rear seat
Removing front seat
Removing luggage carrier
Remove the case carrier
Removing tail section
Removing number-plate carrier
Removing silencer
Releasing rear-wheel cover
Core activity
(-) Removing rear frame
Heat screws (1) and (2).
Technical data
temperature

ATTENTION
Component damage
Carefully work rear frame (3) up to remove.
(-) Replacing rear frame
Remove screws (1).

Transfer footrest brackets (2) and brackets for case carriers (3) to new rear
frame (4).
Install screws (1).
Tightening torques

encapsulated)
(-) Installing rear frame
Clean the threads.

ATTENTION
Component damage
Carefully work rear frame (3) into position.

Install screws (2).
Tightening torques
Rear frame, top, to main frame
encapsulated)
Install screws (1).
Tightening torques
Rear frame, bottom, to main frame
encapsulated)
Follow-up work
Securing rear-wheel cover
Securing silencer
Installing number-plate carrier
Installing tail section
Installing case carrier
Installing luggage carrier

46 51 120 Removing/installing frame

+ 46 51 575
0456 - Style HPOE
46 51 512 Additional work for removing/installing frame (with Dynamic ESA)
Preparatory work
Removing rear seat
Removing front seat
Removing left cover
Removing battery
Removing fuel tank
Draining coolant
Removing left radiator
Removing right radiator
Removing thermostat
Removing top front-wheel cover
Removing slipstream deflector, right
Removing cockpit fairing
Removing headlight
Removing complete front panel carrier
Removing engine lifter

46 51 520 Replacing frame (frame removed)
Preparatory work
Removing mounted parts, frame
Core activity
(-) Replacing frame
If necessary, use foil to mask off vehicle identification number (1) on new
frame (2).
Affix type plate (3) at the appropriate position.
Transfer reusable small items to the new frame.
Dispose of the old frame in accordance with locally applicable legislation.
Follow-up work
Installing mounted parts, frame

46 52 000 Removing/installing or replacing centre stand

+ 46 52 502
Preparatory work
Removing tension springs for centre stand
Core activity
(-) Removing centre stand
Extend the side stand (1).

Work plain-bearing pins (3) inward to remove it.
Remove the centre stand (4).
(-) Installing centre stand
Hold centre stand (1) in position.

Check plain-bearing pins (2) for damage; replace if necessary.
Install plain-bearing pins (2) from the inboard side.
Install circlips (3).
Follow-up work
Installing tension springs for centre stand

46 52 002 Replacing swivel mount for centre stand

+ 46 52 558
Preparatory work
Removing tension springs for centre stand
Core activity
(-) Removing centre stand

Remove the centre stand (4).
(-) Installing centre stand
Hold centre stand (1) in position.

Install new plain-bearing pins (2) from the inner.
Install circlips (3).
Follow-up work
Installing tension springs for centre stand

46 52 011 Renewing tension spring for centre stand

+ 46 52 503
Preparatory work
Core activity
(-) Removing tension springs for centre stand
Requirement
Centre stand is retracted.
Position mount (No. 46 5 746) at spring plate (1).

Position basic unit (No. 46 5 741) at spring plate (2).
CAUTION
Components spring-loaded
Risk of injury caused by flying parts
Carefully relieve and, as applicable, apply spring tension.
Apply tension to tension springs (3) and remove together with spring plates
(1) and (2), while keeping the centre stand pressed up against the stop.
(-) Replacing tension springs for centre stand
Relieve strain on tension springs (1).

Hook new tension springs (1) into spring plates (2).
Position basic unit (No. 46 5 741) and mount (No. 46 5 746) on spring plates
(2).
Pretension tension springs (1).
(-) Installing tension springs for centre stand
Position spring plates (1) and (2) clamped in basic unit (No. 46 5 741) and
mount (No. 46 5 746) on the retaining studs (arrows).
Relieve tension springs (3), while keeping the centre stand pressed up
against the stop.

Follow-up work

46 53 005 Removing/installing/cleaning and lubricating side stand

+ 46 53 505
Core activity
(-) Removing side-stand springs
Extend the side stand.

CAUTION
Detach springs (1) with installation/disassembly tool (No. 00 9 521).
(-) Disengaging switch for side stand
Remove screw (1).

Remove side-stand switch (2).
(-) Removing side stand
Remove bolt (1).

Remove the side stand (2).
(-) Checking bearing bushings
Check
Check bearing bushings (1) for scores, damage, etc.

Result:
Bearing bushings are worn.
Measure:
=> 46 53 501, Replacing pivot mount for side stand (side stand removed)
(-) Installing side stand
Clean shouldered bushings (1), check them for damage and replace them if
necessary.
Clean the threads.

Hold side stand (2) in position.
Install bolt (1).
Tightening torques
encapsulated)
(-) Securing switch for side stand
Clean the threads.

Position side-stand switch (1) in such a way that switch pin (2) is seated in
hole (3) of the side stand.
Install screw (4).
Tightening torques

encapsulated)
(-) Installing side-stand springs
Attach springs (1) individually with hooks (No. 00 9 521).
Follow-up work

46 53 011 Renewing tension spring for prop stand

+ 46 53 602
Core activity
(-) Removing side-stand springs

CAUTION
Detach springs (1) with installation/disassembly tool (No. 00 9 521).
(-) Installing side-stand springs
Attach springs (1) individually with hooks (No. 00 9 521).
Follow-up work

46 53 501 Replacing pivot mount for side stand (side stand removed)
Core activity
(-) Replacing bearing bushings of side stand
Replace bearing bushings (1), using a suitable tool.

46 54 030 Replacing left case carrier

+ 46 54 725
0456 - Style HPOE
Preparatory work
Removing rear seat
Removing front seat
Core activity
(-) Removing left case carrier
Slacken screw (1).

Remove screw (2).
Pivot cross-member (3) down.

Remove left case carrier (4).
Remove screws (1).

Remove footrest bracket (2) and retaining plate (3).
(-) Installing left case carrier

Clean the threads.
Hold footrest bracket (2) and retaining plate (3) in position.
Install screws (1).
Tightening torques
encapsulated)
Clean the threads.

Hold left case carrier (4) in position.
Install screws (2), (3) and (1).
Tightening torques
encapsulated)
encapsulated)
Hold cross-member (3) in position.

Insert screw (2).
Tightening torques
M8 x 20 19 Nm
Follow-up work

46 54 031 Replacing right case carrier

+ 46 54 726
0456 - Style HPOE
Preparatory work
Removing rear seat
Removing front seat
Core activity
(-) Removing right case carrier
Slacken screw (1).

Remove screw (2).
Pivot cross-member (3) down.

Remove right case carrier (4).
Remove screws (1).

Remove footrest bracket (2) and retaining plate (3).
(-) Installing right case carrier

Clean the threads.
Hold footrest bracket (2) and retaining plate (3) in position.
Install screws (1).
Tightening torques
encapsulated)
Clean the threads.

Hold right case carrier (4) in position.
Tightening torques
encapsulated)
encapsulated)

Insert screw (2).
Tightening torques
M8 x 20 19 Nm
Follow-up work

46 54 200 Removing/installing or replacing luggage carrier

+ 46 54 505
0456 - Style HPOE
Preparatory work
Removing rear seat
Removing front seat
Core activity
(-) Removing luggage carrier
Remove screws (1).

Remove screws (2).
Remove luggage carrier (3) and bushings (4).
(-) Installing luggage carrier
Clean the threads.

Install bushings (4).
Place luggage carrier (3) in position.
Engage threads of screws (1) and (2) and tighten.
Tightening torques
encapsulated)
encapsulated)
Follow-up work

46 61 009 Removing/installing top right front-wheel cover

+ 46 61 550
Preparatory work
Removing front seat
Disengaging right side panel
Removing top right front-wheel cover
Core activity
(-) Replacing right top front-wheel cover
Remove screws (1).

Unclip extension (2) at the lugs (arrows) and transfer it to the new front-
wheel cover.
Transfer grommets (3) to the new front-wheel cover.
Transfer the flat nuts (arrows) and edge protector (1) to new front-wheel
cover (2).
Follow-up work
Installing top right front-wheel cover
Installing right slipstream deflector
Securing right side panel

46 61 014 Removing/installing top left front-wheel cover

+ 46 61 551
Preparatory work
Removing front seat
Core activity
(-) Replacing left top front-wheel cover
Transfer the flat nuts (arrows) and edge protector (1) to new front-wheel
cover (2).
Follow-up work

46 61 030 Remove/install or replace top front wheel cover

+ 46 61 505
Preparatory work
Removing front seat
Removing both slipstream deflectors
Core activity
(-) Removing top front-wheel cover
Remove screws (1).
Remove screw (1).

Work front-wheel cover (2) forward off the tabs (arrows) to remove.
(-) Replacing top front-wheel cover
Transfer flat nuts (1) and grommets (2) to new front-wheel cover.
(-) Installing top front-wheel cover

Push front-wheel cover (2) on to the tabs (arrows).
Install screw (1).
Install screws (1).
Tightening torques
M5 x 14.5 2 Nm
Follow-up work
Installing both slipstream deflectors

46 61 037 Removing/installing front-wheel cover, bottom

+ 46 61 506
Preparatory work
Core activity
(-) Removing bottom front-wheel cover
Remove screws (1).

Remove front-wheel cover (2).
(-) Installing bottom front-wheel cover
Place front-wheel cover (2) in position.

Install screws (1).
Tightening torques
M5 x 14.5 2 Nm
Follow-up work

46 62 000 Replacing rear-wheel cover

+ 46 62 502
0456 - Style HPOE
0603 - Anti-theft alarm (DWA)OE
Preparatory work
Removing rear seat
Removing front seat
Disconnecting voltage regulator
Removing rear-light unit
Core activity
(-) Disengage the rear wiring harness
Disconnect connector (1) for the anti-theft alarm.

Disengage cable (2) for the rear light, cable (3) for the left flashing turn
indicator plug and cable (4) for the anti-theft alarm from the holders (arrows).

Disconnect connector (1) for the RDC control unit.
Disconnect plug (2) for the connecting resistor.
Disconnect and remove connector (1) for audio frequency aerial.

46 62 011 Removing/installing spray guard, rear wheel

+ 46 62 505
Core activity
(-) Removing spray guard
Remove screws (1).

Remove spray guard (2).
(-) Installing spray guard
Clean the threads.

Hold spray guard (2) in position.
Install screws (1).
Tightening torques
encapsulated)
Follow-up work

46 62 050 Renewing number plate carrier

+ 46 62 508
0456 - Style HPOE
Preparatory work
Removing rear seat
Removing front seat
Core activity
(-) Removing number-plate carrier
Disengage and disconnect plug (1) for the right flashing turn indicator.
Disengage and disconnect plug (2) for the left flashing turn indicator.
Remove screws (1).

Pull down and remove number-plate carrier (2).
(-) Disassembling license-plate carrier

Removing left and right turn indicators
Disengage cable (1) from the retainer (arrow).
Remove screw (2) and nut (3).
Turn flashing turn indicator (4) up and remove.

Remove nuts (1) and washers (2).
Remove reflector (3).
Remove inserts (1).
(-) Assembling number-plate carrier
Install inserts (1).
Hold reflector (3) in position.

Install nuts (1) and washers (2).
Installing left and right turn indicators
Work cable (1) into position.

Hold flashing turn indicator (2) in position and turn it toward the rear.
Install nut (4).

Install screw (3).
Tightening torques
M6 x 20 3 Nm
Secure cable (1) in the retainer (arrow).
(-) Installing number-plate carrier
Work flashing turn indicator plugs (1) and (2) through the openings (arrows).
Engage number-plate carrier (1) in the openings (arrows) and swing it up.
Engage number-plate carrier (1) in the tabs (arrow).

Install screws (long collar) (2).
Tightening torques
M6 x 17.5 8 Nm
Connect and secure plug (1) for the right flashing turn indicator.
Connect and secure plug (2) for the left flashing turn indicator.

Follow-up work

46 62 055 Replacing rear section

+ 46 62 509
0456 - Style HPOE
Preparatory work
Removing rear seat
Removing front seat
Core activity
(-) Removing tail section
Remove tail section (1).
(-) Removing lock barrel for seat lock
Insert key (1) into lock barrel (2).

Press the locking pawl (arrow).
Remove lock barrel (2) with key (1).
(-) Removing seat latch
Remove screws (1).

Remove shaped clamp (2).

46 63 030 Replacing windscreen adjuster

+ 46 63 710
Preparatory work
Removing windscreen
Removing instrument panel
Disengage the preparation for navigation system
Core activity
(-) Remove the windscreen adjuster
Remove bolt (1).

CAUTION
Remove trim (2) and coil spring (3).
Remove lock washers (1) and bearing journal (2).

Release arms for windscreen adjuster (3) and (4) from windscreen adjuster
(5).
Disconnect connector (1) for socket.

Remove screws (2) and remove windscreen adjuster (3).
(-) Replacing windscreen adjuster
Install new camshaft bearing (1) (4x) on new part (2).

Remove nut (3) and socket (4).
Secure socket (4) on new part, paying attention to the lug (arrow).
(-) Install the windscreen adjuster
ATTENTION
Damage by unsuitable lubricants
Component damage
Do not lubricate components.
Insert windscreen adjuster (1) into carrier plate (2).

Install screws (3).
Adjust windscreen adjuster (1) to maximum height.
Insert coil spring (4) in windscreen adjuster (1) and attach in lug (Arrow).
Connect connector (5) for socket.
Place trim (1) on coil spring (2) and carrier plate (3), paying attention to
brackets (arrows).
Install bolt (1).
Tightening torques
Trim for coil spring to windscreen adjuster
M6 x 16 5 Nm

Fasten arms for windscreen adjuster (3) and (4) to windscreen adjuster (5).
Install bearing journal (2) dry.
Install lock washers (1).
Follow-up work
Securing preparation for navigation system
Installing instrument panel
Install the cockpit fairing
Install the windscreen

46 63 031 Replacing windscreen

+ 46 63 830
Core activity
(-) Removing windscreen
Adjust windscreen with adjuster knob (1) to the maximum height.
Remove screws (1).

Loosen windscreen (2) to the bottom and remove.
(-) Replacing windscreen
Remove screws (1).

Remove the trims (2) and bracket (3).
Install new grommets (1) in new windscreen (2).

Position new holder (1) and new trims (2) on new windscreen (3).
Install new screws (4) (without collar).
Tightening torques
(-) Install the windscreen
Hold the windscreen (2) in position.

Install screws (1).
Tightening torques
Follow-up work

46 63 039 Removing/installing windscreen holder

+ 46 63 836
Preparatory work
Removing windscreen
Remove the windscreen adjuster
Core activity
(-) Removing left windscreen holder
Remove the screw (1), while counter-holding the screw (2).

Push the guide rod (3) as far as required to the bottom, do not remove.
Remove windscreen holder (4) .
(-) Install windscreen holder, left
ATTENTION
Component damage
Slide windscreen holder (4) onto guide rod (3).

Secure guide rod (3) with bolt (1).
Tighten the screw (1), while counter-holding the screw (2).
Tightening torques
M5 x 10 4 Nm
(-) Removing right windscreen holder
Remove the screw (1), while counter-holding the screw at bottom (2).
Push the guide rod (3) as far as required to the bottom, do not remove.
Remove windscreen holder (4) .

(-) Install windscreen holder, right
ATTENTION
Component damage
Slide windscreen holder (4) onto guide rod (3).

Secure guide rod (3) with bolt (1).
Tighten the screw (1), while counter-holding the screw (2).
Tightening torques
M5 x 10 4 Nm
Follow-up work
Install the windscreen adjuster

46 63 053 Replacing left front carrier

+ 46 63 753
Preparatory work
Removing front seat
Removing headlight
Disengaging wiring harness from front panel carrier, left
Core activity
(-) Removing left front panel carrier
Remove screws (1) with washers (2).
Disengage turn-indicator cable (1) from the holder (arrow).

Remove screws (2).
Remove front panel carrier (3).

(-) Replacing front panel carrier, left
Remove screw (1).

Transfer holder (2) for the slipstream deflector to new front panel carrier (3).
Install screw (1).
Remove screw (1).

Remove flashing turn indicators (2).
Transfer holders (3) to new front panel carrier (4).
Install flashing turn indicator (2).
Install screw (1).
Tightening torques
M6 x 16 4 Nm
(-) Installing left front panel carrier
Clean the threads.

Hold front panel carrier (3) in position.
Install screws (2).
Secure turn-indicator cable (1) in the holder (arrow).
Install screws (1) with washers (2).

Tightening torques
Front panel carrier, left/right to frame
encapsulated)
Install screws (1) and (2).
Tightening torques
Front panel carrier, left/right to front panel carrier, centre
Front, M6 x 16, Replace screw 8 Nm
Rear, M6 x 30, Replace screw 8 Nm
Follow-up work
Securing wiring harness to front panel carrier, left
Installing headlight
Checking headlight beam throw

46 63 054 Replacing right front carrier

+ 46 63 754
Preparatory work
Removing front seat
Removing headlight
Disengaging wiring harness from front panel carrier, right
Core activity
(-) Remove the right front panel carrier

Remove nuts (3) with contact discs (4) and remove front panel carrier (5).
(-) Replacing front panel carrier, right
Unclip connector (1) for turn indicator.

Remove bolt (2).
Remove turn indicator (3).
Remount holder (4) and connector holder (5) on new front panel carrier (6).
Install turn indicator (3).

Install bolt (2).
Tightening torques
M6 x 16 4 Nm
Attach connector (1) for turn indicator on connector holder (5).
(-) Installing right front panel carrier
Clean the threads.

Hold front panel carrier (5) in position.
Position screws (1) and (2).
Install screws (3) with contact discs (4).
Tightening torques
M6 x 25 8 Nm
Tightening torques
Trim panels
M5 2 Nm
Install screws (2).
Tightening torques
Install screws (1).
Tightening torques
Follow-up work
Securing wiring harness to front panel carrier, right


46 63 200 Replacing fuel-tank cover, middle

+ 46 63 860
Preparatory work
Removing front seat
Core activity
(-) Replace the centre cover of fuel tank
Remove bolts (1) for storage compartment cover.

Remove rubber pads (arrows).
Remove (1) storage compartment cover.

Transfer screen inserts (2) to new centre trim panel (3).
Transfer seal (4) to new centre trim panel (3).
Transfer catch (5) to new centre trim panel (3).
Transfer insert (6) to new centre trim panel (3).
Fit storage compartment cover (1) on new centre trim panel (3).
Install bolts (1) for storage compartment cover.

Install rubber pads (arrows).
Follow-up work

46 63 221 Replacing front carrier centre section

+ 46 63 821
00 00 520 Additional work with preparation for navigation system
Preparatory work
Removing front seat
Removing headlight
Removing windscreen
Disengaging wiring harness in front panel carrier
Core activity
(-) Removing front panel carrier centre section
Remove screws (1).

Lift centre section of front panel carrier (2) and remove.

(-) Disassembling front panel carrier, centre section
Remove bolt (1).

CAUTION
Remove trim (2) and coil spring (3).
Remove screws (1).

Remove screws (2).
Remove shouldered bushings (3) and (4).
Remove windscreen adjuster (5).
Remove bolt (1).

Remove carrier plate (2).
Remove rubber bush (3) and grommets (4).
Remove holders (5) and (6).
(-) Replace the front panel carrier, centre section
Remove nut (1) and socket (2) from centre section of front panel carrier (3).
Remount rubber bush (4), holder (5) and cable clip (6) on new centre
section of front panel carrier (3).
Install socket (2), noting the positioning (arrow).
Install the nut (1).
(-) If necessary, retrofit the front panel carrier centre part
NOTICE

Only the front panel carrier is available for replacement from 08/2017
onwards. In case of repair, other devices may have be converted to this. For
this purpose, additional separate components are required (see EPC).
Secure adapter (1) with screw connection (2).
(-) Assembling front panel carrier, centre section
Install holders (5) and (6).

Install rubber bush (3) and grommets (4).
Install carrier plate (2) with bolt (1).
ATTENTION
Component damage
Position windscreen adjuster (5).

Install shouldered bushings (3) and (4).
Install screws (2).
Secure windscreen adjuster (5) with screws (1).
Adjust windscreen adjuster (1) to maximum height.

Insert coil spring (2) and attach in lug (Arrow).
Install trim (1), paying attention to the retaining lugs (arrows).

Install bolt (2).
(-) Installing front panel carrier centre section
Install centre section of front panel carrier (2) and attach to frame (3) with
retaining lug (arrow).
Install screws (1).
Tightening torques
Front panel carrier, centre, to frame
M8 x 55 19 Nm
Install screws (2).
Tightening torques
Install screws (1).
Tightening torques
Follow-up work
Securing wiring harness in front panel carrier

46 63 333 Replacing side panel, left

+ 46 63 900
Preparatory work
Removing front seat
Core activity
(-) Replacing fairing side panel
Transfer flat nuts (1) to new side panel (2).
Transfer badge (1) and grommets (2) to new side panel (3).
Follow-up work
Install the side panel

46 63 334 Replacing side panel, right

+ 46 63 901
Preparatory work
Removing front seat
Core activity
(-) Replacing right side panel
Transfer flat nuts (1) to new fairing side panel (3).

Remove screws (2).
Remove radiator cowl (4) and fit on new fairing side panel (3).
Install screws (2).
Follow-up work

46 71 029 Replacing front left footrest

+ 46 71 838
Core activity
(-) Removing front left footrest

Remove pin (2).
Remove footrest (3) with spring (4).
(-) Install the front left footrest
Lubricate pin (2).
Lubricant
Insert spring (4) into footrest (3).

Hold footrest (3) in position.
Install pin (2).
Install lock washer (1).
Follow-up work

46 71 170 Replacing right rear footrest

+ 46 71 701
Core activity
(-) Remove the right footrest
Remove lock washer (1) and pin (2).

Remove footrest (3).
(-) Installing right footrest
Lubricate pin (2).
Lubricant

Install pin (2) and lock washer (1).
Follow-up work

46 71 176 Renewing rear left or right footrest

+ 46 71 818
Core activity
(-) Removing rear footrest

(-) Installing rear footrest
Lubricate pin (2).
Lubricant

Follow-up work

46 71 208 Replacing rear left foot support

+ 46 71 823
Preparatory work
Removing left footrest
Core activity
(-) Replacing left footrest bracket
Remove screws (1).

Remove footrest bracket (2).
Clean the threads.
Install new footrest bracket (2) with screws (1).
Tightening torques
encapsulated)
Follow-up work
Installing left footrest

46 71 210 Replacing rear right foot support

+ 46 71 824
Preparatory work
Remove the right footrest
Core activity
(-) Replacing right footrest bracket
Remove screws (1).

Clean the threads.
Tightening torques
encapsulated)
Follow-up work
Installing right footrest

51 16 044 Replacing left mirror

+ 51 16 554
Core activity
(-) Removing mirror
Remove bolt (1).

Remove bolt (1).

(-) Installing mirrors
or
or
Position mirror (2) with contact discs (3).

Install bolt (1).
Tightening torques
M10 x 50 25 Nm
–
with HP Billet PackOE (0799)

or
or

Install bolt (1).
Tightening torques
Cover cap to mirror
M3 x 5 1 Nm
Follow-up work

51 25 020 Replacing lock barrel for fuel tank

+ 51 25 591
Core activity
(-) Removing lock barrel for fuel filler cap
Open fuel filler cap (1).

Cover the fuel filler neck.
ATTENTION
Component damage
Push the latching tab (arrow) down using a suitable 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).
(-) Installing lock barrel for fuel filler cap
Lubricate lock barrel (5).
Lubricant
MI-Setral-43 N 83 23 2 152 082
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

51 25 041 Replacing ignition switch/steering lock including ring aerial

+ 51 25 606
Core activity
(-) Removing ring aerial
Disconnect plug (1) for the ring aerial/ignition lock.

Apply masking tape as necessary to protect other components in the
vicinity.
Tie back the wires to ensure adequate clearance for working with the power
drill.
Gather up or vacuum the metal chips.
Drill out non-removable screws (2) in 2 steps.
Technical data
Drilling depth for Pilot hole 6 mm
drilling out non- diameter 4.5 mm
removable screws Diameter for max 6 mm
drilling out
fully 8.5 mm
Remove ring aerial/steering-lock housing (3).
Use a suitable tool to remove pin (1).

Clean the threads.
(-) Transferring lock barrel, steering lock housing
Insert ignition key (1) and turn it to the ON position.

Push in retainer (2) by inserting a length of stiff wire (3) or similar as far to
the outside as possible into the hole (arrow).
Remove lock barrel (4) with ignition key (1).
Lubricant
MI-Setral-43 N 83 23 2 152 082
Use ignition key (1) to insert lock barrel (4) in the ON position into new
steering-lock housing (5).
Push lock barrel (4) down.
Turn ignition key (1) to the OFF position.

(-) Installing ring aerial
Hold ring aerial/steering-lock housing (1) in position.

Install non-removable screws (2) with special socket wrench insert (No. 51 0
531).
Tightening torques
Ignition/steering lock to fork bridge
Non-removable screw, M8, Replace 20 Nm
screw
encapsulated)
Connect plug (3) for the ring aerial/ignition lock.
Follow-up work
Programming the vehicle control, control unit with BMW Motorrad
diagnosis system

51 25 060 Removing/installing or replacing lock barrel for seat lock

+ 51 25 596
Core activity

(-) Installing lock barrel for seat lock
Insert key (1) into new lock barrel (2).

Lubricant
MI-Setral-43 N 83 23 2 152 082
Insert lock barrel (2) with key (1) and turn it until the locking pawl (arrow)
engages.
Follow-up work

51 25 091 Install a single key locking system set

+ 51 25 605
Core activity
Disconnect plugs (1) and (2) for the control unit for Keyless Ride.

vicinity.
drill.
Technical data
drilling out
fully 8.5 mm

Clean the threads.

531).

Tightening torques
Replace screws
encapsulated)
Connect plugs (1) and (2) for the control unit for Keyless Ride.

(-) Installing lock barrel for seat lock
Insert key (1) into new lock barrel (2).

Lubricant
MI-Setral-43 N 83 23 2 152 082
Insert lock barrel (2) with key (1) and turn it until the locking pawl (arrow)
engages.
Follow-up work

diagnosis system

52 53 385 Replacing holder for dual seat on frame

+ 52 53 589
Preparatory work
Removing front seat
Core activity
(-) Removing base plate for seat adjuster

Disengage fuse carrier (1).
Remove bushing (1).

Remove base plate (2) with the seat adjuster.
(-) Replacing base plate for seat adjuster
Note the mark (arrow) for the installed position of seat adjustment (1).
By pressing lug (2), remove seat adjuster (1) from old base plate (3) and
reinstall it in the same position in new base plate (3).
Release fuse carrier (4) through hole (5), work it to the rear to remove and
install it in new base plate (3).
(-) Installing base plate for seat adjuster
Install base plate (2) with the seat adjuster.

Lightly lubricate bushings (1) and install.
Installation tool
Install screws (3) and (2).
Tightening torques
Fuel tank to frame
M8 x 45 19 Nm
Seat adjuster to frame
M6 x 14.5 8 Nm
Secure fuse carrier (1).

Follow-up work

Electrical System
Repair Guide
BMW Motorrad
61 00 002 Testing software

+ 61 00 502
Preparatory work
Core activity
(-) Checking the software with the BMW Motorrad diagnosis
system
Start the diagnosis system.

Read out the software release.
Perform diagnosis. Rectify faults, if found, before starting

programming/coding.
=> Programming control units of vehicle (along with testing software)

Follow-up work

61 00 003 Resetting/learning adaptation values (with replacing component)

+ 61 00 503
Preparatory work
Core activity
(-) Reading fault memory with BMW Motorrad diagnostic system
and resetting adaptation values
NOTICE
When working with the BMW Motorrad diagnostic system, always follow the
instructions it issues.
Read out the fault memory.
Perform all requisite repair work.

Reset the adaptation values.
This is the only way of ensuring correct operation of the vehicle.
Follow-up work

61 00 510 Programming control units of vehicle (along with testing software)
Core activity
(-) Programming the vehicle control, control unit with BMW
Motorrad diagnosis system
Start the programming routine and follow the instructions issued by the
diagnostic system.

61 11 004 Wiring-harness repair for throttle-twistgrip sensor

+ 61 11 543
Preparatory work
Disconnecting plug at right multifunction switch
Core activity
(-) Preparing wiring-harness repair for throttle-twistgrip sensor
Open holder (1).

Release wiring harness (2).
Carefully cut open shroud (1) of wiring harness (2) for throttle twistgrip to
length (A) and remove.
Technical data
Length (A) approx. 280 mm
Cut the cables for the throttle twistgrip, measured from plug (1), to the
following lengths:
Technical data
Lengths and colours, Cable length Grey/brown and
cable repair set for (A) 230 mm grey/black/yellow
throttle twistgrip Cable length Grey/blue and
(B) 190 mm grey/red
Cable length Grey/black and
(C) 150 mm grey/brown/yellow
(-) Repairing wiring harness for throttle twistgrip
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).
Slip shrink-on hose (1) over wiring harnesses (2) and into position and heat
slightly.
Follow-up work
Connecting plugs at right multifunction switch
Securing cable for throttle twistgrip

61 11 008 Wiring-harness repair, left multifunction switch

+ 61 11 516
ATTENTION
Preparatory work
Removing left multifunction switch
Core activity
(-) Repairing wiring harness for left multifunction switch
Requirement
Use a hot-air gun for shrink fitting/soldering; never use a naked flame.
ATTENTION
Overheating of components
Charring of electrical lines or plastic parts
When using a hot-air gun protect these areas to prevent overheating, for
example by using appropriate covers.
Carefully cut heat-shrink tubing (1) along the line, using side cutters.
Open heat-shrink tubing (1) to repair area (A) carefully by hand and cut off
the heat-shrink tubing.

Cut through wires (1), (2) and (3) in repair area (A), taking care to offset the
cuts. Be sure to identify the wires correctly by pulling directly at
connector (4).
Technical data
Cable colours, repair Red, yellow, brown
kit for multifunction
switch, left
Pull cables (1), (2) and (3) up and out of protective tubing (5) and rubber
grommet (6).
Cut the wires of cable leg (1) from the repair kit to length to suit cut wires
(2).

Unlatch clutch switch connector (1): slightly raise the cap (arrow).
Carefully make a note of the arrangement of cable ends (2) in clutch
switch connector (1).
Release cable ends (2) with release tool (No. 61 0 326) and disengage them
from connector (1).

Work repair kit wires (1), (2) and (3) singly through rubber grommet (4) and
protective tubing (5).
Introduce cable (1) into solder connector (2), and check that the stripped
wire is inside the solder ring (arrow).
Shrink solder connector (2) at the coloured mark (3) with a suitable hot-air
gun to secure cable (1).
Introduce cable (4) with the colours matched so that the stripped
conductors are in solder connector (2).
Push the opposing conductors into each other.
Working from the outside toward the inside, heat solder connector (2) while
turning the cable so that it is heated uniformly all round.
The solder ring (arrow) liquefies and flows into the conductors.
Hot-melt adhesive (arrows) escapes between solder connector (2) and
cables (1) and (4).
Slip connectors (1), (2) and cable (3) for the clutch switch with rubber
grommet (4) and protective hoses (5) through heat-shrink tubing (6) from the
repair kit.
Secure cable ends (1) in connector (2), making sure that the colours are
correctly matched.
Technical data
Cable colours, clutch Pin 1 green/blue –
switch
Pin 2 black/green with shift
assistant ProOE
Pin 3 black/green/yellow (0222)
or
– with cruise
Latch clutch switch connector (1): press the cap closed (arrow). controlOE (0538)
Slip heat-shrink tubing (1) into position overlapping existing protective tubing
(2) and heat repair area (A).
Cut heat-shrink tubing (1) to length at top until the connectors wrapped in
adhesive tape are accessible.
Follow-up work
Installing left multifunction switch
Securing left grip unit

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.

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.
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
0456 - Style HPOE
05AC - ABS ProOE
61 11 517 Additional work for removing/installing or replacing main wiring harness (with Dynamic ESA)
Preparatory work
Removing rear seat
Removing front seat
Removing left cover
Removing battery
Removing fuel tank
Removing rear ride-height sensor with bracket
Disconnecting voltage regulator

Follow-up work
Connecting plugs at right multifunction switch
Installing top front-wheel cover
Connecting voltage regulator
Installing rear ride-height sensor with bracket

Installing battery

61 11 355 Replacing wiring harness for auxiliary headlights

+ 61 11 540
Preparatory work
Removing front seat
Core activity
(-) Removing wiring harness for auxiliary headlights
Remove the cable strap (arrows).

Disconnect connectors (1) and (2) for additional headlight.
Release cable (3) from holder (4).

Release cable (1).

Release cable (1).

Insert a suitable tool (1) , e.g. a small screwdriver, in opening (2) and
carefully press lock (arrow) upwards.
Pull off connector (3) for the additional headlight towards the rear.
Insert a suitable tool (1) , e.g. a small screwdriver, in opening (2) and
carefully press lock (arrow) downwards.
Pull off connector (3) for the additional headlight towards the rear.
Release and guide out cable (4) from holder (5).
(-) Installing wiring harness for auxiliary headlights
Route wiring harness (1) for the additional headlight.




Secure cable (1) with cable strap (arrows).
Secure cable (1) with cable strap (arrows).
Connect connectors (1) and (2) for additional headlight.

Secure the clutch cable (3) in holder (4).
Follow-up work
Installing left intake air pipe


61 13 010 Replacing fuse for alternator regulator

+ 61 13 510
0456 - Style HPOE
Preparatory work
Removing rear seat
Removing front seat
Core activity
(-) Removing fuse for alternator regulator
Requirement
Battery is disconnected.
Cut through adhesive tapes (1).

Disengage cable (2) from the holder (arrow).
Disengage retainer (3) and open lid (4).
Remove screws (1).

Remove retainer (2).
(-) Installing fuse for alternator regulator
Carefully bend back the hooks (arrows).

Disengage holder (1) from engine control unit (2).

Secure cable shoes (1) and fuse (2) with screws (3).
Tightening torques
Fuse for voltage regulator to holder
M5 x 8 - 10.9 3.5 Nm
Technical data
Fuse holder Fuse 1: 50 A
Voltage
regulator
Close cover of holder (1) (hook (2) engages) and wrap in adhesive tape (3).
Engage cable (4) in holder (5) and secure with a cable tie (arrow).
Secure holder (1) to engine control unit (6).
Hooks (7) engage.
Follow-up work

61 21 005 No-load current test, complete vehicle

+ 61 21 505
Preparatory work
Core activity
(-) Measuring battery voltage
NOTICE
Battery voltage and standby current can be measured with various devices
(observe respective operating instructions):
Conventional multimeter
BMW Motorrad MBOX (Measurement Box)
ICOM Next
Set expected voltage range on the measuring device (1).

Position gauge tip (2) on positive terminal (3) of the battery and position
gauge tip (4) on negative terminal (5) of the battery.
Enter the measured battery voltage in the measured-data record.
Check
Check the battery voltage.
Result:
Measured battery voltage < 12.5 V.
Measure:
Charge battery fully, note charging date on battery (label).
(-) Idle-current measurement
Requirement
Motorcycle's ignition is switched OFF.
Battery is fully charged.
NOTICE
To prevent activation of the control units, do not disconnect the battery from
the wiring harness. A cable jumper must ensure the current flow when
connecting/disconnecting.
Wait until the ZFE control unit has switched off before starting measurement.
Technical data
Deactivation delay for if no 60 s
control units consumers
are active

Connect cable jumper (1) on the negative terminal of the battery (2) and on
the cable shoe of the wiring harness (3).
This is to prevent a reset of the electronic control units when the battery is
disconnected.
Remove bolt (4) and take off cable (3).
Set ammeter (5) to highest measuring range, connect terminals (6) to

battery negative terminal (2) and cable shoe of the wiring harness (3). It is
very important to check that the cables are correctly connected to the
ammeter and the battery.
Disconnect cable jumper (1) and read current level on scale (7).
Check
Perform two measurements:
with ignition OFF
with ignition switch/steering lock locked
Technical data
permissible standby with/without max 2 mA
current value anti-theft
alarm system
Result:
Ammeter shows a measured current of 0.0 A.
Measure:
Check the fuse in the ammeter; replace if necessary and repeat the
measurement.
Result:
No current or measured value is not shown correctly on the scale.
Measure:
Connect cable jumper (1).
This is to avoid a reset of the electronic control units when the ammeter is
set to the next lowest measuring range.
Set ammeter to the next lower measuring range (5).

Disconnect cable jumper (1) and read current level again.
Result:
Measured current is greater than permissible value.
Measure:
Enter the current in the measured-data record and use the measured-data
record to identify the cause of the fault.
The measured-data record is available in the Service Information No.
59/2005.
Follow-up work

61 21 011 Renewing battery

+ 61 21 522
Preparatory work
Core activity
(-) Removing battery
Remove bolt (1).

Loosen grounding cable (2) and insulate with adhesive tape (arrow).
Disengage rubber band (1) from the hooks (arrows).
Pull battery holder plate (1) off mounts (2) and (3).
Pull battery (1) out of bracket (2).

Remove bolt (3).

(-) Replacing battery
NOTICE
Installation/exchange/removal of the adapter plate may be required during
battery change.
Dispose of battery in a manner compliant with national regulations.
(-) Installing battery

Install bolt (3).
Tightening torques
M6 x 11 8 Nm
Slide battery (1) in battery holder (2) and while doing so, pay attention to the
correct routing of the positive wire (4).
Position battery holder plate (1) in top mount (2).

Press battery holder plate (1) into bottom mounting (detail), sliding battery
holder plate (1) under the height adapter (3).
Secure rubber band (1) in the hooks (arrows).


Fit grounding cable (2).
Install bolt (1).
Tightening torques
M6 x 11 8 Nm
Follow-up work
Evaluation of transport readiness of lithium batteries at service outlets

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 frame and suspension electronics
Use only chargers approved by BMW Motorrad.
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 electric consumers from the on-board socket, if connected.
Check
Switch on the ignition.

Control units switch on.
Switch off the ignition.
Technical data
Deactivation delay for if no 60 s
control units consumers
are active
Control units remain on, because of the deactivation delay.

Within the deactivation delay, connect the BMW Motorrad battery charger
with charging cable to on-board socket (1) first.
The battery charge state is displayed.
Result:
Battery is not fully charged.
Measure:
Connect the BMW Motorrad battery charger to the local 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 21 128 Removing/installing battery carrier

+ 61 21 526
06AC - Intelligent emergency callOE
Preparatory work
Removing front seat
Removing fuel tank
Removing battery
Removing left cover
Core activity
(-) Remove the cover for battery holder
Unlatch the tabs (arrows).

Work cover (1) up to remove.
Remove cover (1).
(-) Removing battery carrier
Remove screws (1).

Remove cap (2).
Remove remote positive terminal (3).
Release diagnostic connector (5).
Remove the bracket (1).

Unclip relay (2) to the front.



Remove cover (1) for the ride-height sensor, noting the retaining pins (2)
and grooves (arrows).

ATTENTION
procedure
tab.

connector (2).

Release lock (2) and detach connector for monitoring oxygen sensor from
battery tray.
Disconnect the connector (1) for monitoring oxygen sensor.

Release rubber bands (1).
Raise cable duct (1).

Disconnect plug (2) for basic module.
Disengage locators (arrow) and remove GM (3) from adapter (4).

Removing the control unit for intelligent emergency call

Carefully push lock (1) on battery tray (2) to one side.
Pull control unit (3) on connector (4) upwards.
Loosen control unit (3) only so much that the connector (4) can still be
disconnected (cable length).
Disconnect connector (1) from control unit (2) and remove control unit (2)
from battery holder (3).
Release control unit (1) and disconnect connector (2).

Remove the control unit (1).

Release rubber bands (1).

Release dirty water hose (1) and vent hose (2) from holder (arrow).
Remove thermal protection (1).

Release line (1) and line (2) from cross-member (3).
Disconnect cross-member (3) from battery tray (4).
Remove cross-member (3).
Remove battery tray (4).
(-) Installing battery carrier
Install cross-member (3).

Secure line (2) and line (1) on cross-member (3).
Install battery tray (4) and connect it to cross-member (3).
Secure the cable strap (arrow)

Install thermal protection (1).
Secure dirty water hose (1) and vent hose (2) in the holder (arrow).

Secure rubber bands (1).
Connect connector (1) for the control unit .

Install control unit (2) while paying attention to guide lugs (arrows).

Installing the control unit for intelligent emergency call

Position control unit (2) on battery holder (3).
Push control unit (2) so far into battery holder (3) that connector (1) can be
connected (cable length).
Connect connector(1) to the control unit (2).
Push control unit (3) on the connector (4) fully into battery tray (2) until lock
(1) engages.
Raise cable duct (1).

Install GM (3) in adapter (4) making sure the locators are fitted correctly
(arrow).
Connect plug (2) for basic module.


Connect the connector (1) for monitoring oxygen sensor.

Attach connector (1) to battery tray.
Ensure that lock (2) is engaged to battery tray.

Install cover (1) for the ride-height sensor, first engaging the grooves
(arrows) and then engaging retaining pin (2).

Install expanding rivet (1).

Secure lines (1) and (2) in holder (3).

Work relay (2) into position from the front.

Install holder (1).
Install screws (1).

Install remote positive terminal (3).
Install cap (2).
Secure diagnostic connector (5).
(-) Installing cover for battery holder
Install cover (1).
Secure cover (1).


Follow-up work
Installing battery

61 21 502 Replace battery (check for battery)
Core activity
NOTICE
battery change.
(-) Evaluation of transport readiness of lithium batteries at service

outlets
NOTICE
Information on hazardous goods, explosives & air freight safety:
https://contenthub.bmwgroup.net/web/gefahrgut_explosivstoffe_luftfrachtsicherheit/gefahrgut
It is necessary to transport a used lithium battery for analytical or disposal

purposes. This lithium-ion based cell modules are classified as hazardous
goods in accordance with UN 38.3 and must only be transported subject to
specific requirements
Batteries with an energy content exceeding 100 Wh are considered as
lithium battery/high-voltage battery.
Corresponds to 12V lithium battery 10Ah
Batteries with energy content of 100 Wh or less are considered as small
batteries.
Corresponds to 12 Vlithium battery 5Ah
Damaged batteries are always considered as hazardous material.
The specially trained person is always responsible for maintaining the
certified transport readiness between determination and transfer of the
battery to disposal / transport companies. For shipment, the influence of the
storage conditions and other possibly occurring events on the established
transport readiness must be taken into account.
Transport in the sense of the Hazardous Goods Law is divided into three
areas:
1. Determination of transport readiness
2. Transport preparation
3. Transport performance
This document contains all necessary information to determine the transport
readiness of a used lithium battery. The transport preparation and
performance is notpart of this document.
For more information, refer to the product information in the ASAP.
NOTICE
Explanation of necessary measures for assuring transport readiness.
The details on how to perform this measure depend on the individual
conditions at the location and are not part of this document. These procedures
must be defined in compliance with the local regulations/laws and adopted in
the valid local work instructions.
Prerequisite from a safety perspective:

The expert is responsible for the certification of transport readiness.
Additionally, compliance with the following specifications for occupational
health and safety is required:
Storage of lithium batteries
This information is available under the product information in the ASAP.

61 31 001 Replacing multi-controller

+ 61 31 950
ATTENTION
Preparatory work
Core activity
(-) Removing left multifunction switch

(-) Removing multi-controller
Remove screws (1).

Disengage plug (2) for the heated grip.
Remove multi-controller (3) from grip (4).

(-) Installing multi-controller
Position Multi-Controller (1) on grip (2), making sure that recesses (3) and
retainers (4) engage each other.
Work plug (5) for the heated grip through Multi-Controller (1).
Hold plug (5) for the heated grip in position and install screws (6), noting the
routing of the grip-heating cable (arrow).
Tightening torques
(-) Installing left multifunction switch
Install handlebar grip (1) , and at the same time insert connector (2) for the
heated grip.
Retaining lug (3) engages.
Follow-up work

61 31 008 Replacing front ride-height sensor

+ 61 31 958
Preparatory work
Removing front seat
Removing fuel tank
Core activity
(-) Remove the left tank bracket
Unclip ball socket (1) from ball head (2).

Disconnect connector (3) for the ride height sensor.

Disconnect connector (1) for impact sensor.


Disconnect connector (1) for impact sensor.
Release hoses (1) from holder (2).

Loosen fuel injection line (3) from holder (4).
Remove screws (5).
Remove tank bracket (6).
(-) Replacing height sensor, front
ATTENTION
Component damage
Press jointed rod (1) of ball stud (2) shut.

Remove nut (3) and ball stud (2).
Remove screws (4) and remove ride height sensor (5).
Secure new ride height sensor (5) with screws (4) in tank bracket (6).
Install new ball stud (2) with nut (1).
Tightening torques
Nut, M6

encapsulated)
Secure jointed rod (2) on ball stud (3) while counter-holding nut (1).
(-) Installing left tank bracket
Position tank holder (6).

Install screws (5).
Tightening torques
M6 x 12 8 Nm
Secure fuel injection line (3) in holder (4).

Secure hoses (1) in holder (2).
Clip ball socket (1) into ball head (2), making sure that arm (3) points
forwards.
Connect connector (4) for the ride height sensor.
Tightening torques
M6 x 25 8 Nm
Connect connector (1) for impact sensor.


Follow-up work

61 31 009 Replacing rear ride-height sensor

+ 61 31 959
Preparatory work
Core activity
(-) Removing height sensor, rear
Detach jointed rod (1) from ball stud (2).

Disconnect connector (3) for the ride-height sensor.
Remove screws (4).
Remove ride-height sensor (5).
(-) Replacing rear ride-height sensor
Remove nut (1) and ball stud (2).

Secure nut (1) and new ball stud (2) on ride height sensor (3).
Tightening torques
Nut, M6
encapsulated)
(-) Installing height sensor, rear
Secure ride height sensor (5) with screws (4).
Tightening torques
Ride-height sensor to bracket
M5 x 10 5 Nm
Oval-head screw for thermoplastic 2 Nm
plastic
Two switch variants can be installed (metric/plastic thread), pay attention to

torque/screw shape!
See Electronic Parts Catalogue.
Connect connector (3) for the ride height sensor.
Secure jointed rod (1) on ball stud (2) while counter-holding ball stud (2).

Follow-up work

61 31 047 Replace operating facility for intelligent emergency call

+ 61 31 647
Preparatory work
Removing front seat
Core activity
(-) Removing the operating facility for intelligent emergency call
Remove bolt (1).

Loosen front-wheel cover with right wind deflector bracket(2) from front
panel carrier (3).

Disconnect plug connection (1) for operating facility and loosen cable (2)
from front panel carrier (3). Feed cable (2) out from between front panel
carrier (3) and wind deflector bracket (4).

Remove cable clip (1).

Remove cable clip (1) and feed out cable (2).
Remove bolt (1).

Remove operating facility (2) from handbrake fitting (3).
(-) Installing the operating facility for intelligent emergency call
Position operating facility (2) on handbrake fitting (3).

Install bolt (1).
Tightening torques
Operating facility for intelligent emergency call to clamp
M5 x 22 3 Nm
(mechanical)
Route cable (2) and install cable clip (1).
Install cable holder (1).


Feed cable (2) between front panel carrier (3) and wind deflector holder (4).
Route cable (2) to front panel carrier (3) and connect plug connection (1) for
operating facility. Lay excess cable length in loops.
Loosen front-wheel cover with right wind deflector bracket(2) from front
panel carrier (3).
Install bolt (1).
Follow-up work

61 31 048 Replace impact sensor for intelligent emergency call

+ 61 31 648
Preparatory work
Removing front seat
Removing fuel tank
Removing left bracket for fuel tank
Core activity
(-) Remove impact sensor for intelligent emergency call
Remove bolts (1) and (2).

Remove holder (3) with impact sensor (4) from tank bracket (5).
(-) Installing impact sensor for intelligent emergency call
Remove bolt (1).

Remove impact sensor (2) from holder (3). Note the locator (Arrow).
Position new impact sensor (2) on holder (3). Note the locator (Arrow).
Install bolt (1).
Tightening torques
Impact sensor to bracket
M6 x 20 6 Nm
(-) Installing impact sensor for intelligent emergency call

Position holder (3) with impact sensor (4) on tank bracket (5).
Install bolt (1).
Tightening torques
M6 x 12 8 Nm
Install bolt (2).
Tightening torques
M6 x 20 6 Nm
Follow-up work
Installing left bracket for fuel tank

61 31 063 Renewing complete multi-function switch on left handlebar

+ 61 31 904
ATTENTION
Preparatory work
Core activity

heated grip.

Follow-up work

61 31 073 Renewing complete multi-function switch on right handlebar

+ 61 31 905
Core activity
(-) Removing right multifunction switch
Press the releases (arrows) at front and back and disconnect plug (1) for the
throttle twistgrip.
Remove screw (1).

Pull cover (2) down slightly.
Push cover (1) forward and up to remove, noting retaining catches (2).
Disconnect plug (1) for the heated grip and unclip it.
Disconnect plug (2) for the multifunction switch.
Remove screw (3).
Remove multifunction switch (4).

(-) Installing right multifunction switch
Hold multifunction switch (4) in position.

ATTENTION
Screws overtightened past the specified value
Component damage
Tighten the screws only to their specified tightening torque.
Install screw (3).
Tightening torques
Connect plug (2) for the multifunction switch.

Connect plug (1) for the heated grip and clip it into position.
Position cover (1) and push backwards and down, paying attention to
retaining catches (2).
Push cover (1) up until the multifunction switch is closed.

ATTENTION
Component damage
Install screw (2).
Tightening torques

Connect plug (1) for the throttle twistgrip.
Follow-up work

61 31 295 Removing/installing or replacing clutch switch

+ 61 31 911
Core activity
(-) Removing clutch switch
Remove bolt (1).

Remove clutch switch (2).
Disconnecting connector (3) for clutch switch.
(-) Install the clutch switch

Insert clutch switch (2) into the grip unit.
The locking tab (arrow) faces down.
Install bolt (1).
Tightening torques
Follow-up work

61 31 302 Replacing switch for side stand

+ 61 31 913
Core activity
(-) Removing switch for side stand
Remove screw (1).

Remove switch for side stand (2).
Unlatch plug (3) for the side-stand switch with the tab (arrow).
Disconnect plug (3) for the side-stand switch.
(-) Installing switch for side stand
Clean the threads.

Connect plug (1) for the side-stand switch.
Latch plug (1) for the side-stand switch at the tab (arrow).
Position switch for side stand (2) in such a way that switch pin (3) is seated
in hole (4) in the side stand.
Install screw (5).
Tightening torques
encapsulated)
Follow-up work

61 31 312 Replacing switch for auxiliary headlight

+ 61 31 943
Preparatory work
Removing front seat
Core activity
(-) Install the switch for auxiliary headlights

Disconnect and unclip plug (1) for the auxiliary headlights.
Work line (2) through toward the rear.

Work line (1) up.
Open the holders (arrows).

Release line (1).

Remove screw (1).

Remove switch (2) for the auxiliary headlights.
(-) Installing switch for auxiliary headlights
Hold switch (2) for the auxiliary headlights in position.

Install screw (1).
Route line (1) down into position and secure it in the holders (arrows).
Route line (1) forward.

Install cable ties (arrows).

Connect plug (1) for the auxiliary headlight.

Route line (2) and secure it with the cable ties (arrows).
Follow-up work

61 33 011 Replacing horn

+ 61 33 502
Preparatory work
Removing front seat
Core activity
(-) Removing horn
Disconnect connector (1) for the horn.

Remove horn (4).
(-) Replacing horn
Transfer flat nut (1) to new horn (2).
(-) Install the horn
Hold horn (4) in position.

Tightening torques
Horn to front panel carrier
M8 x 18 - 10.9 19 Nm
Connect connector (1) for the horn.
Follow-up work

61 34 000 Replacing on-board socket, front

+ 61 34 550
Core activity
(-) Removing on-board socket
Disconnect plug (1) for the on-board socket.

Remove nut (2).
Remove on-board socket (3).
(-) Installing on-board socket
Install on-board socket (3).

Install nut (2).
Connect plug (1) for the on-board socket.
Follow-up work

61 35 002 Replacing angular rate sensor

+ 61 35 652
05AC - ABS ProOE
ABS Pro with riding modes ProOA
Preparatory work
Removing rear seat
Core activity
(-) Removing angular rate sensor
Disconnect connector (1) for the angular rate sensor.

Remove nuts (2).
Remove angular rate sensor (3) with retaining plate (4), noting shouldered
bushings (5).
(-) Installing angular rate sensor
Install retaining plate (4), noting shouldered bushings (5).

Install angular rate sensor (3) and nuts (2).
Tightening torques
Angular rate sensor to rear-wheel cover
(mechanical)
Connect connector (1) for the angular rate sensor.
Follow-up work

61 35 003 Replacing control unit for electronic suspension adjustment

+ 61 35 655
Preparatory work
Removing front seat
Removing fuel tank
Removing left cover
Core activity
(-) Removing control unit for electronic suspension adjustment

Cut through the cable straps (arrows).
Slightly raise cable duct (2).
Remove cable clamps (3).
Disengage control unit (1) and disconnect connector (2).

Remove control unit (1).
(-) Install the control unit for electronic suspension adjustment
Connect connector (1) for the control unit.

Install control unit (2) paying attention to guide lugs (arrows).
Install cable strap holder (3).

Secure cable duct (2) with expanding rivet (1).
Follow-up work
Secure the starter relay

a separate item)

separate item)

61 35 026 Replacing control unit basic module (without testing software/programming)

+ 61 35 653
Preparatory work
Removing front seat
Removing fuel tank
Core activity
(-) Removing control unit basic module

Disconnect connector (2) for the basic module.
Disengage locators (Arrow) and remove control unit of basic module (3) out
of the adapter (4).
(-) Installing control unit basic module

Install control unit basic module (3) in adapter (4), making sure that the
locators (Arrow) are correctly seated.
Connect connector (2) for the basic module.
Follow-up work
Securing cable duct
Securing engine control unit

a separate item)
separate item)

61 35 028 Replace control unit for intelligent emergency call (without checking/programming
software)
+ 61 35 528
Preparatory work
Removing front seat
Removing fuel tank
Core activity
(-) Releasing wiring harness

Loosen wiring harness (1), cable (2) and cable (3) from cable duct (4).
(-) Removing the control unit for intelligent emergency call
Carefully push lock (1) on battery tray (2) to one side.

Pull control unit (3) on connector (4) upwards.
Loosen control unit (3) only so much that the connector (4) can still be
disconnected (cable length).
Disconnect connector (1) from control unit (2) and remove control unit (2)
from battery holder (3).

(-) Installing the control unit for intelligent emergency call
Position control unit (2) on battery holder (3).

Push control unit (2) so far into battery holder (3) that connector (1) can be
connected (cable length).
Connect connector(1) to the control unit (2).
Push control unit (3) on the connector (4) fully into battery tray (2) until lock
(1) engages.
(-) Securing wiring harness
Position wiring harness (1), cable (2) and cable (3) in cable duct (4).

Follow-up work
Logging on to control unit for intelligent emergency call

61 35 505 Setting service-due date and service countdown distance with BMW Motorrad
diagnostic system (for maintenance)
Core activity
(-) Set the service-due date and service countdown distance
Start diagnosis system and conduct vehicle test.

Call up the Service Schedules in the Activities menu item and set the
service date and service countdown.

61 36 040 Replacing main relay

+ 61 36 540
Preparatory work
Core activity
(-) Remove main relay
Release diagnostic connector (1).

Remove the bracket (1) for the diagnostic connector.

Unclip the relay carrier (1).
Unlock the retaining hook (2).
Remove the main relay (3) from the relay carrier (1).
(-) Install main relay
Install the main relay (3) in the relay carrier (1).

Retaining hook (2) locked.
Clip in the relay carrier (1).

Clip in holder (1) for diagnostic connector.

Secure diagnostic connector (1).
Follow-up work

62 11 199 Replacing instrument cluster (without (testing software/programming)

+ 62 11 510
NOTICE
Preparatory work
Removing front seat
Removing front panel carrier trim
Removing headlight
Core activity
(-) Removing instrument panel
Remove retaining clips (1).
Pull instrument cluster (2) out of grommets (1).

Disconnect connector (3) for the instrument cluster (2).
Pull instrument cluster (2) out of grommets (1).

Disconnect the connector (3) for navigation device preparation.
Disconnect connector (4) for the instrument cluster (2).
(-) Installing instrument panel
Lubricate grommets (1).
Care products
Connect connector (3) for instrument cluster (2).

Install instrument cluster (2) in grommets (1).
Connect connector (4) for instrument cluster (2).

Connect connector (3) for navigation device preparation.
Install instrument cluster (2) in grommets (1).
Install retaining clips (1).

Follow-up work
Install front panel carrier trim

a separate item)

separate item)

63 13 002 Replacing front left flashing turn indicator

+ 63 13 521
Preparatory work
Removing front seat
Core activity
(-) Removing front left flashing turn indicator
Disengage cable (1) from retaining tab (2).

Disconnect plug (3) for the flashing turn indicators.
Remove screw (4).
(-) Installing front left flashing turn indicator
Work cable (1) with plug (2) into the correct position.
Make sure that flashing turn indicator (3) is facing up, and turn it forward.
Install screw (4).
Secure cable (1) in retainer (5).
Connect plug (2) for the flashing turn indicator.
Follow-up work

63 17 000 Replacing left auxiliary headlight

+ 63 17 522
Core activity
(-) Removing auxiliary headlights
Carefully press connector (1) slightly to the outside to release the lock
(Arrow). Disconnect connector (1) for additional headlight (2).
Remove bolt (1) and nut (2).

Remove additional headlight (3).
(-) Replacing the additional headlight
Remove screws (1).

Remount holder (2) on new additional headlight (3).
Install screws (1).
Tightening torques
Adapter to LED auxiliary headlight
encapsulated)
(-) Installing auxiliary headlights
Position additional headlight (1).

Install bolt (2) and nut (3), but do not tighten yet.

63 21 380 Removing and installing or replacing complete rear light

+ 63 21 502
0456 - Style HPOE
Preparatory work
Removing rear seat
Removing front seat
Core activity
(-) Removing rear-light unit

Remove washers (2).
Remove rear light (1).

Disconnect plug (2) for the rear light.
(-) Installing rear-light unit
Connect plug (2) for the rear light.

Install rear light (1).

Install washers (2).
Install retaining clips (1).
Follow-up work

63 23 012 Replacing left rear turn indicator

+ 63 23 501
Preparatory work
Removing rear seat
Core activity
(-) Removing left flashing turn indicator

(-) Installing left turn indicator
Work cable (1) into position.

Install nut (4).
Install screw (3).
Tightening torques
M6 x 20 3 Nm
Secure cable (1) in the retainer (arrow).
Follow-up work

63 12 000 Adjust headlight

+ 63 12 500
Core activity
(-) Checking headlight beam throw
Requirement
Motorcycle standing on a smooth, level surface.
Rider's weight applied to the motorcycle.
Set the preload of spring strut to the basic setting (Auto (1)).
Set pivot lever (1) to the neutral position (vertical).
Start the engine and check that the headlight setting.

Check
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 10 m
headlight and vertical
surface

For headlight
adjustment
Distance from ESA mode "1- 5 cm
light/dark limit to up without
upper edge of low- cases -
beam headlight light- Comfort" and
emitting surface vehicle
loaded
with 85 kg
Result:
Headlight beam angle not correct.
Measure:
Correcting headlight beam angle
Adjust headlight beam throw by turning adjusting screw (1).
Requirement
Motorcycle standing on a smooth, level surface.
Rider's weight applied to the motorcycle.
Set the preload of spring strut to the basic setting (Auto (1)).

Start the engine.

Switch on the auxiliary headlights.
Check the alignment of the auxiliary headlights; adjust if necessary.
Technical data
Distance between 5m
auxiliary headlight
and vertical surface
For headlight
adjustment
Distance between Vehicle 10 cm
light/dark cut-off and loaded with
mark at height of 85 kg
centre of auxiliary
headlight
(a): Distance between additional headlight and vertical surface

(b): Height of centre of additional headlight
(c): distance to light/dark cut-off
Secure additional headlight (1) against twisting and tighten bolt (2) with nut
(3).
Tightening torques
Auxiliary headlight to bracket
M6 x 40 6 Nm
Recheck the alignment of the auxiliary headlights.
Follow-up work

63 12 091 Replacing headlight

+ 63 12 637
CAUTION
Hot control unit
Risk of burning
The control unit gets hot during operation; allow the control unit to cool down
before starting work.
Preparatory work
Removing front seat
Removing front panel carrier trim
Core activity
(-) Removing headlight
Disconnect connector (1) for the headlight.

Remove washers (2) .
Remove headlight (3) to the front.

63 12 505 Replacing control unit for LED bulb (headlight removed)
Core activity
(-) Replacing control unit for LED lights
Remove screws (1).

Remove control unit (2) with seal (3).
Hold new control unit (2) with seal (3) in position.
Install screws (1).

65 75 020 Replace batteries for control unit of anti-theft alarm system

+ 65 75 520
0456 - Style HPOE
NOTICE
Preparatory work
Removing rear seat
Removing front seat
Core activity
(-) Changing batteries in control unit for anti-theft alarm (DWA)
Remove screws (1).

Remove cover (2).
WARNING
Attempt to charge dry batteries.
Heat development and explosion.
Do not attempt to charge dry batteries.
Remove batteries (3) and dispose of them in a manner compliant with

national regulations.
Install new batteries (3).
Install cover (2) with screws (1).
Follow-up work

65 75 510 Replacing control unit of anti-theft alarm (without testing software/ programming)
0456 - Style HPOE
NOTICE
Preparatory work
Removing rear seat
Removing front seat
Core activity
(-) Removing anti-theft alarm (DWA)
Disconnect plug (1) for DWA.

Remove screw (2).
Remove DWA (3).
(-) Installing anti-theft alarm (DWA)
Hold DWA (3) in position.

Install screw (2).
Connect plug (1) for DWA.
Follow-up work

a separate item)

separate item)

65 81 050 Replacing ambient-temperature sensor

+ 65 81 550
Core activity
(-) Removing ambient-temperature sensor
Disconnect plug (1) for the ambient-temperature sensor.

Unclip ambient-temperature sensor (2).
(-) Installing ambient-temperature sensor
Clip in ambient-temperature sensor (2).

Connect plug (1) for the ambient-temperature sensor.
Follow-up work

66 12 001 Replacing control unit for Keyless Ride

+ 66 12 501
Core activity
Disconnect plugs (1) and (2) for the control unit for Keyless Ride.

vicinity.
drill.
Technical data
drilling out
fully 8.5 mm

Clean the threads.

531).

Tightening torques
Replace screws
encapsulated)
Connect plugs (1) and (2) for the control unit for Keyless Ride.
Follow-up work
diagnosis system

66 12 002 Replacing the antenna for Keyless Ride

+ 66 12 502
0456 - Style HPOE
Preparatory work
Removing rear seat
Removing front seat
Core activity
(-) Removing LF aerial
Disconnect plug (1) for the LF aerial and disengage.

Remove lock washers (2).
Remove LF aerial (3).
(-) Installing LF aerial
Hold LF aerial (3) in position.

Install lock washers (2).
Connect plug (1) for the LF aerial and secure.
Follow-up work

Workshop installation instructions
Repair Guide
BMW Motorrad
77 02 011 Install adapter for lifting stands

+ 77 02 511
Core activity
(-) Removing nut from engine screw connection
Remove nut (1), counter-holding screw (2), if necessary.
(-) Installing adapter for variable height stand on engine
Clean thread of screw (1).

Apply screw locking agent to thread of adapter for variable height stand (2).
Install adapter for variable-height stand (2), counter-holding screw (1), if

necessary.
Tightening torques
Adapter for variable height stand to engine screw connection
M12 100 Nm

77 02 012 Attach adapter plate on the lifting stands

+ 77 02 512
Core activity
(-) Removing screws and adjusting plates
Remove screws (1) and adjusting plates (2) and (3).
(-) Installing adapter plate on variable-height stand
Assemble screws (1), narrow compensation piece (2), adapter plate (3) and
thick compensation piece (4) as shown.
Install pre-assembled package (1) with screws (2) hand-tight at lowest

position (arrows) on mounting (3) of variable-height stand.
Slide variable-height stand centred to motorcycle and position mounting (1)

on connecting bolts (2).
Align adapter plate (3) and lower mounting (4) with pivoting point (5) and
slide in.
Tighten screws (6) temporarily.

Detach variable-height stand from motorcycle.

Tighten screws (1) to the specified torque.
Tightening torques
Adapter plate to variable height stand
M10 x 70 40 Nm

77 11 001 Installing chrome-plated silencer

+ 77 11 582
CAUTION
Hot exhaust system
Risk of burn injury
Preparatory work
Core activity
Loosen nut (1).

Push clamp (2) to the rear.
Remove bolts (1) and shaped washer (2) and store. Components will be
reused.
Remove silencer (3) and washer (4). Keep washer (4), will be reused.
(-) Remounting mounted parts on chromed silencer
Remount flat nuts (1) on chromed silencer (2).
(-) Installing chrome-plated silencer

Lightly lubricate the inner face of clamp (1).
Lubricant
Optimoly TA 18 21 9 062 599
Slide clamp (1) onto new silencer (2).

Push new silencer (2) to stop.
Tightening torques
M8 x 35 19 Nm
Tighten screws (1).
Tightening torques
Clamp to silencer
M5 x 16, Renew screw 8 Nm
encapsulated)
Position clamp (2) with the recess in the lug (arrow).

Tighten the nut (1).
Tightening torques
M8 22 Nm
Follow-up work

77 11 010 Installing sports silencer

+ 77 11 510
Sports silencerOA
Core activity
(-) Removing silencer cover
Remove screws (1).

Remove silencer cover (2).
Loosen nut (1).

Push clamp (2) to the rear.
Remove bolts (1) and shaped washer (2) and store. Components will be
reused.
Remove silencer (3) and washer (4). Keep washer (4), will be reused.
(-) Installing sports silencer
ATTENTION
Use of unsuitable cleaning agents
Damage to the surface
Clean the outer skin of the sports silencer only with a care spray
recommended by an authorised BMW Motorrad dealer and a soft, dry cloth.

NOTICE
The lifespan of the insulating material in the silencer depends on engine
performance and style of riding.
Consult an authorised BMW Motorrad dealer if the silencer becomes louder
or if its external appearance changes.
Note, however, that slight discolouration of the silencer is normal. This
discolouration is caused by the high temperature of the exhaust gas.
Lightly lubricate new clamp (1).
Lubricant
Optimoly TA 18 21 9 062 599
Push new clamp (1) onto new silencer (2).

Push new silencer (2) to stop.
Tightening torques
M8 x 35 19 Nm
With case attached, make sure the sports silencer (arrows) is aligned
correctly, correct if necessary.
Tighten screw (1) of clamp (2).
Tightening torques
Sports silencer to rear frame
M8 x 35 19 Nm
(-) Installing heat protection cover
Position heat protection cover (3).

Install screws (1) with washers (2).
Tightening torques
Heat protection cover to exhaust manifold

M5 x 12 3 Nm
Follow-up work

77 11 040 Install exhaust manifold with chromium coating

+ 77 11 540
CAUTION
Hot exhaust system
Risk of burn injury
Preparatory work
Removing silencer
Core activity
(-) Removing exhaust manifold
Protect the area (arrow) on swinging arm (1) against damage.
Remove nuts (1).

Remove gaskets (2).
Remove exhaust manifold (3).
(-) Replacing exhaust manifold

Remount holder (1) on new exhaust manifold (2).
Remount flat nut (1) on new exhaust manifold (2).

Remount left oxygen sensor (3) on new exhaust manifold (2).
Tightening torques
M18 x 1.5 45 Nm
TA)
Remount right oxygen sensor (4) on new exhaust manifold (2).
Tightening torques
M18 x 1.5 45 Nm
TA)
Remount oxygen sensor monitor (5) on new exhaust manifold (2).
Tightening torques
M12 x 1.25 25 Nm
TA)
(-) Installing exhaust manifold
Position new seals (2) on exhaust manifold (3).

Install new nuts (1).
Tightening torques
M8 21 Nm
Remove cover (arrow) on swinging arm (1).
Follow-up work
Installing silencer

77 12 004 Install the front engine housing cover

+ 77 12 504
0499 - Low-slungOE
Preparatory work
Draining engine oil
Core activity
(-) Installing rear-wheel stand
If necessary, prepare rear-wheel stand (No. 36 3 980):

Push the locking button and remove retaining pin (No. 36 3 985).
Push axle adapter (No. 36 3 982) into basic stand (No. 36 3 981) and secure
with retaining pin.
Fit adapter shaft (No. 36 3 986) to axle adapter (No. 36 3 982).
If applicable, adjust height of the axle mounting (No. 36 3 982) and secure
with bolt (1).
Working from the left, install the rear-wheel stand in the rear axle.
Push on bushing (No. 36 3 989) and retaining pin (No. 36 3 985) from the
right, while holding the locking button down.
ATTENTION
Hold the motorcycle upright and at the same time press lever (No. 36 3 983)
down.
Lever is flat on the round.
Make sure the motorcycle is upright.
(-) Removing front crankcase cover
Remove screws (1).
Push off engine housing cover (1) with extractor (No. 11 0 833) and remove.
NOTICE
If the crankcase cover and leading link come into contact with each other,
adjust the rear-wheel stand to a higher setting.

Remove extractor (No. 11 0 833) from engine housing cover (1).

Sealant
Dow Corning 07 58 0 397 777
Position engine housing cover (1).
Hand-tighten screws (1) to (16).

direction.
Tightening torques
M6 x 20 Tightening
sequence: See
repair manual
10 Nm
(-) Removing rear-wheel stand
ATTENTION
Extend side stand (1).

Secure the motorcycle to ensure that it cannot topple and slowly lower it
forward.
Place the motorcycle on its side stand (1).
Push the locking button and remove retaining pin (No. 36 3 985) and
bushing (No. 36 3 989) .
Work the auxiliary stand to the left until it is clear of the rear axle.
Follow-up work

77 12 014 Installing cylinder-head cover guard

+ 77 12 516
Aluminium cylinder-head cover guardOA
Core activity
(-) Installing left buffer
Insert buffer (1) in recesses (arrows) at cylinder-head cover guard (2).
(-) Installing right buffer
Insert buffer (1) in recesses (arrows) at cylinder-head cover guard (2).
(-) Removing left engine protection bar
Remove bolt (1).


(-) Remove the right protection bar
Remove bolt (1).

(-) Remove screw from left cylinder head cover
Remove screw (1) from cylinder head cover (2).
(-) Installing left stud bolt in cylinder-head cover
Lubricate the sealing face of the stud bolt.

Installation tool
Install stud bolt (1) in cylinder head cover (2).
Tightening torques
M6 10 Nm
(-) Installing left cylinder-head cover guard
Hold cylinder-head cover guard (1) in position and install bolt (2) until hand-
tight.
Tighten the screw (2).
Tightening torques
M6 10 Nm
Tightening torques
M5 x 12 5 Nm
(-) Remove screw from right cylinder head cover
Remove screw (1) from cylinder head cover (2).
(-) Installing right stud bolt in cylinder-head cover
Lubricate the sealing face of the stud bolt.
Installation tool
Install stud bolt (1) in cylinder head cover (2).
Tightening torques

M6 10 Nm
(-) Installing right cylinder-head cover guard
Hold cylinder-head cover guard (1) in position and install bolt (2) until hand-
tight.
Tighten the screw (2).
Tightening torques
M6 10 Nm
Tightening torques
M5 x 12 5 Nm
(-) Installing left crash bar

Set screws (2), (3) and (4) and tighten them in the given sequence.
Tightening torques
M10 x 45 Tightening
sequence: 1. rear
bottom with frame
to engine
55 Nm
M8 x 30 Tightening
sequence: 2. front
top to frame
19 Nm
M10 x 45 Tightening
sequence: 3. front
bottom to engine
55 Nm
Install bolt (5).
Tightening torques

M8 x 16 19 Nm
(-) Install the right crash bar

Set screws (2), (3) and (4) and tighten them in the given sequence.
Tightening torques
M10 x 45 Tightening
sequence: 1. rear
bottom with frame
to engine
55 Nm
M8 x 30 Tightening
sequence: 2. front
top to frame
19 Nm
M10 x 45 Tightening
sequence: 3. front
bottom to engine
55 Nm
Install bolt (5).
Tightening torques
M8 x 16 19 Nm

Follow-up work

77 12 015 Install cylinder head cover

+ 77 12 515
Option 719OA
HP Milled partsOA
Preparatory work
Installing slip pads
Core activity
(-) Removing right cylinder-head cover

oil.
Remove screws (1).
Clean the sealing surfaces.

Install seal (2).


Install screws (2).
Tightening torques
M6 10 Nm

Install screws (2).
Tightening torques
M6 10 Nm
(-) Removing left cylinder head cover

oil.
Remove screws (1).

Clean the sealing surfaces.

Install seal (2).

Install screws (2).
Tightening torques

M6 10 Nm

Install screws (2).
Tightening torques
M6 10 Nm
Follow-up work

77 14 002 Installing enduro engine guard

+ 77 14 661
0456 - Style HPOE
Enduro engine guardOA
Preparatory work
Core activity
(-) Preparing enduro engine guard
Install rubber grommets (1) in holes in enduro engine guard (2).

Install shouldered bushings (3) in rubber grommets (1).
(-) Mounting retaining plate on enduro engine guard
Secure retaining plate (1) to enduro engine guard (2) with screws (3),
washers (4) and nuts (5) and tighten the fasteners until hand-tight.
(-) Remove the right plain-bearing pin


(-) Preassembling Enduro engine guard
Hold the Enduro engine guard (1) in position.

(-) Installing new right plain-bearing pin
Install new plain-bearing pins (1) through holders (2) from the inboard side.
(-) Installing pipe clamp with retaining plate on frame tube
Bend open pipe clamp (1), position the clamp curved side to the front at
frame tube (2) and squeeze them together.
From the front, seat the flat of pipe clamp (1) against retaining plate (3).
Slip screw (4) through the holes in pipe clamp (1) and retaining plate (3)
from front to rear and install washer (5) and nut (6).
Tightening torques
Pipe clamp with retaining plate to frame tube
M6 x 16 8 Nm
(-) Installing Enduro engine guard
Tighten screws (1).
Tightening torques
Enduro engine guard to bracket
M6 x 25 8 Nm
Counter-hold nuts (2) and tighten screws (3).
Tightening torques
Enduro engine guard to retaining plate

M6 x 16 8 Nm
Follow-up work

77 14 006 Installing the radiator protection

+ 77 14 506
Core activity
(-) Installing the left radiator protection
Remove screws (1).
Lift bottom end of air duct (1).

Feed in radiator protection grill (2) from the bottom until retaining lugs (3) are
seated in the openings of air duct (4).
Install screws (1).
(-) Installing the right radiator protection
Remove screws (1).

Lift bottom end of air duct (1).

Feed in radiator protection grill (2) from the bottom until retaining lugs (3) are
seated in the openings of air duct (4).
Install screws (1).

77 15 000 Install cover for rear axle

+ 77 15 500
Core activity
(-) Install cover for rear axle Machined
Remove protective film of cover for rear axle Machined.

Apply screw locking agent in both threaded holes of the threaded rod (1).
Screw in threaded rod (1) with cover for rear axle Machined on right (2)
hand-tight, thereby bracing on mounting flats (arrow) where required.
Fit plastic ring (3) on cover (2).
Insert cover for right rear axle Machined (1) into rear axle and install in axle
tube.
Connect cover for left rear axle Machined (1) together with plastic ring (2),
expanding spinner (3) and the limit position for expanding spinner (4).
Insert cover for left rear axle Machined (1) in rear axle and screw to
threaded rod (2) hand-tight.

(-) Cover for rear axle Machined
Tighten the cover for rear axle Machined on the right (1) and left (2).
Tightening torques
Cover for rear axle Machined
Tightening
sequence: 1.
10 Nm
Tightening
sequence: 2.
15 Nm
Follow-up work

77 15 002 Install adjustable gearshift lever

+ 77 15 502
Core activity

Disengage gearshift lever (4).
Remove washer (5).
Disengage ball end complete with selector rod (1) from gearshift lever (2).
(-) Installing adjustable gearshift lever
Secure ball studs together with gearshift rod (1) to gearshift lever (2).
Tightening torques
M8 19 Nm
ATTENTION
Clean shouldered bushing (3) and gearshift lever (4).

Hold gearshift lever (4) in position with washer (5) and shouldered bushing
(3).
Tightening torques
M8 x 25 19 Nm
Follow-up work

77 22 003 Installing both handlebar levers

+ 77 22 505
ATTENTION
Preparatory work
Core activity
Remove the nut (1).

Remove screw (2) and lay it safely aside (subsequently needed for
reassembly).
Pull out the lever unit (3), noting the rubber sleeve (4).
Remove sleeve (1) and lay it safely aside (subsequently needed for
reassembly).
Remove lever mount with pushrod (2) and spring (3), pushrod (2) and spring
(3) (will be re-used).
(-) Installing milled brake lever

Lubricant
Teflon spray 83 23 0 154 884
Lubricate bolt (1).
Lubricant
Teflon spray 83 23 0 154 884

Install bolt (1) and nut (6).
Tightening torques
holding the bolt
7 Nm
Adjustment of milled brake lever
WARNING
Adjusting the handbrake lever while riding
Risk of accident
Do not attempt to adjust the handbrake lever unless the motorcycle is at a
standstill.
At adjustment lever (1), the distance between brake lever (2) and handlebar
grip (3) can be adjusted.
Remove the nut (1).

reassembly).
reassembly).
(-) Installing milled clutch lever

Lubricant
Teflon spray 83 23 0 154 884
Lubricate bolt (1).
Lubricant
Teflon spray 83 23 0 154 884

Tightening torques
(mechanical)
the nut, counter-
holding the bolt
7 Nm
Adjustment of milled clutch lever
WARNING
Adjusting the clutch lever while riding
Risk of accident
Adjust the clutch lever only when the motorcycle is at a standstill.
At adjustment lever (1), the distance between clutch lever (2) and handlebar
Follow-up work

77 22 008 Installing lid for expansion tank

+ 77 22 513
ATTENTION
Material damage
rubber components.
Core activity
(-) Removing cover for clutch expansion tank
Remove screws (1).

Remove gaiter (3).
(-) Installing lid for clutch expansion tank
Turn the handlebars to a position in which the clutch fluid reservoir is

horizontal.
lint-free cloth.
Install screws (3).
(-) Removing lid for brake expansion tank
Remove screws (1).

Remove gaiter (3).

(-) Installing lid for brake expansion tank
ATTENTION
Component damage
-fluid reservoir.

horizontal.
lint-free cloth.
Install screws (3).
Tightening torques
Cap to reservoir
M4 x 16 2.5 Nm
Follow-up work

77 22 012 Installing brake lever

+ 77 22 618
Brake lever, milledOA
ATTENTION
Preparatory work
Core activity
Remove the nut (1).

reassembly).
reassembly).
(-) Installing milled brake lever

Lubricant
Teflon spray 83 23 0 154 884

Lubricate bolt (1).
Lubricant
Teflon spray 83 23 0 154 884

Tightening torques
holding the bolt
7 Nm
Adjustment of milled brake lever
WARNING
Adjusting the handbrake lever while riding
Risk of accident
Do not attempt to adjust the handbrake lever unless the motorcycle is at a
standstill.
At adjustment lever (1), the distance between brake lever (2) and handlebar
Follow-up work


77 22 013 Installing clutch lever

+ 77 22 619
Clutch lever, milledOA
ATTENTION
Malfunction in clutch system
Preparatory work
Core activity
Remove the nut (1).

reassembly).
reassembly).
(-) Installing milled clutch lever

Lubricant
Teflon spray 83 23 0 154 884

Lubricate bolt (1).
Lubricant
Teflon spray 83 23 0 154 884

Tightening torques
holding the bolt
7 Nm
Adjustment of milled clutch lever
WARNING
Adjusting the clutch lever while riding
Risk of accident
Adjust the clutch lever only when the motorcycle is at a standstill.
At adjustment lever (1), the distance between clutch lever (2) and handlebar
Follow-up work


77 22 028 Install the mirror on the left and right

+ 77 22 528
Core activity
(-) Removing both mirrors
Push back cover (1).

Turn lock nut (2) clockwise to slacken.
Remove left mirror (3).
Remove the left/right adapter (4) and washer (5) ( save the washer (5), it
will be reused.).
Push back cover (1).

Turn lock nut (2) clockwise to slacken.
Remove right mirror (3).
Remove the left/right adapter (4) and washer (5) ( save the washer (5), it
will be reused.).
(-) Installing both mirrors
Insert screw (1) with washers (2) and bush (3) in left mirror (4).
Fit the original washer (5) and mirror (4) with the previously used mounting
parts.
Install bolt (1).
Tightening torques
M10 x 50 25 Nm

Install bolt (2).
Tightening torques
Cover cap to mirror
M3 x 5 1 Nm

Insert screw (1) with washers (2) and bush (3) in right mirror (4).
Fit the original washer (5) and mirror (4) with the previously used mounting
parts.
Install bolt (1).
Tightening torques
M10 x 50 25 Nm

Install bolt (2).
Tightening torques
Cover cap to mirror
M3 x 5 1 Nm
Follow-up work

77 22 185 Installing heated handlebar grips

+ 77 22 795
Heated gripsOA
Preparatory work
Core activity
throttle twistgrip.
Remove screw (1).

Disconnect 2-pin plug (1) with blanking cap.

Remove screw (3).

Remove screw (1).


Install screw (1).
Tightening torques
M3.5 x 30 2 Nm

ATTENTION
Component damage
Install screw (3).
Tightening torques


ATTENTION
Component damage
Install screw (2).
Tightening torques
(-) Removing left grip unit
Remove rubber bands (1).

Slightly pull back rubber grip (1).

Remove bolt (2).
Unlock tabs (arrows).

Remove trim (1).
Unlock lug (arrow).

Disconnect the connector (2) for DVDC.
Turn the handlebars all the way to left.

Pull off grip unit (1).
Lay line (2) to the side.
Remove 2-pin plug (1) with the blanking cap.


(-) Installing left handlebar grip
Install new handlebar grip (1), and at the same time insert plug (2) for the
heated grip.
Remove the blanking cap and connect plug (1) for the heated grip.
(-) Install the left grip unit

Slide on grip unit (1), route line (2).

Connect connector (1) for the heated grip.

The lug (arrow) engages audibly.
Connect connector (2) for DVDC.
Install trim (1).

Check that the tabs (arrows) are correctly seated.

Install bolt (2).
Tightening torques
M3.5 x 30 1 Nm
Connect connector (2) for clutch switch.

Install rubber straps (1).

Follow-up work
Performing software update with the BMW Motorrad diagnosis system

77 25 008 Installing frame guard

+ 77 25 508
Core activity
(-) Installing left frame guard
Clean contact surface.

ATTENTION
The locks (arrow) (2) of the rubber bands are inside, or below.
(-) Installing right frame guard
Clean contact surface.

ATTENTION
The locks (arrow) (2) of the rubber bands are inside, or below.
Follow-up work

77 25 011 Installing front footrests

+ 77 25 777
FootrestOA
Core activity
Remove lock washer (1) and lay it safely aside (subsequently needed for
reassembly).
Remove the bolt (2) and lay it safely aside (subsequently needed for
reassembly ).
Remove footrest (3) with spring (4) and bush (5).
(-) Install the front left footrest
Lubricate the bearing positions and bolts (1).
Lubricant
Connect the new spring (2) on footrest (3).

Insert footrest (3) with spring (2) in footrest bracket (4).
Install bolts (1).
(-) Removing front right footrest
Remove lock washer (1) and lay it safely aside (subsequently needed for
reassembly).
Remove the bolt (2) and lay it safely aside (subsequently needed for
reassembly ).
Remove footrest (3) with spring (4) and bush (5).
(-) Installing front right footrest
Lubricate the bearing positions and bolts (1).

Lubricant
Connect the new spring (2) on footrest (3).

Insert footrest (3) with spring (2) in footrest bracket (4).
Install bolts (1).
Follow-up work

77 25 015 Installing adjustable front footrests

+ 77 25 781
FootrestOA
Core activity
Remove locking washer (1) and lay it safely aside (subsequently needed
for reassembly).
Remove pin (2) and lay it safely aside (subsequently needed for
reassembly).
Remove footrest (3) with spring (4) and lay spring (4) safely aside
(subsequently needed for reassembly).
(-) Installing adjustable left front footrest
Lubricate bearing seats and pin (1).
Lubricant
Push spring (2) on to footrest (3).

Install footrest (3) with spring (2) in footrest bracket (4).
Install pin (1).
(-) Adjusting footrest height at adjustable left front footrest
Check
Adjust the footrest height of the adjustable front footrest to suit rider needs
and preferences.
Result:
Footrest is not positioned at the desired height.
Measure:
Removing adjustable left front footrest
Remove pin (1).
Remove adjustable front footrest (3) with spring (2) from footrest bracket (4).

Adjusting footrest height at adjustable left front footrest

Removing carrier for footrest
Requirement
Footrest is clamped in bench vice.
Remove screws (1).

Remove carrier for footrest (3).
Remove screw (1) and bushing (2).

Clean the threads.
Reinstall screw (1) with bushing (2) at the desired height (arrows).
Tightening torques
Mount to carrier
M8 x 25 20 Nm
encapsulated)
Install the carrier for footrest

Hold carrier for footrest (1) in position.
Install clamping block (2).
Seat carrier for footrest (1) against the stop (arrow) of clamping block (2)
and tighten screws (3).
Tightening torques

M8 x 20 20 Nm
Installing adjustable left front footrest

Lubricant

Install footrest (3) with spring (2) in footrest bracket (4).
Install pin (1).
Result:
Measure:
Repeat the procedure as described above.
Remove locking washer (1) and lay it safely aside (subsequently needed
for reassembly).
Remove pin (2) and lay it safely aside (subsequently needed for
reassembly).
Remove footrest (3) with spring (4) and lay spring (4) safely aside
(subsequently needed for reassembly).
(-) Installing adjustable right front footrest
Lubricant

Install adjustable front footrest (3) with spring (2) in footrest bracket (4).
Install pin (1).
(-) Adjusting footrest height at adjustable right front footrest
Check
Adjust the footrest height of the adjustable front footrest to suit rider needs
and preferences.
Result:
Measure:
Removing adjustable right front footrest
Remove pin (1).
Remove adjustable front footrest (3) with spring (2) from footrest bracket (4).
Adjusting footrest height at adjustable right front footrest

Removing carrier for footrest
Requirement
Footrest is clamped in bench vice.
Remove screws (1).

Remove carrier for footrest (3).

Remove screw (1) and bushing (2).
Clean the threads.
Reinstall screw (1) with bushing (2) at the desired height (arrows).
Tightening torques
Mount to carrier
M8 x 25 20 Nm
encapsulated)
Install the carrier for footrest

Install carrier for footrest (1).
Install clamping block (2).
Seat carrier for footrest (1) against the stop (arrow) of clamping block (2)
and tighten screws (3).
Tightening torques
M8 x 20 20 Nm
Installing adjustable right front footrest
Lubricant

Install adjustable front footrest (3) with spring (2) in footrest bracket (4).
Install pin (1).
Result:

Measure:
Repeat the procedure as described above.
Follow-up work

77 25 021 Installing footrest bracket for passenger

+ 77 25 520
Core activity
(-) Removing left footrest

Remove left footrest (3).
(-) Replacing left footrest bracket
Remove screws (1).

Clean the threads.
Tightening torques
encapsulated)
(-) Installing left footrest
Lubricate pin (2).
Lubricant

(-) Remove the right footrest


(-) Replacing right footrest bracket
Remove screws (1).

Clean the threads.
Tightening torques
encapsulated)
(-) Installing right footrest
Lubricate pin (2).
Lubricant

(-) Final check of work performed
Check the following:

The work as performed achieved the intended purpose.
All reservoirs and containers have been filled and all fluids and lubricants
are at their correct levels.
All threaded fasteners released beforehand have been correctly retightened.
The fuel system is free of leaks.
The lights and signalling equipment are fully operational and the vehicle is
roadworthy.
The brake pads of the front and rear brakes are bedded against the brake
discs.
Function test, engine start suppression

Check
Set kill switch to centred position.

Select neutral.
Switch on the ignition.
Neutral telltale light "N" lights up.
Select a gear.
Neutral indicator light "N" goes out.
Press the starter button.
Starter does not operate.
Pull the clutch lever.
Press the starter button.

Starter does not operate.
Retract the side stand.
Press the starter button without releasing the clutch lever.

Starter operates.
Result:
Not all test steps completed successfully.
Measure:
Check the appropriate parts with the BMW Motorrad diagnostic system.

77 25 024 Install gearshift lever and foot brake lever

+ 77 25 524
Core activity
(-) Installing step piece for gearshift lever
Remove bolt (1).

Install step piece (2) and align in desired position.
Install bolt (1).
Tightening torques
M6 x 20 10 Nm

Release gearshift lever (4).

Release gearshift rod (2) from ball stud (3).
(-) Installing gearshift lever
Fasten gearshift rod (1) on ball stud (2).


ATTENTION
Hold gearshift lever (1) in position with shouldered bushing (2) and thrust
washer (3).
Install bolt (4) and washer (5).
Tightening torques
M8 x 25 19 Nm
(-) Installing step piece for footbrake lever
Remove bolt (1).

Install step piece (2) in desired bore hole and align.
Install bolt (1).
Tightening torques
M6 x 20 10 Nm

Remove pin (2).
Remove footrest (3) with spring (4).

(-) Removing footbrake lever
Remove cotter pin (1).

Disengage spring (1).
Remove bolt (1) with washer (2).

Remove footbrake lever (4) and thrust washer (5).
(-) Installing footbrake lever
ATTENTION
Clean footbrake lever (1) and shouldered bushing (2).

Hold footbrake lever (1) in position with shouldered bushing (2) and thrust
washer (3).
Install bolt (4) with washer (5).
Tightening torques
M8 x 25 19 Nm
Engage spring (1).
Technical data
footbrake
lever

Install bolt (2) and washer (3).
Install new cotter pin (4).
Tightening torques
M8 17 Nm

(-) Installing front right footrest
Lubricate pin (2).
Lubricant
Insert spring (4) into footrest (3).

Install pin (2).
Follow-up work

77 31 018 Installing cover for grab-handle mounting hole

+ 77 31 755
Trims for holes for grab handlesOA
Preparatory work
Removing rear seat
Core activity
(-) Installing covers for holes for grab handles
NOTICE
The covers are marked “L” (for left) and “R” (for right) on the underside and
must be installed accordingly.
Clean the threads.

Insert front covers (1) and rear covers (2) into tail cover (3).
Apply thread-locking compound to screws (4) and (5).
Install long screws (4).

Install screws (5).
Tightening torques
encapsulated)
encapsulated)
Follow-up work
Installing passenger seat

77 31 026 Fix label set

+ 77 31 526
Sticker set GSOA
ATTENTION
Ensure that driving or cleaning are carried out outside the drying period
Labels are damaged or loose
Allow labels to dry for 24 hours.
Do not drive this vehicle before this drying period.
ATTENTION
Damage caused by high water pressure of high pressure cleaners
Labels are damaged or loose
Do not clean labels with high pressure or steam jet cleaning equipment
Use high pressure or steam jet cleaning equipment carefully.
NOTICE
This is an exemplary description for labelling decor.
The alignment and placement on the vehicle is also shown in the figures.
The foils are to be positioned in such a way that there is an even distance to
component edges around it.
The rounded area of the foils should be aligned with the component rounded
area.
Core activity
(-) Work preparation
Dilute application fluid concentrate with tap water and fill in a spray bottle.
Technical data
Quantity of water for 5l
application fluid
Pad the edges of the doctor blade, e.g. by sticking on a piece of microfibre
cloth.
Clean the bonding surface on the vehicle with a cleaning cloth.
(-) Affixing sticker
Wet down the bonding surfaces on the vehicle with the diluted application
fluid.
Labels are affixed when wet.
Pull the backing film off the front half of the label and wet with the diluted
application fluid.
Trim panel label

Case label
Labels for wheels
In the case of spoked wheels, the labels are to be affixed on the rim base.
Align label on the front edge (arrow) and press it on.
Remove the rest of the backing film and wet with diluted application fluid.
Align label along the edge (arrow) and affix it.
Press the lower part with doctor blade paying attention to creases on the
edge (arrow).
Brush on water towards the edge with a doctor blade until the label is
properly affixed on the entire surface.

Press down the upper part with the doctor blade from the centre to the edge.
In order to remove all the folds from the foil completely, selectively use the
Teflon side of the doctor blade.
Affix the rest of the labels in the same way.
Follow-up work

77 31 027 Attaching GS Trophy sticker set

+ 77 31 510
Core activity
(-) Affix label for rear frame
Pull off backing film

Align label along the top edge (arrow) and glue it.
Press down label with the doctor blade from the centre towards right and
left.
Affix label on the opposite side in the same way.
(-) Affix label for the top front-wheel cover
Pull off backing film.

Align label on the front edges (arrow) and glue in the front.
Align label on the rear edges (arrow) and glue it completely.
Press down label with the doctor blade starting from the centre towards the
front and the back.

(-) Affix label for fairing side panel
Pull off backing film.

Align label on the edges (arrow) and glue it.
Press down label with the doctor blade starting from the centre towards the
front and the back.
(-) Affix label for fuel tank

Align label on the front edge (arrow) and glue it.
Align label in a stretched state at the rear end (arrow) and press down.

There is a cavity between both sides (arrow).
Press down front edge (arrow) with doctor blade.
Press down label in semicircular movements starting from the back towards
the front with the doctor blade.
Label has strong creases at a defined point and can no longer be pressed
lightly. Then heat up the label with hot air blower in light upward and
downward movements until creases disappear visibly.

Allow label to cool down, then press with fingers starting from the front tip to
the centre and to the back.
Press label with fingers starting from the centre and following the kink in the
fuel tank, upwards and downwards.
Finally, press down crease-free glued label with doctor blade once again.
(-) Affix label on country flag

Curl up label on the sides and align in centre to the tip (arrow) of the top
front-wheel cover. First glue label in the centre and then roll out sides and
glue.
left.
(-) Affix windscreen label
NOTICE
The vehicle is not allowed in street traffic with in-built labels for windscreen.
Use labels for windscreen only on specified roads or with off-road drives.

Removing windscreen
Remove screws (1).

Remove screws (1).

Remove covers (2) and bracket (3).
Remove grommets (1) from windscreen (2) .
Loosen one half of the label from the backing film and fold down.

Cut out an approximately 4 cm wide strip in the middle of the backing film.
Firstly, affix remaining backing film again on the label, to dispose off the cut-
out strip.
Put windshield on a soft, flat surface.

Fold open label and affix in the centre of the windscreen, aligning on the
marked points (arrow).
Press down label in the centre completely with the doctor blade.
Fold open one side of the label and remove backing film.

Stretch the label tight with thumb and index finger, holding up the
windscreen with middle and ring fingers.
Press down label in semicircular movements starting from the centre with
the doctor blade, holding the label tight.
First press down bottom, large surface (1) to avoid formation of creases.
Then hold the label on top (2) and press down with doctor blade.
Process other half of the label in the same way.

Fold down label and remove backing film.

Stretch the label tight with thumb and index finger, holding up the
windscreen with middle and ring fingers.
Press down label in semicircular movements with the doctor blade. First
press down bottom surface. Keep label taut.
Then press down upper part of the label.
In the case of strong creases, heat up the label with hot air blower and then
allow to cool down again.
Press down label completely with the doctor blade.
Heat up the label on the holes of the screw connection with hot air blower,
until creases visibly disappear.

Press down areas of the holes completely with the doctor blade.
To ensure a durable bonding, the foil must be completely free of creases

around the holes.
Then cut out holes with knife.
Install grommets (1) in windscreen (2).

Position bracket (1) and covers (2) on windscreen (3).

Install screws (4) (without collar).
Tightening torques

Install screws (1).
Tightening torques
(-) Affix label for helmet

Glue label on the desired position.
left.
Follow-up work

77 32 001 Installing hand protector, left and right

+ 77 32 500
Core activity
(-) Removing left mirror
Remove bolt (1).

Remove bolt (1).

Remove screw (1).

Remove bushing (2).
(-) Removing left hand protector

Remove screw (1).

Remove bracket (2).

Install screw (4).
Tightening torques
M5 x 14.5 2 Nm
(-) Installing left hand protector


position.
Tightening torques
M10 x 50 38 Nm
(-) Installing left mirror
or
or
Position mirror (2) with contact discs (3) and align it.
Install bolt (1).
Tightening torques
M10 x 50 25 Nm
or
or

Install bolt (1).
Tightening torques
Cover cap to mirror
M3 x 5 1 Nm
(-) Removing right mirror
Remove bolt (1).


Remove bolt (1).

Remove mirror (2).
(-) Remove the right handlebar weight
Remove screw (1).

Remove bushing (2).
(-) Removing right hand protector
Remove screw (1).

Remove bracket (2).

Install screw (4).
Tightening torques
M5 x 14.5 2 Nm
(-) Installing right hand protector
(-) Installing right handlebar weight

position.
Tightening torques
M10 x 50 38 Nm
(-) Installing right mirror

or
or
Set mirror (2) with discs (3).

Install bolt (1).
Tightening torques
M10 x 50 25 Nm
or
or

Install bolt (1).
Tightening torques
Cover cap to mirror
M3 x 5 1 Nm
Follow-up work

77 33 001 Installing slipstream deflectors

+ 77 33 796
Wind deflectorOA
Core activity
(-) Removing slipstream deflector, left
Remove screws (1).

Remove slipstream deflector (2) with grommets (3) and bushings (4)
(grommets<(3) and bushings (4) are subsequently needed for
reassembly).
(-) Installing left tinted slipstream deflector
Insert grommets (3) and bushings (4) into slipstream deflector (2).
Install slipstream deflector (2) with screws (1).
Tightening torques
M5 x 20 2 Nm
(-) Removing right slipstream deflector
Remove screws (1).

Remove slipstream deflector (2) with grommets (3) and bushings (4)
(grommets<(3) and bushings (4) are subsequently needed for
reassembly).
(-) Installing right tinted slipstream deflector

Tightening torques
M5 x 20 2 Nm
Follow-up work

77 33 025 Installing high windscreen

+ 77 33 525
Core activity
Remove screws (1).

Remove screws (1).


Position new holder (1) and new trims (2) on the new windscreen (3).
Tightening torques

Install screws (1).
Tightening torques
Follow-up work

77 33 026 Installing low windscreen

+ 77 33 526
Windscreen, tintedOA
Core activity
Remove screws (1).

Remove screws (1).


Position new holder (1) and new trims (2) on new windscreen (3).
Tightening torques

Install screws (1).
Tightening torques
Follow-up work

77 34 150 Installing luggage plate

+ 77 34 650
Luggage plateOA
Preparatory work
Removing front seat
Removing rear seat
Removing screws for rear carrier
Removing screws for case carrier
Core activity
(-) Prepare lid for luggage plate
Slightly over-tension spring (1) so that spring (1) sits beneath the lugs
(arrows) of adapter (2).
Install spring adapter (1) with the spring in cap (2). Make sure that the lug
(arrow) is toward the open side (arrow).
(-) Preparing carrier plate and cover
Peel backing paper off spacer adhesive strips (1).

Centre spacer adhesive strips (1) on carrier plate (2) and briefly press them
down.
NOTICE
Faces that will be in contact with the adhesive must be dry, clean and free
from dust and grease.
Install flat nuts (3) in carrier plate (2).

Peel backing paper off spacer adhesive strips (1).

Position spacer adhesive strips (1) at the marks (arrows) on the inside of
cover (2) and briefly press them down.
NOTICE
Install damping elements (1) in cover (2).
(-) Install the luggage rack
Position spacing bushings (1) and shouldered bushings (2) on case carrier
(3).
Install short screws (1) at the back with washers (2) in backing plate (3).

Seat backing plate (1) with screws (2) inserted on shouldered bushings (3),
align correctly and tighten screws (2) until hand-tight.
Insert long screws (4) at the front with washers (5) in backing plate (1) and
position the plate on shouldered bushings (3).
Make sure that shouldered bushings (3) are seated correctly.
Tighten short screws (1) and long screws (2) in diagonally opposite
sequence.
Tightening torques
Carrier plate to rear frame
M8 x 35 19 Nm
M8 x 50 19 Nm
Position and install lid for luggage plate in trim

Position lid (1) in trim (2) and let guide pin rest (Arrow) on the recess (Arrow)
in trim (2) .
Set cover (1) with lid (2) opened in position, noting the locating pins
(arrows).
Install screws (3).
Tightening torques
Cover to carrier plate
M5 x 14.5 2 Nm
Close lid (2); lid engages with an audible click.

NOTICE
Insert the ignition key into the seat lock and turn it clockwise so that the lid can
be re-opened.
(-) Stick label to note tyre pressure

NOTICE
Open lid (1).

Pull off protective film and stick appropriate label (2) for tyre pressure in
shown area.
Close cover (1).
Lid engages with an audible click.
Follow-up work

77 41 020 Installing sealing kit for closure unit on aluminium case

+ 77 41 520
Sealing kit for closure unit on aluminium caseOA
Preparatory work
Opening case, removing if necessary
Core activity
(-) Removing closure unit
Requirement
Case lid is open.
Remove screws (1) from the case side where the vent hole (arrow) is
located.
Counter-hold at closure unit (2) and remove closure unit (2).
(-) Removing latching plate
Remove latching plate (1) from closure unit (2).

(-) Removing guide for left closure unit
Remove guide (1) for closure unit (2) from guide pin (3), counter-holding at
guide (4).
(-) Installing guide for left closure unit
Install new guide (1) for closure unit (2) on guide pin (3), counter-holding at
guide (4).
(-) Removing guide for right closure unit
Remove guide (1) for closure unit (2) from guide pin (3), counter-holding at
guide (4).
(-) Installing guide for right closure unit
Install new guide (1) for closure unit (2) on guide pin (3), counter-holding at
guide (4).

(-) Installing latching plate
Install latching plate (1) in closure unit (2).
(-) Installing O-ring
NOTICE
The procedure for replacing the guide for the closure unit applies by analogy
for the other side, if that is where the vent hole is located.
The O-ring seal must always cover the vent hole.
Apply lubricant to O-ring (1) and install O-ring (1) in the groove (arrow) in
guide (2) for the closure unit.
Installation tool
(-) Deburring vent hole
Use a suitable tool to deburr the sealing face of the vent hole (arrow) on the
outside of the case.
(-) Installing closure unit
Hold closure unit (1) in position against case wall (2) from the outside. Make
sure that the O-ring (arrow) covers the vent hole (arrow) and that the bore
holes are aligned with each other.

Counter-hold at closure unit (1).
Install screws (3) from the inside in the side where the vent hole (arrow) is
located. Make sure that the screws do not skew.
Tightening torques
Closure unit to aluminium case
self-tapping screw for plastic 3 Nm
Follow-up work
Closing case, installing if necessary

77 42 138 Installing case carrier for aluminium case

+ 77 42 507
0456 - Style HPOE
Preparatory work
Removing rear seat
Removing front seat
Core activity
(-) Removing left footrest bracket
Remove screws (1) and remove footrest bracket (2) from rear frame (3)
(screws (1) are subsequently needed for reassembly).
(-) Installing left bracket for case carrier with footrest bracket
Clean the threads.

Hold footrest bracket (1) with bracket (2) for case carrier in position on rear
frame (3).
Apply thread-locking compound to screws (4).
Install screws (4).
Tightening torques
encapsulated)
(-) Removing right footrest bracket
Requirement
Silencer is covered by a cloth.
ATTENTION

Component damage
Remove screws (1) and remove footrest bracket (2) from rear frame (3)
(screws (1) are subsequently needed for reassembly).
(-) Installing right bracket for case carrier with footrest bracket
Requirement
Silencer is covered by a cloth.
ATTENTION
Component damage
Clean the threads.

Hold footrest bracket (1) with bracket (2) for case carrier in position on rear
frame (3).
Apply thread-locking compound to screws (4).
Install screws (4).
Tightening torques
encapsulated)
(-) Removing screws for rear carrier

(-) Installing case carrier
Clean the threads.

Hold right case carrier (4) in position.
Tightening torques
encapsulated)
encapsulated)
Clean the threads.

Hold left case carrier (4) in position.
Tightening torques
encapsulated)
encapsulated)

Insert screw (2).
Tightening torques
M8 x 20 19 Nm

Follow-up work

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 44 030 Encode lock barrel

+ 77 44 530
Core activity
(-) Encoding lock barrel
Retainers (1) are installed according to the cut-in depths (arrows) of vehicle
key (2).
Align lock barrel (1) with chamber (2) without pressure spring mount facing
up.
Chamber (3) is not occupied.
Install compression springs (4) in lock barrel (1).
Install retainers (1) in chambers (2).

Protect retainers (1) from falling out and turn lock barrel (3).
Install compression springs (1) in lock barrel (2).

Install retainers (1) in chambers (2).

Install lock plate (3) in last chamber (4).
Insert ignition key (1) in lock barrel (2).

Retainers (3) are pulled in when ignition key (1) is inserted, lock plate (4)
remains protruded.
Check
Check if all retainers (1) were pulled in flush in lock barrel (2).
Result:
All retainers (1) are pulled in flush.

Measure:
Lock barrel completely encoded and can be installed in lock.
Result:

One or more retainers (1) are protruding over lock barrel (2).
Measure:
Pull out ignition key (1) and replace corresponding retainer with matching
encoding.

77 44 046 Installing luggage carrier

+ 77 44 501
0456 - Style HPOE
Preparatory work
Removing rear seat
Removing front seat
Core activity
(-) Removing luggage carrier
Remove screws (1).

Remove screws (2).
Remove luggage carrier (3) and bushings (4).
(-) Installing luggage carrier
Clean the threads.

Install bushings (4).
Place luggage carrier (3) in position.
Engage threads of screws (1) and (2) and tighten.
Tightening torques
encapsulated)
encapsulated)
Follow-up work

77 44 049 Installing lock barrel for aluminium topcase

+ 77 44 504
Lock barrel for topcaseOA
Core activity
(-) Installing lock barrel for aluminium topcase
NOTICE
Adopt the same procedure to install all the lock barrels of this product.

Lubricant
MI-Setral-43 N 83 23 2 152 082
Use the key to insert lock barrel (2) all the way into lock housing (3)
positioning the lock barrel with retainer (4) facing up.
Retainer (4) engages (with an audible click).
Lock barrel (2) is secure in lock housing (3) and cannot be pulled out.
Follow-up work

77 44 051 Installing lock barrel for aluminium case

+ 77 44 506
Lock barrel for caseOA
Core activity
(-) Installing lock barrel for aluminium case
NOTICE
Adopt the same procedure to install all the lock barrels of this product.

Lubricant
MI-Setral-43 N 83 23 2 152 082
Use the key to insert lock barrel (2) all the way into lock housing (3)
positioning the lock barrel with retainer (4) facing up.
Retainer (4) engages (with an audible click).
Lock barrel (2) is secure in lock housing (3) and cannot be pulled out.
Follow-up work

77 44 056 Installing backrest pad for aluminium topcase

+ 77 44 556
Backrest pad for aluminium topcaseOA
Core activity
(-) Peeling backing film off small backrest pad
Peel the strips of backing film (arrows) off small backrest pad (1).
(-) Installing small backrest pad
NOTICE
Seat small backrest pad (1) at bottom edge (2) first, then working upward
along the contour, press lightly into position. Make sure that the small
backrest pad is centred between the two hinges (3).
Fix the small backrest pad in position by pressing it firmly against the
topcase.
(-) Peeling backing film off large backrest pad
Peel the backing film (arrow) off large backrest pad (1).
(-) Installing large backrest pad

NOTICE
Centre large backrest pad (1) between the two hinge mounts (2).
The rivet (arrow) is centred in the recess (arrow).
Fix the large backrest pad in position by pressing it firmly against the
topcase.
Follow-up work

77 45 006 Installing attachment for tank rucksack

+ 77 45 561
Tank bagOA
NOTICE
It is not necessary to remove the attachments before riding the motorcycle
without the tank rucksack fitted.
Preparatory work
Removing rear seat
Removing front seat
Core activity
(-) Removing screw for front attachment
Remove screw (1).
(-) Installing front attachment
Position front attachment (1) on centre trim panel (2) and secure with new
screw (3).
Tightening torques
Front attachment for tank rucksack to frame
M6 x 28 8 Nm
(-) Removing screws for rear connection
Remove screws (1) from seat adjustment base plate (2) and frame (3).

(-) Installing rear attachment
Position rear connection (1) and use new screws (2) to secure on base plate
for seat adjuster (3) on frame (4).
Follow-up work
Installing rider’s seat

77 49 002 Fit adapter plate on case holder

+ 77 49 507
Core activity
(-) Installing left adapter plate
Insert screws (1) with washers (2) in the guiding grooves (3) in the adapter
plate.
Position adapter plate (4) on case carrier (5).
Position clamping blocks (6) from the rear on the case carrier (5) and install
screws (1) into the clamping blocks (6) equally hand-tight.
Insert screws (1) with long washer (7) in guiding groove (3) in the adapter
plate.
Position long clamping block (8) from the rear on the case carrier (5) and
install screws (1) into the long clamping block (8) hand-tight.
(-) Tightening left adapter plate
NOTICE
Before tightening the adapter plate, check if the required height has been
achieved.
Fasten the adapter plate as low as possible due to the centre of gravity of the
vehicle, vehicle height and driving conditions can however require a different
position.
Align adapter plate (1) to the centre of the case carrier (2).
Tighten all screws (3) equally.
Tightening torques
M6 x 40 8 Nm
(-) Attaching the adhesive tape in the bracket for the adapter plate
NOTICE
Allow the adhesive tape to rest on the bracket of the adapter plate (1) and
mark the contour of the bracket on it.
Cut the adhesive tape into 3 strips.
Pull off the protective film and stick on the strips of adhesive tape (2), (3)
and (4).

(-) Attaching bracket for right adapter plate to case carrier
Attach bracket (1) for the adapter plate centrally between the lugs (Arrows)
on the case carrier (2).
(-) Installing right adapter plate
Position adapter plate (1) on bracket (2) for the adapter plate.
Insert screws (3) with washers (4) in guiding grooves (5) on adapter plate
(1).
Position clamping blocks (6) from the rear on the bracket (2) for the adapter
plate and install screws (1) equally hand-tight in the clamping blocks (6).
Insert screws (3) with washers (4) in guiding groove (5) on the adapter plate
(1).
Position clamping block (6) from the rear on the case carrier (7) and install
screws (3) into the clamping blocks (6) equally hand-tight.
Insert screws (3) with long washer (8) in guiding groove (5) on adapter plate
(1).

Position long clamping block (9) from the rear on the case carrier (7) and
install screws (3) into the long clamping block (8) hand-tight. While doing so,
please note that the clamping block (8) is installed over the lug (Arrow).
(-) Tightening right adapter plate
NOTICE
Before tightening the adapter plate, check if the required height has been
achieved.
Fasten the adapter plate as low as possible due to the centre of gravity of the
vehicle, vehicle height and driving conditions can however require a different
position.
Align bracket (1) for the adapter plate centrally to the lugs (Arrows).
Tighten all screws (2) equally.
Tightening torques
M6 x 40 8 Nm
(-) Fix reflectors on the left and right adapter plate (only for US
versions)
Install reflector (1) with bolt (2), washer (3) and nut (4) in the middle guiding
groove (arrow).
Tighten reflector (1) in the lowest position.
Secure reflector on the left side in the same way.

77 51 001 Installing LED auxiliary headlights

+ 77 51 502
NOTICE
The LED auxiliary headlights have an overheat cutout. The headlights
automatically reduce their brightness if a certain temperature is reached;
under extreme circumstances the headlights can even switch themselves off.
The headlights return to full brightness once they have cooled down
sufficiently.
Preparatory work
Removing front seat
Core activity
(-) Installing switch for LED auxiliary headlights
Remove bolt (1).

Remove bolt (1).



Remove screw (1).
Remove bushing (2).
Removing clamping block

Remove screws (1).
Remove clamping block (2) from handlebar fitting (3).

Installing clamping block for handlebar fitting for clutch

Hold clamping block (1) in position at handlebar fitting (2).
Position handlebar fitting (2) at the marks (arrow).
Tighten screws (3).
Tightening torques
M6 x 30 Tightening
sequence: tighten
8 Nm


position.
Tightening torques
M10 x 50 38 Nm
Installing mirrors
or
or
Position mirror (2) with contact discs (3).

Install bolt (1).
Tightening torques
M10 x 50 25 Nm
or
or

Install bolt (1).
Tightening torques
Cover cap to mirror
M3 x 5 1 Nm
Installing switch for LED auxiliary headlights

Hold switch for LED auxiliary headlights (1) in position at clamping block (2).
Install screw (3).
Tightening torques
Additional switch to clamping block
M5 x 12 2 Nm
Installing access line for switch for LED additional headlight
Route line (1) down into position and secure it in the holders (arrows).

Route line (1) forward.

Remove original cable straps (arrows) and secure line (1) on front panel
carrier (2) using cable straps (arrows) and secure the earlier released lines
at the same place once again, if required.
(-) Installing connecting line for LED auxiliary headlight
Route connecting line (1) for the LED auxiliary headlight down behind wiring
harness (2) at both sides along frame tube (3).
At line branch (4), work both plugs with Y-cable out underneath front panel
carrier (5) and behind radiator bracket (6).
Secure connecting line (1) for the LED auxiliary headlights with cable ties
(arrows).
(-) Connecting switch for LED auxiliary headlight and LED

auxiliary headlight
Installing holder for cable tie on front cover

Install holder (1) for cable tie on front panel (2).
Disconnecting plug of daytime riding light

Disconnect plug (1) of daytime riding light (2).
Remove cable (3) from the holder (arrow).
Work plug (1) with cable (3) toward the outside.
Connect plug (1) for the connecting line for the LED auxiliary headlight to
plug (2) for the daytime riding light.
Connect plug (3) for the switch for the LED auxiliary headlights to plug (4) on
the line branch.
Secure plug connection (1), (2) and connecting line with a cable tie (arrow)
to fork shield (5).
Secure plug (3), (4) and line branch with cable tie (arrow) to front panel (6).
Install holder (7) on fork shield (5).
Insert connecting line (8) for LED auxiliary headlight into holder (7).
Secure connecting line (8) for the LED auxiliary headlight with a cable tie
(arrow) to mount for tank guard (9).
Remove protective cap (10) from plug (11) for the daytime riding light and
work the plug toward the inside.
Connecting plug for the daytime riding light
Install cable (3) in holder (4) and in the holder (arrow).
Connect plug (1) to daytime riding light (2).

(-) Installing left intake air pipe
Work intake air pipe (1) into position from in front.

(-) Installing top left front-wheel cover
Position left front-wheel cover (1), thereby paying attention to the lug
(arrow) .
Install screws (2).
Install bolt (3).
Tightening torques
M5 x 14.5 2 Nm
(-) Installing left slipstream deflector
(-) Installing left air guide
Fit air duct (1) from the rear on lug (arrow).

Install screws (shorter collar) (1).

Install expanding rivet (2).
(-) Installing left side panel
Position fairing side panel (1).


Install screws (longer collar) (2).
Install screw (1) (long collar).

(-) Installing left tank guard
Clean the threads.

Position tank protection bar (3).
Install bolt (2).
Tightening torques
M8 x 40 19 Nm
Install bolt (1).
Tightening torques
M8 x 16 19 Nm
(-) Installing fuel-tank cover
Position tank cover (1) from top, thereby attaching the lugs (arrow) to front-
wheel cover (2).

Close storage compartment cover (1).


Install bolt (2).
Tightening torques
M6 x 25 8 Nm
(-) Installing front seat
Seat front seat (1) firmly in bracket (2).

Firmly press down on front seat (1) at the rear.
Front seat (1) engages with an audible click.
(-) Installing left LED auxiliary headlight
Position LED additional headlight (1) on holder (2) an tank protection bar.
Install LED additional headlight (1) with bolt (3) and nut (4), do not tighten
yet.
(-) Installing right LED auxiliary headlight
Position LED additional headlight (1) on holder (2) on tank protection bar.

Install LED additional headlight (1) with bolt (3) and nut (4), do not tighten
yet.
(-) Connecting the LED additional headlight and routing the line
Connect connector (1) for the LED additional headlight.

Install holder (2) in tank protection bar (3).
Install holder (1) in engine protection bar (2).

Connect connector (1) for the LED additional headlight.

Install holder (2) in tank protection bar (3).
Install holder (1) in engine protection bar (2).


Follow-up work

77 51 004 Installing headlight guard

+ 77 51 653
Headlight guardOA
0192 - LED headlightOE
77 51 751 Additional work for installing headlight guard (with LED headlight)
NOTICE
Use the headlight guard only when off-roading. Riding on public roads with the
headlight guard fitted to the motorcycle is prohibited.
Preparatory work
Removing front seat
Core activity
Remove bolt (1).

Pull wheel trim (2) off retaining lug (Arrow).
Pull trim (3) down at removal of the headlight.

Remove retaining clip (1) with suitable pliers.

Remove contact disc (2).
(-) Removing rubber grommets
Remove rubber grommets (1).
(-) Installing rubber grommets in bottom holders
Lightly lubricate rubber grommets (1) and install in bottom bracket (2).
(-) Installing holder

Install bracket (1) with recess (arrow) and bracket (2) on front panel carrier
(3).
(-) Installing headlight
Hold headlight (3) in position.

Set disc (2).
Set and hold disc (1).

Push headlight (2) down slightly.
Install retaining clip (3) with suitable pliers.
Connect connector (1) for the headlight.
Connect connector (2) for the daytime running light.

Secure the cable (1) in the holder (arrow).

Install screws (1) and contact discs (2).
Tightening torques
M6 x 20 5 Nm
(-) Install the cockpit fairing
Set cockpit fairings (2).

Install screws (1).
(arrow) .
Install screws (2).
Install bolt (3).
Tightening torques
M5 x 14.5 2 Nm

(-) Securing left side panel


wheel cover (2).



Install bolt (2).
Tightening torques
M6 x 25 8 Nm

(-) Installing brackets on cockpit fairing
Position bracket (1) on cockpit fairing (2).

Install screws with collar (3) and tighten until hand-tight.

(-) Removing screws
Remove screws (1).
Remove screws (1).
(-) Installing headlight guard
Hold headlight guard (1) in position.

Install screws (2), counter-holding in each case at hexagon (3).
Tightening torques
Spacer studs to headlight guard
M6 x 10 2.5 Nm
Centre headlight guard (1).
Tighten screws (1) of the brackets.

Tightening torques
Bracket to cockpit fairing
M5 x 17.5 2 Nm
Follow-up work

77 51 006 Installing daytime riding light

+ 77 51 655
Preparatory work
Removing front seat
Core activity
(-) Removing finisher
Remove screws (1).
Push back the locators (arrows).

Disengage cover (1) from retaining pins (2).
Work cover (1) forward to remove.
(-) Removing cockpit fairing
Remove screws (1).

Remove cockpit fairing (2).

Disconnect plug (1) for the headlight.

Remove washer (2).

Remove washer (2).
Work headlight (3) up and forward to remove.

(-) Exposing plug for daytime riding lights
Remove the cable tie (arrow) and expose plug (1) for the daytime riding
light.
(-) Mounting daytime riding light on headlight
Position daytime riding light (1) on headlight (2) and install screws (3).
Tightening torques
Daytime running light to headlight
(-) Installing headlight
Install headlight (1).

Install washer (2).
Install washer (1) and hold in position.

Push headlight (2) with daytime riding light down slightly.
Connect plug (1) for the headlight.
Connect plug (2) for the daytime running light.

Secure cable (1) in the holder (arrow).
Install screws (1) and washers (2).
Tightening torques
M6 x 20 5 Nm
Hold cockpit fairing (2) in position.


(-) Installing trim for daytime riding light

Transferring flat nuts to trim for daytime riding light
Remove flat nuts (1) from trim (2).

Install flat nuts (1) in trim of daytime riding light (3).
Insert cover (1) and secure at retaining pins (2).

Engage the retainers (arrows).
Install screws (1).
Tightening torques
Trim for daytime riding light to front panel carrier
M5 x 20 2 Nm
Remove screw (1).

Remove bushing (2).


Remove bolt (2).

Remove trim (1).
Unlock lug (arrow).



ATTENTION
Do not attempt to open the switch unit.
Unclip the retaining tabs (arrows).

Remove cover (1).

Disconnect plug (2) for the heated grip.


heated grip.



Install trim (1).


Install bolt (2).
Tightening torques
M3.5 x 30 1 Nm



position.
Tightening torques
M10 x 50 38 Nm
Follow-up work

77 51 007 Installing LED headlight

+ 77 51 656
LED headlightOA
Preparatory work
Removing front seat
Core activity

Remove washer (2).

Remove washer (2).
Work headlight (3) up and forward to remove.
(-) Installing LED headlight
Remove screw (1).

Disengage wheel cover (2) from the retainer (arrow).
Pull cover (3) down for installation of the headlight.
Hold headlight (3) in position.

Hold washer (2) in position.
Secure wheel cover (2) at the retainer (arrow).

Hold cover (3) in position.
Install screw (1).
Install washer (1) and hold in position.

Push headlight (2) down slightly.

Connect connector (1) for the headlight.
Install screws (1) and washers (2).
Tightening torques
M6 x 20 5 Nm
Hold cockpit fairing (2) in position.

(arrow) .
Install screws (2).

Install bolt (3).
Tightening torques
M5 x 14.5 2 Nm
(-) Securing left side panel



wheel cover (2).


Install bolt (2).
Tightening torques
M6 x 25 8 Nm


Remove screw (1).

Remove bushing (2).


Remove bolt (2).

Remove trim (1).

Unlock lug (arrow).


ATTENTION
Unclip the retaining tabs (arrows).

Remove cover (1).


Disconnect plug (2) for the heated grip.

heated grip.



Install trim (1).


Install bolt (2).
Tightening torques
M3.5 x 30 1 Nm



position.
Tightening torques
M10 x 50 38 Nm
Follow-up work

77 51 151 Installing LED flashing turn indicators

+ 77 51 651
LED flashing turn indicatorOA
0456 - Style HPOE
Preparatory work
Removing rear seat
Removing front seat
Core activity
(-) Removing front left flashing turn indicator
Release cable (1) for the turn indicator from retaining tab (2).
Disconnect plug (3) for turn indicator.
Remove bolt (4).
Turn turn indicator (5) upwards and remove, carefully pulling out cable (1)
with plug (3).
(-) Installing front left LED flashing turn indicator
Feed the cable (1) with plug (2) into position.

Hold turn indicator (3) in position facing up and turn it forwards.
Install bolt (4).
Tightening torques
M6 x 16 4 Nm
Insert cable (1) for the turn indicator in retaining tab (5).
Connect plug (2) for the LED flashing turn indicators.
Install new cable strap (arrow) and secure cable (1) for turn indicator (in the
same way as the previously loosened cables).
(-) Removing front right flashing turn indicator

Disengage cable (1) from retaining tab (2).
Disconnect plug (3) for the flashing turn indicators.
Remove screw (4).
Turn flashing turn indicator (5) up and remove, carefully working cable (1)
with plug (3) clear of the motorcycle.
(-) Installing front right LED flashing turn indicator
Work cable (1) with plug (2) into the correct position.
Make sure that flashing turn indicator (3) is facing up, and turn it forward.
Install screw (4).
Tightening torques
M6 x 16 4 Nm
Connect plug (2) for the LED turn indicators.

Insert cable (1) for the flashing turn indicator into retainer (5).
Install a new cable tie (arrow) and secure cable (1) for the flashing turn
indicators (in the same way as the cable disengaged beforehand).
(-) Removing number-plate carrier
Disengage and disconnect plug (1) for the right flashing turn indicator.
Disengage and disconnect plug (2) for the left flashing turn indicator.
Remove screws (1).

Pull down and remove number-plate carrier (2).
(-) Removing rear right flashing turn indicator

(-) Removing rear left flashing turn indicator

(-) Installing rear right LED flashing turn indicator
Work cable (1) with the plug into the correct position.
Install nut (4).
Install screw (3).
Tightening torques
M6 x 20 3 Nm
(-) Installing rear left LED flashing turn indicator
Work cable (1) with the plug into the correct position.
Install nut (4).
Install screw (3).
Tightening torques
M6 x 20 3 Nm
Insert the cable into the retainer (arrow).
(-) Installing number-plate carrier with LED turn indicators

Work plugs (1) and (2) for the LED turn indicators through the openings
(arrows).
Engage number-plate carrier (1) in the openings (arrows) and swing it up.
Engage number-plate carrier (1) in the tabs (arrow).

Install screws (long collar) (2).
Tightening torques
M6 x 17.5 8 Nm
Connect plugs (1) and (2) the LED turn indicators and secure.
Follow-up work


77 52 008 Installing preparation for navigation system

+ 77 52 730
Preparatory work
Core activity
(-) Exposing connector for connecting Mount Cradle

Remove protective cap (1) from connector (2).
(-) Installing preparation for navigation system
Insert key (1) in lock barrel (2).

Lubricate the lock barrel (2).
Lubricant
MI-Setral-43 N 83 23 2 152 082
Insert lock barrel (2) with key (1) and turn until locking pawl (arrow) is
locked.
Hold retaining bracket (1) in position.

Install screws (2) (M6 x 18) and nuts (3) and tighten until hand-tight.
Position retaining bracket (1).

Install screws (2) (M6 x 16) and nuts (3) and tighten until hand-tight.

Push retaining bracket (1) up.

Tightening torques
M6 x 18 8 Nm
M6 x 16 8 Nm
Route cable (1) down and secure it with the cable straps (arrows).
Connect bush (1) , 3-pin, to plug (2) for navigation system.

Loop excess lengths of cable and secure with cable splitter (3) with cable
strap (arrow) to front trim panel (4).
Locate 3-pin bush (1) and 2-pin bush (5) with cable strap (arrow).
Remove screw (1).

Remove bushing (2).



Remove bolt (2).

Remove trim (1).
Unlock lug (arrow).




(-) Removing blanking plug from multifunction switch
Remove blanking plug (1) from multifunction switch (2).

(-) Installing left handlebar grip with Multi-Controller
ATTENTION
Install handlebar grip (1), inserting connector (2) for the heated grip and
connector (3) for the Multi-Controller.
(-) Securing left grip unit

Slip grip unit (1) into position, noting cable (2).


Install screw (2).
Tightening torques
M3.5 x 30 1 Nm
Connect plug (2) for the clutch switch.


position.
Tightening torques
M10 x 50 38 Nm
Follow-up work

77 53 005 Installing RDC

+ 77 53 910
Preparatory work
Removing rear seat
Removing front seat
Core activity
(-) Disengaging front wheel-speed sensor
Remove bolt (1).

Release wheel speed sensor (2).
(-) Removing left brake calliper
Remove screws (1).

(-) Remove the right brake calliper

Remove screws (1) from brake calliper (2).

(-) Removing front wheel
Use straps to pull the rear of the motorcycle down and secure it in this
position.
Slacken axle clamping screws (1).
Remove bolt (2).
Roll the front wheel forward to remove (4).
(-) Removing front tyre
ATTENTION
Component damage
Remove the tyre with commercially available tools.

Pry off the tyre (1) at the point opposite (arrow) the valve.
Remove the tyre (1) with commercially available tools.


Tightening torques
Renew nut 6 Nm
encapsulated)

Check
Result:

Measure:
(-) Installing front tyre
When fitting the tyre, note the tyre pressure monitoring sensor (RDC
sensor).
ATTENTION
Component damage

Use commercially available tools/jig and work to the manufacturer's
specifications to fit the tyres, and make sure that the direction-of-rotation
arrows on tyre and rim point in the same direction.
Check
Inflate the tyre to test pressure and check the valve for leaks.
Technical data
pressure
Result:
Valve is leaking.
Measure:
Result:
Valve is leaktight.
Measure:
Technical data
(2).
preloaded.
Technical data
wheel imbalance
front wheel
Weights have to be
on the left and one
other words centred
on the rim
(-) Install the front wheel

Make sure that spacer bush (1) is installed with the collar (arrow) toward
the outside.
Clean and lubricate quick-release axle (1).
Lubricant
Optimoly TA 18 21 9 062 599
Hold front wheel (2) in position.

Install quick-release axle (1).

Install screws (2).
Tightening torques
M10 x 65 38 Nm

Install screws (1).
Tightening torques
M10 x 65 38 Nm


Disengage tensioning straps (1) at the rear.

Fold in centre stands (2).
Firmly compress the front forks several times.
Place the motorcycle on its centre stand (2).
Install bolt (1)
Tightening torques
M12 x 20 30 Nm
Tighten clamping bolts (2).
Tightening torques
M8 x 35 19 Nm
(-) Securing left brake calliper

Install screws (1).
Tightening torques
M10 x 65 38 Nm


(-) Securing right brake calliper

Install screws (2).
Tightening torques
M10 x 65 38 Nm
(-) Securing front wheel-speed sensor
Clean the threads.

Hold wheel speed sensor (2) in position.
Install bolt (3).
Tightening torques
encapsulated)
(-) Remove the rear wheel
Remove wheel studs (1).

Remove rear wheel (2).
(-) Removing rear tyre

ATTENTION
Component damage
Remove the tyre with commercially available tools.

Pry off the tyre (1) at the point opposite (arrow) the valve.
Remove the tyre (1) with commercially available tools.

Tightening torques
Renew nut 6 Nm
encapsulated)

Check

Result:
Measure:
(-) Installing rear tyre
When fitting the tyre, note the tyre pressure monitoring sensor (RDC
sensor).
ATTENTION
Component damage
Use commercially available tools and work to the manufacturer's

specifications to fit the tyres, and make sure that the direction-of-rotation
arrows on tyre and rim point in the same direction.
Check
Inflate the tyre to test pressure and check the valve for leaks.
Technical data
pressure
Result:
Valve is leaking.
Measure:
Result:
Valve is leaktight.
Measure:
Technical data

Technical data
wheel imbalance
rear wheel
Weights have to be
on the left and one
other words centred
on the rim
(-) Install the rear wheel
Clean the wheel centring spigot and the contact surfaces of the wheel hub.
Hold rear wheel (2) in position.

Engage all wheel studs (1) on their threads, then tighten uniformly.
Tightening torques
M10 x 1.25 x 40 Tightening

diagonally opposite
sequence
60 Nm
(-) Exposing plug for RDC

Remove the protective cap (2).
(-) Install the RDC control unit
Connect plug (1) to RDC control unit (2).

Hold RDC control unit (2) in position.
Install screws (3).
Follow-up work
77 53 006 Installing cruise control

+ 77 53 911
Cruise controlOA
Preparatory work
Core activity


Remove bolt (2).

Remove trim (1).
Unlock lug (arrow).




(-) Removing clutch switch
Remove screw (1).

Remove clutch switch (2).
(-) Install the clutch switch
Insert new clutch switch (1) in grip unit (2).

The locking tab (arrow) faces down.
Install screw (3).
Tightening torques
heated grip.


Install trim (1).



Install bolt (2).
Tightening torques
M3.5 x 30 1 Nm

throttle twistgrip.
Remove screw (1).


Disconnect plug (1) for the heated grip and unclip it.
Remove screw (3).
Remove screw (1).


Install screw (1).

Tightening torques
M3.5 x 30 2 Nm

ATTENTION
Component damage
Install screw (3).
Tightening torques


ATTENTION
Component damage
Install screw (2).
Tightening torques

Follow-up work

77 53 008 Installing Hill Start Control

+ 77 53 913
Preparatory work
Ordering enabling code for software update with BMW Motorrad
diagnosis system
Core activity
(-) Connecting BMW Motorrad diagnostic system to vehicle
Remove cap (1).

Connect the BMW Motorrad battery charger to negative terminal (2) and
remote positive terminal (3).
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.
Unlock holder (arrow) and release cap (4) with diagnostic connector (5).
Remove cap (4).
Connect diagnostic connector (5) with connecting cable (6) for diagnosis
system.
NOTICE
See the information about the BMW Motorrad diagnostic system for all further
instructions.
(-) Performing software update with the BMW Motorrad diagnosis

system
Requirement
Engine is off.
Battery is fully charged and battery charger is connected.
NOTICE
Do not attempt to perform work of any other kind on the motorcycle while
programming/coding is in progress.
Switch off all electrical consumers.

Start the diagnosis system.
Identify the vehicle.
Select the retrofit.
Create a measures plan and perform the retrofit.
(-) Disconnecting BMW Motorrad diagnostic system from vehicle
Disconnect diagnostic connector (5) from connecting cable (6) for diagnosis
system.
Secure diagnostic connector (5) in cap (4).
Secure the cap (4), the holder (arrow) must lock.

BMW Motorrad Disconnect battery charger from remote positive terminal
(3) and negative terminal (2).
Install cap (1).
Terminate the diagnosis session correctly and switch off the ignition.
Follow-up work

77 53 009 Installing battery

+ 77 53 509
Preparatory work
Core activity
(-) Removing battery
Remove bolt (1).

Loosen grounding cable (2) and insulate with adhesive tape (arrow).
Disengage rubber band (1) from the hooks (arrows).
Pull battery holder plate (1) off mounts (2) and (3).
Pull battery (1) out of bracket (2).

Remove bolt (3).

NOTICE
battery change.
(-) Install lithium ion battery

Install bolt (3).
Tightening torques
M6 x 11 8 Nm
Slide battery (1) in battery holder (2) and while doing so, pay attention to the
correct routing of the positive wire (4).
Position battery holder plate (1) in top mount (2).

Press battery holder plate (1) into bottom mounting (detail), sliding battery
holder plate (1) under the height adapter (3).
Secure rubber band (1) in the hooks (arrows).


Fit grounding cable (2).
Install bolt (1).
Tightening torques
M6 x 11 8 Nm
Follow-up work

77 53 070 Installing Pro shift assistant

+ 77 53 920
Preparatory work
Ordering enabling code for software update with BMW Motorrad
diagnosis system
Core activity
(-) Disengaging selector rod

(-) Removing shift lever
Remove screw (1).

Disengage shift lever (2) from selector shaft (3) and remove.
(-) Masking off frame tube for protection
NOTICE
Affix masking tape to frame tube (1) (arrow).

(-) Exposing connector for Pro shift assistant
Release the cable strap (arrow) and expose connector (1) for the shift
assistant.
Remove protective cap (2) from connector (1).
(-) Installing shift assistant
(arrow).
Connect plug (1) for the shift assistant and lock (arrow).
Position shift assistant (2) on selector shaft (3).
Press on shift assistant (1) with new screw (2) and washer (3).
Tighten screw (2) with insertion tool (No. 23 0 832).

Tightening torques
encapsulated)
(-) Securing selector rod

Follow-up work

77 53 100 Installing anti-theft alarm

+ 77 53 501
Anti-theft alarm (DWA)OA
0456 - Style HPOE
Preparatory work
Removing rear seat
Removing front seat
Core activity
(-) Exposing plug for anti-theft alarm
Remove plug (1) with terminating resistor (2) and clip (3).
Remove terminating resistor (2) from plug (1).
(-) Install the anti-theft alarm (DWA)
Install DWA (5).

Install screw (4).
Secure cable (2) in holder (3).
Connect plug (1) for DWA.
Follow-up work

77 53 154 Installing rear extra socket

+ 77 53 554
Preparatory work
Removing front seat
Removing fuel tank
Core activity
(-) Removing cable ties
(-) Disengage the engine control unit
Remove screws (1).

Removing the fuse carrier (2).
Push locks (3) slightly to the side and release engine control unit (4).

(-) Affixing drilling template for on-board socket
Peel the backing paper off the drilling template.

NOTICE
Align drilling template (1) with the edges (arrows) and affix it to left of rear-
wheel cover (2).
(-) Drilling holes in left rear-wheel cover
Drill a hole at position (1).
Technical data
Drilling to size Drill out to 4 mm
size with HSS
drill bit, dia.
Drill a pilot hole at position (2).

Use a centre bit to drill out the hole to the correct size to accommodate the
power socket.
Technical data
Drill the pilot and drill Drill the pilot 4 mm
out to size with HSS drill
bit, dia.
Drilling to size max 18 mm
with centre bit
Remove the drilling template.

Use a round file to deburr the hole.
(-) Installing and connecting on-board socket in rear-wheel cover
Remove screws (1).

Release bracket for control unit (2) from grommets (arrows) and remove.

Route adapter lead (1) forward in rear-wheel cover (2).
Insert socket (1) with lug in the bore hole (arrow) on rear-wheel cover (2).
Connect nut (1) to socket (2).

Connect connector of adapter lead (3) to socket (2).
Install nut (1) with 22-mm open-end spanner hand-tight.
Lubricate grommets (arrows).
Care products
Install bracket for control unit (2) in grommets (arrows).

NOTICE
Make sure that the rubber grommets are correctly installed and are not
pushed out of position in the installation process.
Install screws (1).
(-) Securing engine control unit
Position and install engine control unit (4).

Locks (3) engage.
Install fuse carrier (2).
Install screws (1).
(-) Routing adapter line
Install the bracket with cable tie (1) on main frame (2).
Route adapter line (1) further forward to cable guide cavity (2) and secure
with cable ties (arrows).
Route adapter line (1) in cable guide cavity (2) to front panel carrier (3) and
secure with cable ties (arrows).

(-) Disconnecting plug for standard on-board socket
Disconnect connector (1) for onboard standard socket, remove cable routing
(2) (will be reused) and remove cable strap (arrow).
(-) Connecting adapter line to standard on-board socket
Connect connector (1) of the adapter lead (2) with standard onboard socket
(3).
Connect connector (4) of adapter lead (2) to connector (5) of the vehicle
wiring harness.
Secure the plug connection (4), (5) with cable straps (arrows).
Install cable routing (6) together with adapter lead and access line of the
wiring harness in side section.
(-) Function check and latching
Check operation by connecting a suitable commercially available 12V device

to the socket.
NOTICE
The circuit of the socket is made safe with a commercial safety fuse of 7.5 A. If
a circuit was switched off through the safety fuse and the fault that caused this
has been removed, the circuit must be secured with a new 7.5 A safety fuse
before switching on the ignition.
Technical data
Electrical rating of on- total for all max 5 A
board sockets sockets

Check additional latching function of the socket cap. Do this by slowly
opening the cap past the detent and releasing the cap. The cap must remain
in the open position.
Follow-up work

BMW R1250 GS Adventure K51 11 Service Manual

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BMW R1250 GS Adventure K51 11 Service Manual

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BMW R1250 GSAdventure

Technical data - R 1250 GS Adventure

0770 - China exportNV

0703 - Power reductionOE

0739 - Brazil exportNV

Designation Precondition Value Valid

Running-in speeds Odometer <5000 min-1

Maximum engine speed max 9000 min-1

Engine type A74B12M

052021 BMW Motorrad, UX-VA-4 1/5

Wear limit max 102.530 mm

11 21 - Crankshaft with bearings

Colour codes of crankshaft bearing Crankcase yellow Bearing shells yellow

Wear limit max 0.080 mm

Marks on crankshaft A front: Identification for Yellow/green/violet dots

052021 BMW Motorrad, UX-VA-4 2/5

11 24 - Conrod with bearings

Conrod bearing, bore diameter Identification/colour A/red or B/blue

Conrod endplay When new 0.130...0.312 mm

ID mark for conrod weight classes Connecting rod weight 542.0...547.9 g

052021 BMW Motorrad, UX-VA-4 3/5

Radial play of small-end bearing bore When new 0.015...0.030 mm

11 25 - Piston with rings and bolts

Wear limit min 102.4 mm

Piston ring height When new 1.03+0.01 mm

052021 BMW Motorrad, UX-VA-4 4/5

Exhaust valve clearance Engine cold max 35 °C 0.34...0.41 mm

052021 BMW Motorrad, UX-VA-4 5/5

Technical data - R 1250 GS Adventure

Designation Precondition Value Valid

Wear limit 1.0 mm

Alternator - rated current at idle speed 23 A

052021 BMW Motorrad, UX-VA-4 1/1

Technical data - R 1250 GS Adventure

0780 - EU market exportNV

0739 - Brazil exportNV

0760 - Thailand exportNV

13 - Fuel preparation and control

Designation Precondition Value Valid

052021 BMW Motorrad, UX-VA-4 1/1

Technical data - R 1250 GS Adventure

0770 - China exportNV

Designation Precondition Value Valid

052021 BMW Motorrad, UX-VA-4 1/1

Technical data - R 1250 GS Adventure

Designation Precondition Value Valid

Coolant capacity total in coolant circuit 1.5 l

052021 BMW Motorrad, UX-VA-4 1/1

Technical data - R 1250 GS Adventure

Designation Precondition Value Valid

Hydraulic fluid (Hyspin V10)

21 21 - Clutch with driver plate

052021 BMW Motorrad, UX-VA-4 1/1

Technical data - R 1250 GS Adventure

Designation Precondition Value Valid

052021 BMW Motorrad, UX-VA-4 1/1

Technical data - R 1250 GS Adventure

0191 - Dynamic ESAOE

31 - Front axle, front-wheel steering

Designation Precondition Value Valid

052021 BMW Motorrad, UX-VA-4 1/1

Technical data - R 1250 GS Adventure

0191 - Dynamic ESAOE