BMW K 1100 RS Reparaturanleitung

BMW AG Motorcycle DivisionAfter SalesK 1100 LT/RSRepair Manual

00.2Contents PageChecking function of electric switch on side stand and adjusting if necessary ...

12.14Alternator [LT from 1992 model year on, RS]•Remove fastening screws (1) from cover.•Release clips (2) and take off cover.•Remove voltage regulato

12.15Checking alternatorL Note:Before measuring the resistance with the BMW di-agnostic tester, this must be zeroed:Connect the positive (yellow) and

12.16Removing and installing starter•Remove control unit.•[ABS I] Remove control unit.•[ABS II] Drain front and rear brake systems.•[ABS II] Remove pr

12.17Disassembling and assembling starter•Clamp starter at retaining lugs in vice with jaw guards.•Release retaining bolts (1).•Detach bearing cap (2)

12.18Removing and installing brush holder1. Hexagon nut2. Outer insulator3. Carbon brush holder4. Brush retaining plate5. O-ring6. Inner insulator LT1

12.19Renewing carbon brushes•With the aid of a small screwdriver, lift spring (1) and pull out carbon brush.L Note:Fit carbon brush so that the chamfe

12.20Checking starter•Connect voltmeter between positive and nega-tive pole of battery.•Operate starter for 2...3 seconds.•Read off value.L Note:If th

12.21Checking starter relay•Connect terminal 86 to positive battery terminal, terminal 85 to earth (ground).L Note:The relay is defective if no switch

12.22TroubleshootingTroubleshooting on alternatorAlternator makes noises.Do carbon brushes whistle?yesRework slip rings/replace carbon brushes. Batter

12.23Indicator lamp lights at only half brightness intensity when engine running.noCheck contacts of cable connections. Do cable connections have poor

00.300Tightening torqueModel K 1100 LT K 1100 RSConnection Nm11 EngineFreewheelCover plate/freewheel cage at countershaft gear 10Oil – water pumpOil p

12.24Indicator lamp lights at half or full brightness with engine running. noCheck regulator.Is regulator defective?yesRenew regulator. noCheck supply

12.25Indicator lamp does not light when engine is stationary and ignition switched on. noCheck indicator lamp.Is lamp defective?yesReplace indicator l

12.26Troubleshooting on starterStarter does not turn when start switch is operated.noSwitch on light. Does light operate?noCheck battery.Is battery di

12.27Starter does not turn when start switch is operated.noSwitch on light. Does light operate?yesConnect jumper at connection between termi-nal 50 an

12.28Starter turns too slowly, does not crank en-gine.noCheck battery voltage.Is battery voltage too low?yesCharge battery, replace if necessary.noChe

12.29Troubleshooting on batteryBattery produces excessive gas.noCheck battery.Is battery defective?yesRenew battery.noCheck contact between regulator/

12.30Acid density too low.neinCheck charge status of battery.Is battery discharged?yesCharge battery.noCheck acid concentration.Is acid concentration

12.31Insufficient power outputnoCheck connection terminals.Are terminals loose/oxidated?yesClean/tighten terminals.noCheck acid level.Is level below t

12.32

13.1Contents Page13Technical data...

00.4Timing chainChain tensioner 9Slide rail at camshaft bearing cap 9Timing case coverTiming case cover 10 (3-Bond 1209)Cover for Hall-effect signal t

13.2

13.313Technical data K 1100 LS K 1100 RSInside ø of throttle stub pipemm (in) 35 (1.37795)CO value % by vol. 1,5 ± 0,5 Idle speed rpm 950 ± 50

13.4

13.5Adjusting idle speedL Note:The basic setting (ignition, valve clearance) must be correct.•Remove knee pad.•Remove left side fairing.•Remove protec

13.6Checking start speed increase (choke), adjusting if necessaryChecking start speed increase•Remove left battery cover.•Set speed increase to limit

13.7Adjusting CO valueL Note:Engine must be at operating temperature (85 °C).Basic settings (ignition timing, valve clearances) must be correct.•Inser

13.8Removing/installing and checking/adjusting throttle position sensorRemoving and installing throttle posi-tion sensor•Unscrew the throttle position

13.9Removing and installing air cleaner insert•Remove both knee pads.•Remove fuel tank.•Remove left and right heat-insulating bulkhead.•Release front

13.10Removing and installing air cleaner housing•Remove both knee pads.•Remove fuel tank.•Remove left and right side fairings.•Remove intake air guide

13.11•Loosen and pull off oil return pipe (5).•Loosen and pull off air return pipe (6).•Pull top section of air cleaner housing (7) out to the right.•

00.513 Fuel preparation and controlInjection rail 9Intake stub pipe 9Lower section of air cleaner housing 21Intake air line 9Motronic control unit 517

13.12Removing and installing throttle rail•Remove fuel tank.•Remove left fairing side section.•Remove left-hand heat-insulating bulkhead.•Release fuel

13.13Removing and installing injectors•Release wire retainer (1) and detach plug (2).•Release clip (3) at the injector and pull it out.•Install in the

13.14Removing and installing Motronic control unite Caution:Disconnect earth (ground) lead at battery!•Release multiplug (1) and disconnect.•Detach Mo

16.1Contents Page16Technical data...

16.2

16.316Technical data K 1100 LT K 1100 RSFuel tankTank capacity l (Imp.gal) 22 (4.84)incl. reserve capacity l (Imp.gal) 5 (1.1)Fuel pumpType Roller-cel

16.4

16.5Removing and installing fuel tank•Open seat.•Remove left/right knee pads.•Remove retaining clips (1).•Release fuel line (2) at fuel tank.•Release

16.6Removing and installing fuel filter•If necessary reduce fuel level with pump until fil-ter is accessible.•Loosen hose clip (1) and slide towards f

16.7Removing and installing fuel level sensor•Removing and installing fuel level sensor•Remove and empty fuel tank.•Remove filler neck.•Release electr

00.623 TransmissionTransmission cover to transmission 9Machine screw for neutral stop 13Stud bolt, selector shaft 17 (Loctite 243)Transmission to inte

16.8Removing and installing fuel pump•Remove and empty fuel tank.•Remove filler neck.•Release electrical connections (1/2) at the fuel pump.•Release h

16.9Checking fuel pump pressure•Connect test pressure gauge, BMW No. 16 1 500, on the delivery side.•Run engine at idle speed.Fuel pressure:Nominal va

16.10

17.1Contents Page17Technical data...

17.2

17.317Technical data K 1100 LT K 1100 RSCooling system capacity l(Imp.gal) 3.0 (0.66)+ 0.4 (0.088) in expansion tankCoolantAntifreezeWater%%Concentrat

17.4

17.5Changing coolantDraining coolant•Remove fuel tank.•Release cap (1) on filler neck. • [RS] Remove lower section of fairing •Release screw plug (2)

17.6Removing and installing thermostat•Remove fuel tank.•Remove right side section of fairing.•Remove radiator cowling.•Remove cover (1).•Pull out the

17.7Removing and installing radiator•Remove fuel tank.•[RS] Remove bottom section of fairing •Remove left/right side fairing.•Remove radiator cowling.

00.732 SteeringClamping screws for handlebar fitting 5Clamping screws 22Clamping block to fork bridge 1633 Rear wheel driveThreaded ring 118 (clean th

17.8Removing and installing fan•Remove radiator.•Remove rubber ring (1) and spacer bush (2).•Release retaining bolts (3, 4).•Install in the reverse or

17.9Removing and installing coolant hoses•Remove fuel tank.•[RS] Remove bottom section of fairing .•Remove left/right side fairings.•Remove correspond

17.10Checking cooling systemChecking cap for filler neck•Remove fuel tank.•Connect adapter (1), BMWNo.170003, to pump, BMWNo.170500. •Screw cap onto

17.11TroubleshootingCoolant temperature warning lamp lights up.noCheck coolant in expansion tank.Is coolant level too low?yesTop up coolant.noCheck th

17.12Übermäßiger Kühlmittelverlust.noCheck coolant circuit.Has coolant circuit a break?yesRepair break.

18.1Contents Page18Removing and installing exhaust system ...3Removing and instal

18.2

18.318Removing and installing exhaust system•Release mounting (1) on cylinder head.•Release mounting (2) on transmission.•Release mounting (3) on foot

18.4Removing and installing oxygen sensor•Separate plug connection for oxygen sensor.•Remove left footrest plate.•Unscrew oxygen sensor at hexagon.L N

21.1Contents Page21Technical Data ...

00.834 BrakesABS pulse wheel 4ABS sensor front/rear 4Brake caliperto sliding tube/rear wheel drive 40Brake line to brake caliper 18Bleed screws at bra

21.2

21.321Technical Data K 1100 LT K 1100 RSType of clutch Single dry plate clutch with diaphragm springOutside-ø of diaphragm springmm (in) 180 (7.0866)

21.4

21.5Removing clutch•Secure lifting gear, BMW No. 00 1 510, to the oil sump.•Remove main stand.•Remove rear mudguard.•Remove right-hand footrest plate.

21.6•Release housing cover (2).•Remove clutch disc (3), pressure plate (4), diaphragm ring (5) and wire ring (6).LT210060654231

21.7Removing clutch housing•Secure retaining fixture?(1), BMW No. 11 2 800, as shown.•Release hexagon nut (2).•Remove thrust ring (3) with pliers.•Mov

21.8Installing clutch housing•Coat tapers in clutch housing with Optimoly MP 3 or similar.•Fit thrust washer (1) on the clutch housing.•Using retainin

21.9Installing clutch•Grease all lubrication points with Optimoly MP 3.Lubrication points:Contact surfaces of pressure plate/diaphragm spring, wire ri

21.10•Release lower retaining bolt (1) of the ignition coil mounting.•Secure centring fixture (2), BMW No. 21 2 670, to intermediate flange.•Centre dr

21.11Adjusting clutch clearance•Detach clutch cable at the clutch release lever (1). •Slightly pull back rubber gaiter (2).•With the aid of setting ga

00.946 FrameFrame to engine 45Fairing support bracket to frame 9Suspension strut to frame/rear wheel drive 51Handlebar to clamping block 22Clamping sc

21.12Removing and installing clutch thrust bearing •Remove rear wheel.•Remove exhaust system.•Detach clutch cable at clutch release lever (1). •Loosen

21.13Removing and installing clutch con-trol rod•Remove rear wheel.•Remove exhaust system.•Remove clutch thrust bearing.•Remove clutch control rod (1)

21.14Removing and installing clutch release lever•Remove exhaust system.•Detach clutch cable at clutch release lever.•Remove retaining ring (4) and wa

21.15TroubleshootingClutch slips.noCheck clutch clearance.Is clutch clearance incorrect?jaAdjust clutch clearance. Replace clutch disc if necessary. n

21.16Clutch operation difficult.Clutch too harsh?noCheck output shaft lubrication. Is output shaft not lubricated?yesLubricate with Optimoly MP 3.

23.1Contents Page23Technical Data ...

23.2Contents PageDisassembling and assembling output shaft ...17Removing ball bearing

23.323Technical Data K 1100 LT K 1100 RSType of gearshift5-speed transmission with dog-clutch engage-ment and integrated damper for all gearsType of g

23.4

23.5Removing transmission (gearbox)Preparatory work•[RS] Remove left fairing side section .•Remove exhaust system.•Disconnect CAT plug connection for

00.10Table of operating fluidsItem Use Order number QuantityLubricantOptimoly MP 3 High-performance lubricating paste 07 55 9 062 476 100 g tubeOptimo

23.6Removing starter•Release positive and negative lead at starter.•Release mounting.•Pull out starter. LT230410

23.7Removing bearing mount with main stand•Secure lifting gear, BMW No. 00 1 510, to the oil sump and slightly raise engine.•Release mounting for main

23.8Removing transmission (gearbox)•Release retaining bolts.•Screw guide pins, BMW No. 23 1 820, in holes with fitted sleeve, long pin on right-hand s

23.9Disassembling transmission (gear-box)Removing transmission cover.•Secure gearbox with holder (arrow “A”), BMW No. 23 1 600, to assembly stand.•Eng

23.10Disassembling/assembling transmis-sion coverRemoving and installing bearing shell•Heat bearing cover to 100 °C. •Remove bearing shell with Kukko

23.11Removing gear selector drum•Remove shafts (1) of gearshift forks.•Press pawl (2) towards the outside and secure with clamping fixture (arrow), BM

23.12Removing transmission shafts•Heat bearing seat of input shaft (1) and the inter-mediate shaft (2) to 100 °C.•Pull out both shafts together.•Remov

23.13Removing selector shaft•Release setscrew (arrow) (secured with Loctite).•Pull out selector shaft together with gearshift le-ver.Removing segment•

23.14Removing and installing shaft sealing ring for gear selector drum•Switch for gear indicator removed.•Gear selector drum removed.•Lever out shaft

23.15Disassembling and assembling input shaftDisassembling input shaft•Clamp spline end of input shaft in vice with jaw guard.•Remove retaining ring (

00.11Key to maintenance intervals – Inspection at 1000 km (600 miles)I– BMW Service at 10,000 km (6000 miles))II– BMW Inspection at 20,000 km (12,000

23.16•Fit universal puller under the spur gear and pull down taper roller bearing as far as it will go on the retaining ring.L Note:There must be no c

23.17Disassembling and assembling output shaft •Before disassembling, measure axial clearance of spur gear for 1st, 2nd and 5th gears.1st gear ... 0

23.18Removing spur gears•Remove spur gear for 1st (1) and 5th gear (2) with spacer shim rings.•Heat bearing bush (4) to 80 °C.•Carefully remove spur g

23.19Installing spur gears•Slide serrated washer (10) over smooth end (ar-row) onto output shaft up to the bearing seat.•Slide on retaining ring (11)

23.20Installing transmission shafts•Heat bearing points for intermediate shaft and output shaft in the housing to 80°C.•Fit input shaft.•Install inter

23.21Measuring distances between trans-mission shaftsMeasuring bearing distance of shafts•Place transmission measuring plate, BMW No. 23 3 660 (arrow)

23.22Measuring transmission cover•Measure from the parting surface of the trans-mission cover to the base of the bearing seat.•Only applies to interme

23.23Measuring distances between transmission shaftsExample:•Remove measuring plate from transmission housing.•Fit calculated spacer shim rings on the

23.24Installing transmission cover•Knock out cap (arrow) from the inside using a drift.•Heat up transmission cover to 100°C.•Parting surface at housin

23.25Installing transmission (gearbox)•Clutch thrust bearing must be removed.•Check centre position of driving disk.•Coat spline of input shaft, for e

Published by BMW AG Motorcycle DivisionAfter SalesUX-VS-2All rights reserved. Not to be reprinted, translated or duplicated either wholly or in part w

00.12Changing oil in rear wheel driveInspections I, III, IV•Drain off oil with drive at operating temperature.•Oil drain plug (1)•Oil filler plug (2)L

23.26Installing bearing mount with main standL Note:Clean threaded holes in transmission and retaining bolts (recut thread).•Place switch (1) for elec

23.27Installing starter•Connect positive and negative leads.X Tightening torque:Positive lead... 5 NmSt

23.28Re-assembling motorcycle•Install battery.•Intall Motronic control unit.•[ABS II] Install ABS unit.•Install battery.•Intall Motronic control unit.

31.1Inhalt Seite31Technical Data ...

31.2

31.331Technical Data K 1100 LT K 1100 RSFront wheel castor mm (in) 95 (3.74)Steering angle °34Spring travel (normal position, 75 kg load) mm (in) 135

31.4

31.5Removing telescopic fork•Secure lifting gear, BMW No. 00 1 510, to oil sump.•Remove fuel tank.•Remove front mudguard.•Remove brake caliper.Removin

31.6Removing and installing lower taper roller bearingRemoving taper roller bearing•Press down steering tube (1) by approx. 5 mm and press back again.

31.7Removing and installing bearing outer race in steering headRemoving bearing outer race•Remove bearing outer race (1) using extractor BMW No. 00 5

00.13Renewing fuel filterInspection III•If necessary, reduce fuel level with pump until fil-ter is clear.•Loosen hose clip (1) and shift towards filte

31.8Measuring telescopic forkL Note:After a collision, the telescopic fork must be exam-ined for cracks and damage.Checking lower fork bridge•Clamp fo

31.9Checking parallel alignment of fixed tubes•Clamp fork bridge at steering tube in vice with jaw guards.•Install upper fork bridge.L Note:Fork bridg

31.10Checking runout of fixed tube•Place both ends of stanchion in V-blocks.•Slowly turn fixed tube while checking dial gauge.e Caution:Distorted fixe

31.11Disassembling telescopic forkRemoving fixed tube•Loosen clamping screws at lower fork bridge.•Remove fixed tube with slider tube from fork bridge

31.12Disassembling fixed tube•Loosen screw plug (1) in fixed tube.•Screw base screw fitting (arrow) loosely into damper cartridge.•Lightly press dampe

31.13•Press apart plain bush (8) on the fixed tube (arrows) and remove.•Slightly preform new plain bush in order to achieve an optimum fit on the fixe

31.14Assembling telescopic forkAssembling fixed tube•Fit fork support spring (6) on damper cartridge (5), small winding spacing at top.•Fit guide slee

31.15•Fit spacer sleeve (4).•Fit perforated disc (3), smooth side facing down-ward.•Fit retainers (2) and relieve clamping fixture.•Screw in screw plu

31.16Assembling slider tube•Install damper cartridge with hole pattern “Z” (tension stage) in the right-hand slider tube.•Install plain bush (1) lubri

31.17Installing telescopic fork•Grease taper roller bearing with Shell “Retinax A” or similar.•Fit telescopic fork from below into steering head.•Inst

00.14Checking brake pads, brake discs for wear and renewing if necessaryInspection II, III Front wheel brake•Remove rear section of mudguard.•Remove b

31.18Adjusting steering bearing play•Fit a piece of adhesive tape (arrow) on the fork bridge above the setting ring.•Mark current position of the sett

31.19Installing fork stabilisor•Install fork stabilisor, handtighten screws.•Install brake distributor (1).•Lay ABS sensor line (2) and connect. •Inst

31.20

32.1Contents Page32Technical Data ...

32.2

32.332Technical Data K 1100 LT K 1100 RSSteering anglel °2 x 34Steering tube-ø mm (in) 22 (0.86614)Handlebar width with weights mm (in) 765 (30.11805)

32.4

32.5Removing and installing left and right handlebar fittingsRemoving and installing left handlebar fitting•Remove fuel tank.•[LT] Cut through cable c

32.6•Cut open rubber grip (1) and remove.•Release multifunction switch (2).•Loosen clamping screw (3) of handlebar fitting.•Remove fitting from handle

32.7Removing and installing right handle-bar fitting•Remove fuel tank.•[LT] Cut through cable clip (1).•Disconnect plug connection (2) for brake light

00.15Checking brake fluid level and cor-recting if necessaryInspections I, II, IIIChecking brake fluid levelL Note:When checking front brake fluid lev

32.8Removing and installing handlebar•Remove fuel tank.•Remove handlebar cover (1).•Disconnect plug connections for switches.•Remove left and right ha

32.9Removing and installing handlebar clamping blocks•Remove stop plate (3).•Remove clamping blocks (4).•Drive out handlebar mounting with drift.•Inst

32.10Removing and installing accelera-tor cable•Remove fuel tank.•Remove cable cover (1) on handlebar fitting.•Detach cable.•Turn in cam disc on throt

32.11Removing and installing clutch cable•Remove fuel tank.•Detach clutch cable (1) at clutch release lever.•Pull clutch hand lever and press out nipp

32.12Removing and installing operating cable for increasing starting speed•Remove fuel tank.•Remove operating lever (1).•Detach cable (2).•On throttle

32.13Adjusting steering bearing play•Fit a piece of adhesive tape (arrow) on the fork bridge above the setting ring.•Mark current position of setting

32.14

33.1Contents Page33Technical data...

33.2

33.333Technical data K 1100 LT K 1100 RSRear wheel driveType of gearingKlingelnberg Palloid spiral bevelNumber of teeth 32 : 11Gear ratio 2.91 : 1Toot

00.16Renewing brake fluidRenewing front brake fluid•Remove the break padse Caution:Do not tilt the brake caliper when removing or install-ing, or the

33.4

33.5Removing, disassembling, assem-bling and installing rear wheel drive•Remove licence plate bracket.•Remove rear wheel.•Remove brake disc, mark posi

33.6•Screw the rear wheel drive centrally with holder, BMWNo.331510, and bearing journal (1).•Screw on locking arm (3).•Move threaded bushings (5) int

33.7Disassembling drive bevel gear•Remove outer bearing race (2).•Remove spacer ring (3) from housing.•Clamp drive bevel gear (1) in vice with jaw gua

33.8Removing needle bearing for drive bevel gear•Destroy needle cage of needle bearing.•Heat housing to 130 °C.•Remove outer race of needle bearing wi

33.9Assembling drive bevel gear•Heat inner race (4) to 100 °C and slide onto drive bevel gear (1) as far as it will go.•Slide outer bearing race (2) t

33.10Installing drive bevel gear•Drive sealing ring (2) into threaded rim (3) with the aid of drift, BMW No. 33 1 760, and retainer, BMWNo.005550. •He

33.11Removing and installing taper needle bearing in rear wheel drive•Remove needle bearing using inner extractor21/4, BMW No. 00 8 573, and support 2

33.12Removing crown wheel•Remove housing cover (1) with crown wheel (2) and bearing (3). •Heat housing cover (1) to 100 °C and remove.•Drive shaft sea

33.13•Remove taper roller bearing from ring gear with puller, BMWNo.007500.•Remove outer bearing race with internal extrac-tor, BMW No. 00 8 560.Insta

00.17Checking function of electric switch on side stand and adjusting if nec-essaryInspections I, II, III•Place motorcycle on centre stand on even sur

33.14Checking/adjusting tooth backlash•Lock drive bevel gear in position with 36 mm (1.4173 in) insert, BMW No. 33 1 720. •Fit measuring ring, BMW No.

33.15Checking contact pattern•The contact pattern must be checked when the set of gears, the housing or the bearing of the drive bevel gear has been r

33.16Shimming housing cover•The housing cover must be shimmed in order to achieve the corresponding preload of the taper roller bearing.•Measure dista

33.17Installing rear wheel drive•Coat spline on sliding piece (arrow), for example with Optimoly MP3.•Fit inner race (5) of right-hand needle bearing

33.18•Apply a load of approx. 85 Kg (1887.43 lb)to the motorcycle and tighten loose strut (4) with the nut on the wheel side.X Tightening torques:Stru

33.19Removing, disassembling and assembling rear swinging arm•Remove left and right footrest plate.•Heat to max. 120 °C at loose bearing of swinging

33.20Removing and installing gaiter•Remove inner retaining ring, pull gaiter out of swinging arm.•Install in the reverse order of removal.•Coat inside

33.21Installing swinging arm•Slide swinging arm over drive shaft.•Lift drive shaft over the support surface in the swinging fork and press forward swi

33.22

34.1Contents Page34Technical Data ...

00.18Checking clutch clearance and adjusting if necessaryInspections I, III•Detach clutch cable at clutch release lever (1).•Slightly push back rubber

34.2Contents Page[ABS II] Installing ABS unit ...

34.334Technical Data K 1100 LT K 1100 RSBrake fluid DOT 4Minimum brake pad thickness mm (in) 1.5 (0.059)Front wheelBrake disc Ø mm (in) 305 (12.01)Bra

34.4

34.5Removing and installing front brake caliper•Mask off brake caliper at top of wheel side with tape (rim guard).•Release brake caliper mounting (1)

34.6Dismantling and assembling front brake calipere Caution:The brake caliper halves must not be unscrewed!Dismantling front brake caliper•Remove the

34.7Assembling front brake caliper•Coat new sealing rings (3,4) with brake fluid and install. •Coat brake caliper pistons (2) with brake fluid and ins

34.8Removing and installing brake pads•Remove brake caliper.L Note:If only the brake pads are to be replaced, do not re lease the brake line at the br

34.9Removing and installing front brake disc•Remove front wheel.•Release retaining screws (1) for brake disc carri-er.•Detach brake disc carrier (2) w

34.10Removing and installing front ABS sensor•Remove fuel tank.•Disconnect plug connection (1) of sensor line.•Remove cover for brake distributor.•Rem

34.11Adjusting front ABS sensor gap•Raise front wheel with front wheel stand, BMW No. 36 3 950.•Secure dial gauge holder (1), BMW No. 34 2 520 with di

00.19Checking increased starting speed (choke) and adjusting if necessaryInspections I, IIIChecking increased starting speed•Remove the left battery c

34.12Removing and installing front brake lineRemoving upper brake line•Drain brake system.•Remove fuel tank.•Release brake line (1) at handbrake cylin

34.13Removing and installing ABS brake line from front pressure modulator•Remove knee pads.•Remove fuel tank.•Release screw connections (1,2).•Release

34.14Removing and installing handbrake cylinder•Drain brake system.e Caution:Ensure brake fluid does not come in contact with painted parts of the veh

34.15Bleeding brakee Caution:Escarping brake fluid can damage painted surfaces.Bleeding front brakeBleeding brake caliper•Remove front brake pads.e Ca

34.16[ABS II] Bleeding pressure modulator•Remove the left battery cover.•Connect a vessel to the brake caliper bleed screws to trap escaping brake flu

34.17Removing and installing pressure modulatore Caution:Work on the ABS unit is only to be carried out by an authorised BMW workshop.[ABS I] Removing

34.18[ABS II] Removing ABS unit•Remove the dualseat.•Remove the left and right battery trim panels.•Remove the Motronic control unit.•Remove the batte

34.19[ABS II] Installing ABS unit•Install ABS unit (6).•Reconnect central plug (5).e Caution:Do not tilt the cables or the insulation may be dam-aged.

34.20[ABS II] Removing and installing relay and relay base[ABS II] Removing relaye Caution:Switch off the ignition and disconnect and insulate the ear

34.21•Install a new cover (1).e Caution:When pushing on, make sur that all cables are cor-rectly located in their guides. Scrap the old cover.[ABS II]

00.20Checking valve clearance and adjusting if necessaryInspections I, IIIe Caution:Never unscrew the spark plugs before measuring the valve clearance

34.22Removing and installing rear brake caliper•Drain brake System.•Release bottom of suspension strut (1).•Detach suspensions strut from stud bolt.•R

34.23Dismantling and assembling rear brake caliperDismantling rear brake caliper•Remove keepers (1).•Drive out spring (2) and retaining pin (3). •Take

34.24Removing and installing rear brake disc•Remove brake caliper.•Remove rear wheel.•Remove brake disc.L Note:Mark installation position of the brake

34.25Removing and installing rear ABS sensor•Remove brake caliper but do not loosen brake line.•Release sensor with socket wrench, BMW No. 00 2 640.•D

34.26Measuring vertical runout at rear pulse wheel•Remove brake caliper.•Remove rear wheel.•Secure dial gauge with retaining fixture to bottom of spri

34.27Removing and installing rear master brake cylinder•Drain brake system.e Caution:Ensure brake fluid does not come in contact with painted parts of

34.28Disassembling rear master brake cyl-indere Caution:Piston is under spring loading.•Using thrust piece (1), push piston (2) a little way inwards.•

34.29Removing and installing brake pedal•Remove footrest plate.•Detach sealing gaiter (1) at master brake cylin-der.•Release mounting (2) for brake pe

34.30Adjusting foot brake pedal•Loosen locknut (1).•Perform basic setting with adjusting screw (2).•Adjust distance „A“ with feeler gauge.Basic settin

34.31Troubleshooting: Front wheel/rear wheel brakeBrake rubs/vibrates.noCheck brake pads.Are brake pads worn/damaged?yesRenew brake pads.Brake pedal s

00.21L Note:Only the bucket tappets replaced during the 1000 km (600 miles) inspection can be re-used.Installing camshafts•The camshafts are marked to

34.32Reduced brake effect when applied hard?noCheck brake fluid.Has brake fluid aged?yesRenew brake fluid.Only mederate brake effect?noCheck brake pad

34.33Brakes rubbing.noCheck hydraulic system.Is there a defect in hydraulic system operation?yesRectify defect.noCheck brake piston.Are brake pistons

34.34

36.1Contents Page36Technical Data ...

36.2

36.336Technical Data K 1100 LT K 1100 RSRim size front 2.50 x 18 MT H 2 3.50 x 17 MT H 2rear 3.00 x 17 MT H 2 4.50 x 18 MT H 2Vertical runout mm (

36.4

36.5Removing and installing front wheel•[RS] Raise the front wheel with the front wheel stand, BMW No. 36 3 950.•[LT] Raise the front wheel with the f

36.6Removing and instaling wheel bearings•Place the wheel on two wooden blocks so that the brake disc is free.Removing left bearing•Take out circlip (

36.7Removing and installing rear wheelRemoving rear wheel•Remove number plate bracket.•Remove the brake caliper.•Pull off cap (1) with an angled screw

IntroductionThis repair manual will help you to perform all the main maintenance and repair work correctly and efficient-ly. If it is consulted regula

00.22Installing cylinder head cover•Screw fitted bolt, BMW No. 11 1 980, (arrow) into inner hole at the front.•Press centring pin, BMW No. 11 1 990, w

36.8Static balancing of front and rear wheelsStatic balancing of front wheel•Remove the wheel.•Insert the balancing shaft, BMW No. 36 3 614, through t

36.9Checking wheel for runoutChecking front wheel for runout•Install the wheel without tyre on the balancing shaft, BMW No. 36 3 614, and balancing st

36.10

46.1Contents Page46Technical Data ...

46.2Contents PageChecking frame with gauge ...18Rem

46.346Technical Data K 1100 LT K 1100 RSLocation of type identification plate Rear right frame tubeLocation of chassis number Rear right frame tubeMax

46.4

46.5Removing and installing front mudguard•Loosen clamping screws (1,2).•Detach cover (3).•Remove rear section of mudguard (4).•[LT] Detach Velcro con

46.6Removing and installing rear sec-tion•Remove dualseat.•Remove combined tail light unit.•Release securing screw (1).•Install in the reverse order o

46.7Removing and installing rear mudguard1. Rubber sleeves on gearbox2. Bracket3. Sheet-metal nuts4. Licence plate support bracketLT4900403421

00.23Checking steering bearing play and adjusting if necessaryInspection III•Place a piece of adhesive tape (arrow) on the fork bridge above the setti

46.8Removing and installing fairing [LT]Removing side sections of fairing•Remove knee pad (1).•Remove storage box (2).•Remove cover (3).•Remove side s

46.9Removing and installing windshield•Release securing screws (1) on left and right and detach screen.Removing and installing windshield complete wit

46.10Disassembling and assembling adjust-able windshieldRemoving and installing actuator motor•Release securing elements (1) for actuator motor and re

46.11Removing lever•Remove actuator motor.•Remove plate.•Detach spring.•Release securing element (3) of guide rod (4), while holding with pin (5).•Pul

46.12Removing and installing upper section of fairing•Remove side sections of fairing and radiator cowling.•Remove cover (1).•Remove complete windshie

46.13Removing and installing fairing [RS]Removing and installing lower section of fairing– Lower section of fairing (1)•Release securing element on si

46.14Removing and installing upper section of fairing•Remove lower section of fairing, side sections and radiator cowling.•Remove cover (1).•Remove su

46.15Removing and installing fairing support bracket•Remove fairing.•[LT] Remove instrument cluster.•Remove horns (1).•Disconnect cable clips for wiri

46.16Checking running gearMeasuring track offset•Mount motorcycle on centre stand on even base.•Position track offset gauge (1), BMWNo.363920, on left

46.17•Calculate track offset ”S”:EXAMPLE:•The track offset ”S” represents the amount by which the longitudinal axis of the front wheel is offset to th

00.24Lubricating guide pins, adjustable screenInspections III, IV•Release retaining screw (1) on both sides.•Slightly raise plate (2).•Spray guide pin

46.18Checking frame with gauge•Remove fairing.•Support motor cycle with lifting gear, BMWNo.001510.•Remove telescopic fork.•Outer bearing race at top

46.19•Fit measuring pins (1), BMW No. 46 5 602, lightly greased, in the outer holes.•Slightly loosen nut on steering head and align gauge so that the

46.20Removing and installing frameRemoving frame•Set motorcycle on centre stand.•Support with lifting gear, BMWNo.001510, un-der oil sump. •Remove sea

46.21Removing and installing seat lock1. Saucer-head screw2. Phillips-head screw3. Stop nutRemoving and installing handle•Lever out spring using screw

46.22Installing frame•Installation basically takes place in the reverse order of removal.•Place frame on drive train and firmly tighten screws and bol

46.23Removing and installing main centre stand•[RS] Remove lower section of fairing.•Raise motorcycle with lifting gear, BMW No. 00 1 510, under the o

46.24Disassembling and assembling side standDisassembling side stand•Detach switch (1).•Detach tension springs (2).•Remove bracket (3) with spring.•Re

46.25Assembling side standL Note:The securing screw of the side support is micro-en-capsulated and cannot be reused. Clean thread and holes. Coat scre

46.26Disassembling and assembling main centre stand •Detach tension springs (1).•Release screws (2) on left/right.•Release retaining ring (3).•Press o

46.27Checking switching function of side stand•Set vehicle on centre stand on even base or lift-ing platform.•Spray switching kinematics of side stand

00.25Checking idle speed, synchronising and CO value and adjusting if nec-essaryInspections I, II, III, IVL Note:The basic settings (ignition, valve c

46.28

51.1Contents Page51Removing and installing ignition switch/steering lock ...3Removing and installing lock cyl

51.2

51.351Removing and installing ignition switch/steering lock•Remove fuel tank.•Disconnect plug connection (1) for ignition switch/steering lock.•Detach

51.4Removing and installing lock cylin-der for fuel tankRemoving lock cylinder•Open cover and release screws (1).•Remove housing (2) for lock cylinder

51.5Removing and installing dualseat lock5. Saucer-head screw6. Phillip-head screw7. Stop nutLT5100402113

51.6

61.1Contents Page61Technical Data ...

61.2

61.361Technical Data K 1100 LT K 1100 RSBatteryAh 19

00.26Adjusting CO value without catalytic converterL Note:Engine must be at operating temperature (85 °C).The basic settings (ignition, valve clearanc

61.4

61.5Removing and installing Motronic control unite Caution:Switch off ignition, disconnect and insulate earth (ground) lead!•Open dualseat.•Press catc

61.6[ABS I] Removing and installing control unite Caution:Switch off ignition, disconnect and insulate earth (ground) lead!•Switch off ignition, disco

61.7Removing and installing batterye Caution:Switch off ignition, disconnect and insulate ground lead!•Remove Motronic control unit.•[ABS I] Remove AB

61.8Relay locations (central electrical unit)•First remove the fuel tank in order to remove a relay.1. Lamp control unit2. Start relay3. Turn indicato

61.9Locations and connections, ABS wiring loomL Note:All ABS plug connections are blue.1. [ABS I] Multi-pin plug, ABS control unit2. [ABS I] Plug conn

61.10Locations, frame wiring loomView from leftL Note:When removing the wiring loom, also remove the central electrical box together with the wiring l

61.11View from right1. Right multi-function switch connection2. Ignition lock connection3. Handbrake light switch plug connection4. Hall generator plu

61.12

62.1Contents Page62Technical Data ...

11.1Contents Page11Technical data ...

62.2

62.362Technical Data K 1100 LT K 1100 RSInstrument clusterTurn signal indicator lamps 12 V/4 W T 8/4Other indicator lamps, instrument lights 12 V/3 W

62.4

62.5Removing and installing instrument cluster[LT]•Remove upper section of fairing.•Release screw (1) and disconnect central plug connector.•Release s

62.6[RS]•Remove upper section of fairing.•Release screw (1) and disconnect central plug connector.•Release screws (2) and remove instrument clus-ter.•

62.7Disassembling and assembling instrument cluster•Release instrument support bracket (1).•Release housing cover (2) and remove together with gasket

62.8Removing and installing p.c. board•Release securing screws and carefully lift out p.c. board (1).L Note:Do not damage p.c. board when removing and

62.9Removing and installing revolution counter•Release screws (1).•Lift out revolution counter (2).Removing and installing speedometer•Release screws

62.10Removing and installing p.c. board for gear indi-cator•Remove tachometer.•Carefully pull pointer (1) off the spindle.•Release screws (2).•Remove

63.1Contents Page63Technical Data ...

11.2Contents PageRemoving pistons with conrods, stripping down and re-assembling ...26Removing piston with conrod ...

63.2

63.363Technical Data K 1100 LT K 1100 RSLightsHeadlight Halogen rectangular headlight with two-stage manual range adjustmentBulbsHigh beam/low beam H

63.4

63.5Disassembling and assembling headlights•Remove upper section of fairing.•Remove headlight.•Release retaining spring (5).L Note:Do not touch the in

63.6Adjusting headlights •Engage swivel lever (1) in top position.•Correct headlight range with adjusting screw (2).•Turning counterclockwise: shorter

11.3Contents PageInstalling timing chain ...

11.4

11.511Technical data K 1100 LT K 1100 RSEngine, generalEngine design Inline four-stroke engine installed longitudinally, with double overhead camshaft

UsageEach chapter starts with the list of contents.The list of contents is followed by the Technical Data table.Chapter 00 “Maintenance and general in

11.6ValvesValve clearances with engine cold (max. 35 °C)Inlet valve mm (in) 0.15…0.20 (0.0059…0.0079)Exhaust valve mm (in) 0.25…0.30 (0.0098…0.0118)Va

11.7ValvesValve guide dia.Extl. dia. mm (in) 11.533…11.544 (0.4541…0.4545)Intl. dia. mm (in) 6.0…6.012 (0.2362…0.2367)Wear limit mm (in) 6.1 (0.2402)B

11.8CrankshaftMain bearing and crankpin markingsno colour spot Grinding stage 0with colour spot Grinding stage 1Width of guide bearing mm (in) 23.020…

11.9Piston rings1st groove Rectangular-sectionHeight mm (in) 1.175…1.190 (0.0462…0.0469)Wear limit mm (in) 1.100 (0.0433)Ring gap mm (in) 0.20…0.40 (0

11.10

11.11Removing engine•Remove fuel tank.•Remove knee pads.•Remove fuel tank.•Remove lower section of fairing at left and right.•Remove radiator surround

11.12Dismantling engine•Remove air cleaner box.•Remove fuel injection rail.•Remove throttle rail.•Attach engine mount, BMW No. 11 0 610, to the engine

11.13Removing intermediate flange•Remove alternator.•Remove coils with holder.Removing driver•To remove the screw, support the driver (arrow).•Pull th

11.14Removing clutch housing•Install the retaining device (arrow), BMWNo.112800, in the position illustrated.•Unscrew hex nut (1) and take off thrust

11.15Stripping down and re-assembling intermediate flangeRemoving the driver bearing•Bearing plate (1) •Cup spring (2) •Pull out ball bearing (3) with

Order No. 01 71 9 799 131 UX-VS-2, 12/98 Printed in GermanyCustomer Registration No.Order No. Signature of mechanicBMW Inspection 1000km/600mlsBMW Ser

11.16Removing and installing shaft sealing ring for driver•If the intermediate flange has been removed, le-ver out the sealing ring.•If the intermedia

11.17Dismantling and assembling freewheelStripping down freewheel•Pull freewheel gear (1) off layshaft (5).•Clamp the layshaft into a vice with soft j

11.18•Place the cup spring in position.•Insert the freewheel (oiled with engine oil) into the outer race.•Install the outer race (with clamp block fac

11.19Removing timing chain coverRemoving the Hall-effect signal transmitter•Remove cover (1).•Take off gasket (2).•Remove Hall-effect signal transmitt

11.20Removing the timing chain•Set cylinder 1 (timing end) to TDC, noting direc-tion of rotation (arrow). Pin (1) on the crankshaft must be aligned wi

11.21Removing camshaft chain sprockets•When taking out the retaining screws, hold the hexagon on the camshaft to prevent it from turn-ing.•Remove chai

11.22Removing, stripping down and assem-bling cylinder headRemoving camshafts•Remove the bearing caps (1) for the thrust bear-ings first, to prevent t

11.23Removing valves•Screw support plate, BMW No. 11 1 749, for the valve spring clamping tool on to the rear of the cylinder head.•Attach valve sprin

11.24Installing valve and valve stem sealL Note:If a valve was removed, the valve stem seal must be renewed.•Oil the stem when installing the valve.•I

11.25Removing crankshaftRemoving big end bearings•Move the piston in cylinders 1 and 4 to the bot-tom dead centre (BDC) position.•Remove the big end b

Order No. 01 71 9 799 131 UX-VS-2, 12/98 Printed in GermanyCustomer Registration No.Order No. Signature of mechanic BMW Pre-delivery checkInspect crat

11.26Removing pistons with conrods, strip-ping down and re-assemblingRemoving piston with conrod•Press the piston with conrod out from the crank-shaft

11.27Assembling pistons•Install piston rings, using piston-ring pliers.1st groove: rectangular-section ring2nd groove: micro-chamfer ring (note pinfor

11.28Assembling pistons and conrodsL Note:[LT] Modified conrod length and pistons from 1993 model year on•Comply with conrod weight tolerances.Weight

11.29Removing, dismantling and assem-bling combined oil-water pumpRemoving pump•Pull off the wires for the oil pressure and water temperature display

11.30Removing slipring seal and shaft sealing ring•Press out slipring seal (6) with a drift.•Using a 5 mm (0.2 in) wide screwdriver, carefully press o

11.31Removing output shaftRemoving oil sump•After removing the screws, loosen the seal with light blows of a plastic-faced hammer.Removing oil filter•

11.32Stripping and assembling output shaftStripping down output shaft•Take off needle roller race (1) and circlip (2).•Pull output shaft (3) out of da

11.33Assembling tensioning gear•Insert the tensioning spring.•Install tensioning gear with counter-holder, BMW No. 12 4 600.•Clamp the tensioning gear

11.34Assembling engineInstalling output shaft•Push circlip (1) and needle roller sleeve (2) on to the bearing point.•Place the output shaft in the cra

11.35Assembling the crankcase•Install O-rings (6,7) for the water and oil passag-es.•Coat the sealing faces (which must be free from oil and grease) l

00 Maintenance and general instructions ... 00.111 Motor...

11.36Measuring crankshaft bearing playMeasuring radial play•Crankshaft bearing points must be clean and lightly oiled.•Place the crankshaft in the cra

11.37Measuring endplay•Install the crankshaft and measure as for radial play.•Screw measuring fixture,BMW No. 00 2 500, with dial gauge into the tappe

11.38Installing crankshaft•Oil the bearings lightly before inserting the crank-shaft.•Install the corresponding bearing caps with the grooves aligned.

11.39Installing piston with conrod•Turn the corresponding crankpin to bottom dead centre.•The piston ring gaps must be offset by app. 120° in each cas

11.40Measuring big end bearing play•Turn the crankpin 30° away from bottom dead centre.•Wipe oil off crankpin and bearing cap.•Place Plastigage strip

11.41Installing combined oil-water pump•Apply a thin coat of 3-Bond 1209 to the sealing faces, which must be free of oil and grease.•Place O-ring on w

11.42Installing cylinder head•Move the piston in cylinder 1 to top dead centre (cylinder 1 = timing end).•Place the cylinder head gasket in position;

11.43Installing camshaftsL Note:Note correct identification of camshafts.Inlet side : three grooves after thrust bearingExhaust side: two grooves afte

11.44Installing timing chain•Turn the camshaft so that the grooves on the ends are vertical in relation to the cylinder head at the rear.•The grooves

11.45•Press serrated washer (8) with eccentric shoul-der into the chain guide rail spacing bushing by a small amount.•Turn the serrated washer until t

33 Rear wheel drive ... 33.134 Brakes ...

11.46Installing intermediate flangeInstalling freewheel•Insert the freewheel into the crankcase with the helical-cut gearwheel leading.•Oil the needle

11.47Installing timing case cover•Apply a thin coat of 3-Bond 1209 to the sealing faces, which must be free from oil and grease.•Pass the wires for th

11.48Installing cover for Hall-effect transmit-ter•Install the wire for the Hall-effect transmitter with rubber grommet (arrow) in the timing case cov

11.49Installing cylinder head cover•Insert reamed bolt (arrow), BMW No. 11 1 980, into inner front hole.•Press centering pin, BMW No. 00 5 500, into m

11.50Installing engine•Attach hoist, BMW No. 00 1 510, to the oil sump.•Set the engine down on the hoist platform.•Release the engine mounting at the

11.51•Connect the engine wiring harness (coolant stub pipe, throttle position sensor, CO detector, injec-tors, air cleaner housing).•Attach cable stra

11.52Checking/adjusting valve clear-ancese Caution:Never unscrew the spark plugs before measuring valve clearances. Particles of oily soot could be-co

12.1Contents Page12Technical data...

12.2

12.312Technical data K 1100 LT K 1100 RSStarterType Permanent magnet motorGear ratio 27 : 1Output kW 0,7AlternatorType Three-phase alternator with in

00.1Contents Page00Tightening torque ...

12.4

12.5Removing and installing Hall gener-ator•Disconnect ground lead of battery and insulate.•Remove radiator cowling.•Remove fuel tank.•Disconnect Hall

12.6Adjusting ignition timing•Remove radiator cowling.•Remove bottom left fairing.•Remove fuel tank.•Disconnect plug connection on Hall generator lead

12.7•Loosen base plate (1) and turn to the left or right until diode (2) on ignition setting device goes out.L Note:Ignition timing adjustmentTurn to

12.8Removing and installing ignition coils•Disconnect earth (ground) lead of battery and in-sulate.•Remove top (1) and bottom (2) ignition coil cover.

12.9Removing and installing ignition output stage•Remove left battery bracket.•Disconnect earth (ground) lead of battery.•Remove ignition coils.•Remov

12.10Removing and installing alternator•Remove right battery panel.•Remove Motronic control unit.•[ABS I] Remove ABS control unit.•Remove battery.•Rem

12.11Disassembling and assembling alternatorAlternator [only LT up to 1992 model year]•Remove damper elements (1)•Remove coupling housing (2) with hol

12.12•Remove regulator (8) with carbon brushes.•Carefully lift out armature (9) together with bear-ing (10).•Remove bearing (10) from armature shaft.•

12.13Checking armature for short to earth•Measure resistance between slip rings and ar-mature.L Note:The resistance must be infinitely large.Measureme