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364
Repair Manual
1
Introduction
3
BMW AG Motorcycle Division
5
(from 1993 onlys)
5
Contents
7
Contents Page
10
Tightening torque
11
Injection rail 9
13
Intake stub pipe 9
13
Intake air line 9
13
(with Loctite 243)
13
Table of operating fluids
18
34 1 500
22
LT000310
23
LT000130
23
LT000140
23
Renewing brake fluid
24
LT000150
25
LT000160
26
LT000170
26
LT000180
26
LT130030
27
LT000190
28
LT000200
28
LT000210
28
Inspections III, IV
32
Slightly raise plate (2)
32
LT000280
33
LT000290
34
LT000300
34
11 Motor
35
± 0.15 (0.006)
40
±0.2 (0.0079)
41
±0.031 (0.0012)
41
-0.004 (0.0002)
43
LT110760
45
LT110830
45
LT110840
45
Dismantling engine
46
11 0 610
46
Removing intermediate flange
47
11 2 800
48
33 1 830
48
00 5 010
50
LT110160
51
LT110170
51
LT110180
51
LT110200
53
LT110210
53
LT110230
54
LT110240
54
LT110790
54
LT110260
55
LT110250
55
LT110270
56
LT110280
57
LT110290
57
LT110300
57
LT110310
57
LT110320
58
Removing crankshaft
59
LT110350
60
LT110360
60
LT110370
61
LT110380
61
LT110390
61
LT110400
61
LT110422
63
Removing output shaft
65
LT110450
66
LT110460
66
LT110470
67
LT110480
67
LT110490
67
LT110500
67
Assembling engine
68
Installing output shaft
68
00 2 500
71
Installing piston with conrod
73
11 2 925
73
Installing big end bearing
74
11 2 210
74
LT110770
85
LT110780
85
LT110800
86
12 Engine electrics
87
LT120020
92
LT120030
92
LT120060
95
LT120100
98
LT120110
98
LT120120
99
LT120130
99
LT120140
99
X Tightening torque:
100
61 1 510
101
X Tightening torques:
102
LT120160
103
LT120170
104
brushes
105
Checking starter
106
LT120200
107
LT120210
107
Troubleshooting
108
Troubleshooting on alternator
108
Troubleshooting on starter
112
Troubleshooting on battery
115
Inside ø of
121
CO value % by vol. 1,5 ± 0,5
121
Idle speed rpm 950 ± 50
121
Adjusting idle speed
123
Retighten locknut (3)
124
Adjusting CO value
125
Caution:
125
LT130060
126
LT130070
127
LT130080
128
LT130100
130
LT130110
130
16 Fuel tank and lines
133
Type Roller-cell pump
135
Make Bosch
135
LT160010
137
LT160020
138
LT160030
139
LT160040
140
Checking fuel pump pressure
141
16 1 500
141
17 Radiator
143
Removing and installing fan
150
LT170090
152
18 Exhaust system
155
X Tightening torques :
157
21 Clutch
159
Removing clutch
163
00 1 510
163
Release housing cover (2)
164
, and pressure tool
165
LT210010
167
LT210070
169
LT210090
169
LT210080
169
LT210100
170
LT210110
171
23 Gearbox
175
Preparatory work
179
Removing starter
180
23 1 820
182
LT230010
183
LT230020
184
LT230030
184
LT230040
184
LT230050
184
Note sleeves on guide pins
185
LT230090
186
LT230100
186
LT230140
188
LT230150
188
LT230160
188
LT230170
189
LT230180
189
LT230190
189
00 7 500
190
LT230210
191
LT230220
191
LT230230
192
LT230250
192
LT230260
193
LT230270
193
LT230280
193
LT230290
194
LT230300
194
23 3 660
195
00 2 550
195
31 Front fork
203
LT310010
207
LT310020
207
LT310030
208
LT310040
208
LT310050
209
LT310060
209
Measuring telescopic fork
210
31 4 620
210
LT310090
211
LT310100
212
LT310110
213
LT310120
213
LT310130
214
LT310140
214
LT310150
214
(arrows) and remove
215
Installing telescopic fork
219
32 Steering
223
Steering anglel °2 x 34
225
Cut through cable clip (1)
227
LT320080
232
Adjust cable after fitting
233
LT320100
234
33 Rear wheel drive
237
LT330350
241
LT330430
241
LT330010
242
RT330350
242
RT330360
242
00 8 570
244
00 8 573
244
LT330070
245
X Tightening torquse:
246
00 8 572
247
LT330110
248
RT330120
248
LT330130
248
RS330140
249
LT330150
249
LT330160
249
RT330170
249
RT330190
250
RT330200
250
RT330210
250
Checking contact pattern
251
Tightening torque:
253
Tightening torques:
253
Check sensor grap
254
LT330360
255
LT330310
255
LT330370
255
Removing drive shaft
256
Installing drive shaft
256
34 Brakes
259
LT340280
265
LT340030
266
LT340040
266
34 2 520
269
34 2 510
269
LT340250
276
LT340270
278
[ABS II] Removing relay base
279
LT340140
280
LT340200
286
36 Wheels and tyres
293
LT360010
297
LT360020
297
LT360030
298
LT360040
299
LT360050
300
Checking wheel for runout
301
46 Frame
303
mm (in) 12 (0.47)
305
LT460010
307
LT460020
307
Remove dualseat
308
Release securing screw (1)
308
1. Rubber sleeves on gearbox
309
2. Bracket
309
3. Sheet-metal nuts
309
LT460050
310
LT460060
310
LT460070
311
LT460080
312
LT460090
312
LT460130
314
LT460140
315
LT460150
315
LT460160
316
LT460170
316
LT460210
318
LT460220
319
Checking frame with gauge
320
46 5 600
320
46 5 602
321
LT460320
322
LT460270
322
LT460280
322
LT510040
323
Disassembling side stand
326
LT460370
328
LT460380
329
51 Equipment
331
LT510030
334
5. Saucer-head screw
335
6. Phillip-head screw
335
7. Stop nut
335
LT610020
342
LT610030
343
LT610040
344
LT610050
345
LT610060
346
LT610070
346
62 Instruments
349
LT620010
353
LT620020
354
LT620030
355
LT620040
355
LT620050
356
LT620060
356
LT620070
356
LT620080
356
LT620090
357
LT620100
357
LT620110
358
63 Lights
359
LT630010
363
Adjusting headlights
364
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