K1600 Service Manual

BMW-Motorrad
11 00 040 Testing compression with BMW Motorrad diagnostic system

+ 11 00 567
Preparatory work
Remove the front seat
Removing left bottom side panel
Removing left radiator cowl
Removing radiator hose cover
Removing left side panel
Removing right bottom side panel
Removing right radiator cowl
Remove the right side panel
Draining cooling system
Removing complete radiator
Removing air guide
Disconnecting distributor rail for secondary air system
Removing direct ignition coils
Removing spark plugs
Connecting BMW Motorrad diagnostic system to motorcycle
Core activity
(-) Testing compression
Test
Install diagnosis adapter (No. 11 7 846) with hose (No. 11 7 842).
Connect the MBOX and follow the instructions.
Test the compression with the MBOX.
Technical data
Compression test Good >14 bar
pressure Normal 12...14 bar
Poor <11 bar
Result: Compression loss greater than normal.

Measure:
Carry out repairs as specified.
Finishing work
Disconnecting BMW Motorrad diagnostic system from motorcycle
Installing spark plugs
Installing direct ignition coils
Securing distributor rail for secondary air system
Installing air guide
Installing complete radiator
Filling and priming cooling system
Install the right side panel
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Install the right radiator cowl

Installing right bottom side panel
Installing left side panel
Installing radiator hose cover
Installing left radiator cowl
Installing left bottom side panel
Installing front seat
Final check of work performed
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11 00 045 Testing for pressure loss with BMW Motorrad diagnostic system
+ 11 00 568
Preparatory work
Removing air guide
Core activity
(-) Checking pressure loss
Test
Install diagnosis adapter (No. 11 7 843) with hose (No. 11 7 842) and
adapter for pressure loss (No. 11 7 841).
Connect the MBOX and follow the instructions.
Check pressure loss with the MBOX.
Technical data
Press loss Engine at max 25 %
through valves or regular
cylinder operating
temperature
Result: Pressure loss greater than maximum permissible value.

Measure:
Pinpoint the cause of the fault.
Possible causes:
Inlet valves
Exhaust valves
Piston and cylinder
Finishing work
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11 00 050 Removing/installing engine 61 FRUs

+ 11 00 541
Equipment trim-level variant:
0266 - Preparation for audio system and navigation device
0267 - ECE audio system and preparation for navigation system
0417 - Central locking
Preparatory work
Disconnecting battery
Removing air guides for intake air pipes, left and right
Removing complete cover of fuel tank
Removing left stowage compartment
Removing inner trim for left side panel
Removing gearbox cover
Removing cross-member for radiator cowls
Removing inner trim for right side panel
Removing right stowage compartment
Draining engine oil
Removing adjusting plate
Disengaging seat support
Disengaging left and right intake air pipes
Removing complete intake air silencer
Removing fuel tank
Removing number-plate carrier
Remove the rear wheel
Removing right footrest plate
Removing left footrest plate
Removing left catalytic-converter shield
Disengaging clamp on left silencer
Removing left silencer
Removing right catalytic-converter shield
Disengaging clamp on right silencer
Removing right silencer
Removing rear brake caliper
Disengaging actuator rod from rear ride height sensor
Releasing Paralever link at rear
Removing bevel gears
Removing universal shaft
Removing rear wheel swinging arm
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Removing strut for radiator
Removing air guide
Disconnecting line for secondary air system
Disengaging wiring harness for engine
Removing intake manifold
Disconnecting left oxygen sensor
Removing exhaust manifold, left
Disconnecting right oxygen sensor
Removing exhaust manifold, right
Disengaging shift lever
Removing clutch slave cylinder
Core activity
(-) Releasing wiring harness from engine
Remove cap (1).
Remove nut (2).
Disengage cable (3) for the starter.
Remove cap (1).

Remove nut (2).
Disengage positive lead (3) for the alternator.
Disconnect plug (4) for the alternator.
Disengage the cables from the clips (arrows).
Attention
The locking tab can be broken off if the correct procedure is not
adopted for disconnecting the plug.
Push the plug away from the locking tab; do not attempt to raise or
bend the locking tab.
Disconnect plugs (1) for the direct ignition coils.

Disconnect plug (2) for the camshaft sensor.
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Remove screws (1).

Disengage earth lead (2).
Disconnect plug (3) for the coolant-temperature sensor.
Disengage cable (1) for the oil-level sensor and cable (2) for the side-
stand switch from the clips (arrows).
Remove screw (1).

Disengage earth cable (2).
Remove cable tie (arrow).
Unclip plug (3) for the oil-level sensor
(-) Disengaging oil lines
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Remove screws (1).

Disengage feed line (2) and return line (3), noting sealing rings (4).
(-) Removing side-stand pivot mount with side stand

Remove screws (1).
Remove the side-stand pivot mount with side stand (2).
Work line (3) for the side-stand switch clear.
(-) Removing blanking plugs

Remove blanking plug (1) from bore (2).
Remove blanking plugs (1) from bores (2).
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(-) Installing engine lifter

Place support (A) from engine adapter (No. 00 1 582) in position.
Install long screw (1), but do not tighten.
Place supports (B) and (C) from engine adapter (No. 00 1 582) in
position.
Install long screws (1), but do not tighten.
Position engine adapter (No. 00 1 582) on supports (A), (B) and (C),
noting the reamed pins (arrows).
Install and tighten short screws (1).
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Tighten long screws (1).
Secure rail (No. 00 1 583) to scissor-type lifter (No. 00 1 571).

Mount extensions (No. 00 1 575) at the very outside of rail (No. 00 1
583).
Raise scissor-type lifter (No. 00 1 571) and install in engine adapter
(No. 00 1 582), making sure that engine adapter is centred on scissor-
type lifter .
(-) Removing engine

Secure strap (1) to the frame.
Use straps to secure the motorcycle to the workshop crane, consisting
of (No. 46 5 671), (No. 46 5 672), (No. 46 5 673), (No. 46 5 674).
Remove screws (1) and (2).

Remove topple preventer (3).
Remove screw (4) with washer (5).
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Remove screw (1).

Slacken collared nut (2).
Slightly back off threaded sleeve (3).
Remove screws (1) with washers (2).

Remove spreader sleeves (3) and red taper elements (4).
Protect frame (1) by applying adhesive tape (arrows).
Protect frame (1) by applying adhesive tape (arrows).
Using the engine lifter, alternately lower the engine and pull it forward
until the frame can be lifted up and clear of the engine. In this process,
take particular care at the right-hand side to prevent collisions between
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the engine and the frame.

Lift the motorcycle with the assembly crane and roll it clear.
(-) Installing engine

Lift the motorcycle with the assembly crane, position it over the engine
and carefully lower it.
Using the engine lifter, alternately raise the engine slightly and pull it to
the rear, until the holes in the frame and the engine are in line. In this
process, take particular care at the right-hand side to prevent collisions
between the engine and the frame.
Hold topple preventer (3) in position.

Loosely install screws (1) and (2).
Loosely install screws (4) and (6) with washers (5).
Insert red taper elements (4).

Insert spreader sleeves (3) with the gap (arrow) down.
Loosely install screws (1) with washers (2).
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Remove the lengths of adhesive tape (arrows).

Tighten screws (1), (2) and (3).
Tightening torques
Engine to frame, left side
Loosely install all
bushings and
screws on left and
right
Tighten screws on
left until hand-tight
M12 x 1.5 x 60 66 Nm
M10 x 80 38 Nm
M10 x 55 38 Nm
Hold threaded sleeve (3) and collared nut (2) in position and align with
the cylinder head, using suitable tools.
Tighten threaded sleeve (3) and collared nut (2), install screw (1).
Tightening torques
Cylinder head, right, to frame
Threaded sleeve, M24 x 1.25 1st step
2 Nm
Collared nut, M24 x 1.25 2nd step
100 Nm
M12 x 1.5 x 70 3rd step
66 Nm
Remove the lengths of adhesive tape (arrows).
Tighten screws (1).
Tightening torques
Engine to frame, rear, right side
M10 x 55 38 Nm
(-) Removing engine lifter
Attention
The motorcycle can topple and fall on its side.
Make sure that the motorcycle cannot topple sideways.
Lower scissor-type lifter (No. 00 1 571) and remove it from engine

adapter (No. 00 1 582).
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Remove short screws (1).

Remove engine adapter (No. 00 1 582) from supports (A), (B) and (C),
noting the reamed pins (arrows).
Remove long screws (1).

Remove supports (B) and (C) from engine adapter (No. 00 1 582).
Remove long screw (1).

Remove support (A) from engine adapter (No. 00 1 582).
(-) Installing blanking plugs
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Install blanking plugs (1) in bores (2).
Install blanking plug (1) in bore (2).
(-) Installing side-stand pivot mount with side stand

Work line (3) for the side-stand switch up into position.
Hold the side-stand pivot mount with side stand (2) in position.
Install screws (1).
Tightening torques
Pivot mount (side stand) to frame
M12 x 37, Replace screw 66 Nm
Micro-encapsulated
(-) Securing oil lines

Check sealing rings (4) for damage; replace if necessary.
Install feed line (2) and return line (3).
Install screws (1).
Tightening torques
Oil cooler lines to crankcase
M6 x 20 10 Nm
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(-) Securing wiring harness to engine

Hold earth cable (2) in position and install screw (1).
Tightening torques
Wiring harness to crankcase
M5 x 12 8 Nm
Clip in plug (3) for the oil-level sensor.
Secure excess length of line (4) for the oil-level sensor with a cable tie
(arrow).
Secure cable (1) for the oil-level sensor and cable (2) for the side-
stand switch in the clips (arrows).
Attention
Connect plugs (1) for the direct ignition coils.

Connect plug (2) for the camshaft sensor.
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Install earth lead (2) with screws (1).
Tightening torques
Engine wiring harness to cylinder head
M5 x 12 8 Nm
Connect plug (3) for the coolant-temperature sensor.
Connect plug (4) for the alternator.

Hold positive lead (3) for the alternator in position
Install nut (2).
Tightening torques
Wiring harness to alternator
M6 8 Nm
Install cap (1).
Secure the cable in the clips (arrows).
Hold cable (3) for the starter in position.

Install nut (2).
Tightening torques
Wiring harness to starter
M6 8 Nm
Install cap (1).
Finishing work
Securing clutch slave cylinder
Securing selector lever
Installing exhaust manifold, right
Securing right oxygen sensor
Installing exhaust manifold, left
Securing left oxygen sensor
Installing intake manifold
Securing wiring harness for engine
Connecting line for secondary air system
Installing strut for radiator
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Installing rear swinging arm
Installing universal shaft
Installing bevel gears
Securing Paralever link at rear
Securing actuator rod to rear ride height sensor
Securing rear brake caliper
Installing right silencer
Securing clamp on right silencer
Installing right catalytic-converter shield
Installing left silencer
Securing clamp on left silencer
Installing left catalytic-converter shield
Installing left footrest plate
Installing right footrest plate
Installing rear wheel
Installing number-plate carrier
Installing fuel tank
Installing complete intake air silencer
Securing left and right intake air pipes
Securing seat support
Installing adjusting plate
Installing right stowage compartment
Installing inner trim for right side panel
Installing cross-member for radiator cowls
Installing inner trim for left side panel
Installing left stowage compartment
Installing complete cover of fuel tank
Installing air guides for intake air pipes, left and right
Connecting battery
Reading fault memory with BMW Motorrad diagnostic system
and resetting adaptation values
Reset system time with BMW Motorrad diagnostic system
Pouring in engine oil
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11 00 209 Oil change, engine, with filter 3 FRUs

+ 11 00 611
Note
Change oil, warmed to normal operating temperature.
Core activity
(-) Engine oil change with filter
Draining engine oil
Place a suitable tray underneath the engine to catch escaping oil.
Warning
Parts of the exhaust system can be hot.
Do not touch hot parts of the exhaust system.
Remove drain plug (1) with sealing ring (2) and drain the engine oil.
Remove old sealing ring (2) from drain plug (1).
Removing threaded plug, sump plate

Remove threaded plug (1) with long 5 mm Allen key.
Removing oil filter

Push shift lever (1) down.
Remove oil filter (2), using oil filter wrench (No. 11 4 661).
Dispose of the oil filter in an environmentally friendly manner.
Remove all oil stains from the manifold and engine.
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Drain off all the engine oil.

Installing oil filter
Clean the sealing face on the engine block (arrow).
Wet sealing ring (3) of new oil filter (2) with engine oil.
Install new oil filter (2), using oil filter wrench (No. 11 4 661).
Tightening torques
Oil filter to engine
Coat seal with engine oil 11 Nm
Check that oxygen sensor cable (1) is correctly routed behind oil filter
(2) and in engine block (3); correct the routing if necessary.
Installing threaded plug, sump plate

Install threaded plug (1) with long 5 mm Allen key.
Tightening torques
Oil drain plug in sump plate
M10 x 1 12 Nm
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Installing drain plug for oil pan

Install drain plug (1) with new sealing ring neuem Dichtring (2).
Tightening torques
Oil drain plug to oil pan
M16 x 1.5 28 Nm

Prepare the correct total quantity of engine oil.
Technical data
Engine oil, capacity with filter 4.5 l
change
Fluids and lubricants
products recommended by BMW Motorrad and
generally admissible viscosity classes
Fill the oil tank to the MAX mark.
Start the engine and allow it to run.
Pour the rest of the oil into the oil tank.
Close the oil tank.
Checking engine oil level
Position the motorcycle upright and allow the engine to idle until the
fan starts up, then allow the engine to continue idling for one minute.
Switch off the engine and wait for about one minute to allow the oil to
drain into the sump.
Remove oil dipstick (1) and clean the dipstick.
Test
Seat oil dipstick (1) on the oil filler neck, but do not engage the
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threads.
Remove oil dipstick (1) and check the oil level.
Technical data
Engine oil, specified level Engine at Between MIN
regular and MAX marks
operating
temperature
Result: Oil level not between MIN and MAX marks

Measure:
Correct the oil level.
Install oil dipstick (1).
Finishing work
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11 00 609 Oil change in engine with filter (for maintenance) 2 FRUs
Note
Change oil, warmed to normal operating temperature.
Core activity
(-) Engine oil change with filter
Draining engine oil
Place a suitable tray underneath the engine to catch escaping oil.
Warning
Parts of the exhaust system can be hot.
Do not touch hot parts of the exhaust system.
Remove drain plug (1) with sealing ring (2) and drain the engine oil.
Remove old sealing ring (2) from drain plug (1).
Removing threaded plug, sump plate

Remove threaded plug (1) with long 5 mm Allen key.
Removing oil filter

Remove oil filter (2), using oil filter wrench (No. 11 4 661).
Dispose of the oil filter in an environmentally friendly manner.
Remove all oil stains from the manifold and engine.
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Drain off all the engine oil.

Installing oil filter
Wet sealing ring (3) of new oil filter (2) with engine oil.
Install new oil filter (2), using oil filter wrench (No. 11 4 661).
Tightening torques
Oil filter to engine
Coat seal with engine oil 11 Nm
Check that oxygen sensor cable (1) is correctly routed behind oil filter
(2) and in engine block (3); correct the routing if necessary.
Installing threaded plug, sump plate

Install threaded plug (1) with long 5 mm Allen key.
Tightening torques
Oil drain plug in sump plate
M10 x 1 12 Nm
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Installing drain plug for oil pan

Install drain plug (1) with new sealing ring neuem Dichtring (2).
Tightening torques
Oil drain plug to oil pan
M16 x 1.5 28 Nm

Prepare the correct total quantity of engine oil.
Technical data
Engine oil, capacity with filter 4.5 l
change
products recommended by BMW Motorrad and
generally admissible viscosity classes
Fill the oil tank to the MAX mark.
Start the engine and allow it to run.
Pour the rest of the oil into the oil tank.
Close the oil tank.
Position the motorcycle upright and allow the engine to idle until the
fan starts up, then allow the engine to continue idling for one minute.
Switch off the engine and wait for about one minute to allow the oil to
drain into the sump.
Remove oil dipstick (1) and clean the dipstick.
Test
Seat oil dipstick (1) on the oil filler neck, but do not engage the
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threads.
Remove oil dipstick (1) and check the oil level.
Technical data
Engine oil, specified level Engine at Between MIN
regular and MAX marks
operating
temperature
Result: Oil level not between MIN and MAX marks

Measure:
Correct the oil level.
Install oil dipstick (1).
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11 12 244 Replacing cylinder head

+ 11 12 820
Preparatory work
Removing fuel tank
Removing air guide
Removing cylinder head cover
Removing left drop-protection pad
Removing crankshaft cover
Core activity
(-) Setting engine to TDC
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Turn the crankshaft to firing TDC of cylinders 1 and 5.
(-) Locking engine at TDC

Turn crankshaft (1) counter-clockwise until the hole (arrow) in the
crankshaft is visible.
Insert locating pin (No. 11 0 811) and lock crankshaft (1).
(-) Removing timing-chain tensioner

Remove screws (1) and remove cover (2) with sealing ring (3).
Remove timing-chain tensioner (4).
(-) Removing bearing cap for camshafts

Screw stud bolts (No. 11 0 812) into spark-plug bores and tighten by
hand until seated.
Screw thrust nuts (No. 11 0 812) on to stud bolts and tighten by hand
until seated.
Removing top guide for timing chain

Remove nuts (1).
Remove guide (2).
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Remove nuts (1).
Uniformly slacken thrust nuts (No. 11 0 812) and remove.

Remove bearing cap (1).
(-) Removing O-rings for camshaft bearing cap

Remove large O-rings (1) and small O-rings (2).
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(-) Removing camshafts

Mark the positions of sprocket (1) of exhaust camshaft and sprocket
(2) of inlet camshaft relative to timing chain (3) (arrows).
Work exhaust camshaft (1) and inlet camshaft (with multi-pole sensor
gear for camshaft sensor) (2) out of timing chain (3) and remove.
Secure timing chain (3) in a suitable way to prevent it dropping out.
(-) Disconnecting left oxygen sensor

Disengage cable (1) for the oxygen sensor from holder (2) and work it
clear.
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Disengage cable (1) for the oxygen sensor between engine (2) and
gearbox (3) and work it clear.
(-) Removing exhaust manifold, left

Remove nuts (1) and remove exhaust manifold (2).
Remove gaskets (3).
(-) Disconnecting right oxygen sensor

Disengage cable (1) for the oxygen sensor from holders (2) and work it
clear.
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clear.
Work cable (1) clear from behind coolant pump (3).
(-) Removing exhaust manifold, right

Remove gaskets (3).
(-) Removing logotype

Carefully pry out cover (1) at the bottom.
Remove cover (1), noting the lugs (arrows).
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Remove screw (1).

Remove logotype (2).
(-) Removing cylinder head

Remove screws (1).
Disengage earth lead (2).
Remove screws (1) with washers (2).

Disengage cable (3) for the crankshaft sensor from holders (4).
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Starting at the outside, remove screws (1) in diagonally opposite

sequence.
Remove screws (1).

Remove radiator adapter (2).
Remove screw (3).
Remove screw (1).

Slacken collared nut (2).
Slightly back off threaded sleeve (3).
Remove cylinder head (1).

Remove gasket (2), tapping lightly to release if necessary, and dispose
of in the correct manner.
(-) Removing bucket tappet
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Remove bucket tappet (1).
(-) Removing coolant-temperature sensor

Remove coolant-temperature sensor (1) with sealing ring (2).
(-) Removing valves

Install flat adapter (No. 11 0 762) in support plate (No. 11 0 761).
Using suitable screws (2), secure cylinder head (1) to support plate
(No. 11 0 761).
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Push support (No. 11 1 754) onto thruster (No. 11 1 753).

Position thruster (No. 11 1 753) on cylinder head (1) and secure with
suitable nuts (2).
Seat thrust cage (No. 11 1 755) with spindle (No. 11 1 745) in support
(No. 11 1 754) and position the assembly on valve heads (1).
Adjust support (No. 11 1 754) and tighten clamping screw (2).
Press down valve heads (1) with thrust cage (No. 11 1 755) and
spindle (No. 11 1 745).
Use a suitable tool to remove valve collets (1).
Back off the special tool.

Remove the following components:
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Spring retainers (1)

Valve spring (2)
Valve (3)
Repeat this procedure with the other valves.

In this process remove screws (2) and secure support plate (No. 11 0
761) at the appropriate position on cylinder head (1).
(-) Removing valve stem seals and spring retainers

Remove valve stem seal (1) with puller (No. 11 1 756).
Remove spring retainer (2).
Repeat this procedure for all valve stem seals and spring retainers.
(-) Installing valve stem seals and spring retainers

Install spring retainer (2).
Carefully seat new valve stem seal (1) with drift (No. 11 5 602).
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Repeat this procedure for all valve stem seals and spring retainers.
(-) Installing valves

Install the following components:
Valve (3)
Valve spring (2) with the coloured mark (arrow) up
Seat thrust cage (No. 11 1 755) with spindle (No. 11 1 745) in support
(No. 11 1 754) and position the assembly on valve heads (1).
Adjust support (No. 11 1 754) and tighten clamping screw (2).
Press down valve heads (1) with thrust cage (No. 11 1 755) and
spindle (No. 11 1 745).
Lightly lubricate valve collets (1) to keep them from slipping out.

Molykote D paste Light-coloured
paste-like lubricant
for assembly and
for running in metal
components
Use a suitable tool to install valve collets (1). Make sure that they
engage the groove in the valve (arrow).
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Repeat this procedure with the other valves.

In this process remove screws (2) and secure support plate (No. 11 0
761) at the appropriate position on cylinder head (1).
Remove nuts (2).

Remove support (No. 11 1 754) and thruster (No. 11 1 753).
Remove screws (2) and remove cylinder head (1) (No. 11 0 761)from
the support plate.
(-) Installing coolant-temperature sensor
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Install coolant-temperature sensor (1) with new sealing ring (2).
Tightening torques
Temperature sensor to cylinder head
M12 x 1.5 15 Nm
(-) Installing bucket tappet

Lubricate bucket tappet (1) with engine oil and install.
(-) Installing cylinder head

Ease cylinder (1) with new gasket (2) into position.
Starting from the inside, install screws (1) in diagonally opposite

sequence.
Tightening torques
Cylinder head to crankcase
M 9 x 1.25 x 126 Tightening
sequence,
working from the
inside toward the
outside
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Initial torque,
20 Nm
Closing torque,
100°
Back off fully
Initial torque,
20 Nm
Final torque, 100°
Install screws (1) with washers (2).
Tightening torques
Cylinder head to crankcase
M6 x 50 10 Nm
Install cable (3) for the crankshaft sensor with holders (4).
Install radiator union (2) with screws (1).
Tightening torques
Coolant adapter to cylinder head
M6 x 25 10 Nm
Install screws (3).
Tightening torques
Cylinder head, left, to frame
M12 x 1.5 x 60 66 Nm
Install threaded sleeve (3), collared nut (2) and screw (1) and tighten.
Tightening torques
Cylinder head, right, to frame
Threaded sleeve, M24 x 1.25 1st step
2 Nm
Collared nut, M24 x 1.25 2nd step
100 Nm
M12 x 1.5 x 70 3rd step
66 Nm
Install earth lead (2) with screws (1).
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Tightening torques
Engine wiring harness to cylinder head
M5 x 12 8 Nm
(-) Installing logotype

Hold logotype (2) in position.
Lubricate screw (1) and install.

Staburags NBU 30 PTM High-performance 07 55 9 056
lubricating grease 992
Seat cover (1) with the top lugs (arrows).

Clip cover (1) into position.
(-) Installing exhaust manifold, right

Install gaskets (3), making sure they are correctly positioned.
Hold exhaust manifold (2) in position and install nuts (1).
Tightening torques
Exhaust header to cylinder head
M7 14 Nm
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(-) Securing right oxygen sensor

Route cable (1) behind coolant pump (3).
Route cable (1) for the oxygen sensor and secure it in holders (2).
(-) Installing exhaust manifold, left

Tightening torques
M7 14 Nm
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(-) Securing left oxygen sensor

Route cable (1) for the oxygen sensor between engine (2) and
gearbox (3) and secure it.
Route cable (1) for the oxygen sensor and secure it in holder (2).
(-) Installing camshafts

Insert inlet camshaft (with multi-pole sensor gear for camshaft sensor)
(2) and exhaust camshaft (1) and loop timing chain (3) over the
camshafts.
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Turn inlet camshaft (2) and exhaust camshaft (1) to top dead centre of
cylinder No. 1, align them with the marks (arrows) applied before
removal and engage timing chain (3) on sprockets.
(-) Installing O-rings for camshaft bearing cap

Check O-rings (1) and O-rings (2) for damage; replace if necessary.
Install large O-rings (1) and small O-rings (2).
(-) Installing bearing cap for camshafts

Lubricate the bearing seats with engine oil.
Place camshaft bearing cap (1) in position.
Install thrust nuts (No. 11 0 812) and tighten uniformly until camshaft
bearing cap (1) is seated on cylinder head.
062011 19/24
BMW-Motorrad
Checking timing
Test
Slip locating device (No. 11 0 813) into the recesses (arrows) of inlet
camshaft (1) and exhaust camshaft (2).
Locating device (No. 11 0 813) must slip in evenly and lie flat on
sealing face (3).
Result: Locating device cannot be slipped in or does not lie flat on the
sealing face, because the recesses of the camshafts well off a common
line.
Measure:
Remove and re-install the bearing cap and turn the camshafts until the
locating device can be slipped into position.
Result: Locating device cannot be slipped in or does not lie flat on the
sealing face, because the recesses of the camshafts are slightly off a
common line.
Measure:
Adjusting camshafts when checking timing
Remove locating pin (No. 11 0 811).
Turn crankshaft (1) slightly until camshafts are in line and the special
tool can be slipped into position
Insert locating pin (No. 11 0 811) in the hole (arrow) and lock
crankshaft (1).
062011 20/24
BMW-Motorrad
Result: Locating device can be slipped in and lies flat on the sealing
face.
Measure:
Removing locating device for checking timing
Remove locating device (No. 11 0 813) from the recesses (arrows) of
inlet camshaft (1) and exhaust camshaft (2).
Install nuts (1) until seated, but do not tighten.
Installing top guide for timing chain

Install guide (2).
Tighten nuts of camshaft bearing cap in specified tightening sequence

(1) to (28).
Tightening torques
062011 21/24
BMW-Motorrad
Camshaft bearing cap to cylinder head

M6 tighten uniformly,
working from the
inside toward the
outside
10 Nm
Remove stud bolts with thrust nuts (No. 11 0 812) from the spark-plug
bores.
(-) Installing timing chain tensioner

Check sealing ring (1) for damage; replace if necessary.
Position sealing ring (1) in the groove (arrow) of cover (2).
Install timing-chain tensioner (4).

Install cover (2) with sealing ring (3) and install screws (1).
Tightening torques
Cover of chain tensioner to cylinder head
M6 x 20 8 Nm
062011 22/24
BMW-Motorrad
(-) Removing locating pin

Remove locating pin (No. 11 0 811).
Finishing work
Installing crankshaft cover
Installing left drop-protection pad
Installing cylinder head cover
062011 23/24
BMW-Motorrad

062011 24/24
BMW-Motorrad
11 12 256 Removing/installing and sealing or replacing cylinder-head cover 16 FRUs

+ 11 12 821
Preparatory work
Removing air guide
Core activity
(-) Removing cylinder head cover
Remove screws (2) with seals (3).
Remove cylinder-head cover (1) with gasket (2).
Remove seal (1).
062011 1/3
BMW-Motorrad
(-) Installing cylinder head cover

Check the gasket for damage; replace if necessary.
Apply surface sealant to the corners (arrows) of the half moons.

Dow Corning Surface sealant 07 58 0 397
777
Check gasket (3) for damage; replace if necessary.

Clean the sealing faces (arrows) on the cylinder head.
Lay large gasket (1) in position on the cylinder head, noting the
position of the tabs (2) inside the cylinder head.
Place gasket (3) in position.
Place cylinder-head cover (1) in position.

Make sure that gaskets (2) and (3) do not slip out of position and are
not pinched out of shape.
062011 2/3
BMW-Motorrad
Install screws (2) with seals (3).
Tightening torques
Cylinder head cover to cylinder head (camshaft bearing cap)
M6 x 20 10 Nm
Finishing work
062011 3/3
BMW-Motorrad
11 13 000 Removing/installing or sealing oil pan 27 FRUs

+ 11 13 531
Preparatory work
Draining engine oil
Removing left fuel-tank cover top section
Removing left cover of fuel tank
Removing left oxygen sensor
Removing right fuel-tank cover top section
Remove the right fuel-tank cover
Disconnecting feed line for coolant
Removing right oxygen sensor
Core activity
(-) Removing oil pan
Remove screws (1).
Remove oil pan (1) and gasket (2).
062011 1/5
BMW-Motorrad
(-) Removing suction pipe for engine oil

Remove screws (1).
Remove intake (2), noting O-ring (3).
(-) Removing sump plate

Remove screws (1).
Remove reinforcement (2).
Remove sump plate (1) and gasket (2).
062011 2/5
BMW-Motorrad
(-) Installing sump plate

Place new gasket (2) and sump plate (1) in position.
Hold reinforcement (2) in position.

Install screws (1).
Tightening torques
Reinforcement/sump plate to oil pan
M6 x 16 10 Nm
(-) Installing suction pipe for engine oil

Check O-ring (3) for damage; replace if necessary.
Hold suction pipe (2) with O-ring (3) in position.
Install screws (1).
Tightening torques
Suction pipe to crankcase (lube-oil pump)
M6 x 25 10 Nm
062011 3/5
BMW-Motorrad
(-) Installing oil pan

Clean the tapped holes.
Place new gasket (2) and oil pan (1) in position.
Install new screws (1), but do not tighten at this point.
Tighten screws (1).
Tightening torques
Oil pan with sump plate to crankcase
M6 x 20, Replace screw Start at the middle
Micro-encapsulated and work outward
when tightening
10 Nm
062011 4/5
BMW-Motorrad
Finishing work
Connecting feed line for coolant
Installing right oxygen sensor
Installing right fuel-tank cover
Installing right fuel-tank cover top section
Installing left oxygen sensor
Installing gearbox cover
Installing left cover of fuel tank
Installing left fuel-tank cover top section
062011 5/5
BMW-Motorrad
11 14 003 Replacing valve-gear cover 5 FRUs

+ 11 14 802
Preparatory work
Removing right drop-protection pad
Core activity
(-) Removing timing-gear cover
Remove screws (1).
Remove timing-gear cover (2) and sleeves (3).
(-) Installing timing-gear cover

Clean the sealing face (arrow) on the engine and in timing-gear cover
(2).
Apply a thin bead of sealing compound to the sealing face (arrow) of
the engine block.

777
Install sleeves (3).
Install timing-gear cover (2).
Install screws (1).
Tightening torques
Cover of timing gear (with drop-protection pad) to crankcase
M6 x 30 10 Nm
Finishing work
Installing right drop-protection pad
062011 1/1
BMW-Motorrad
11 14 004 Replacing right drop-protection pad 2 FRUs

+ 11 14 872
Preparatory work
Core activity
(-) Removing right drop-protection pad
Remove screw (1) and screws (2).
Remove outer shell (3) with rubber damper (4).
(-) Replacing drop-protection pad

Transfer the necessary small items to the new drop-protection pad.
(-) Installing right drop-protection pad

Hold outer shell (3) with rubber damper (4) in position.
Install screws (2) and screw (1).
Tightening torques
M6 x 30 10 Nm
Finishing work
062011 1/1
BMW-Motorrad
11 14 005 Replacing left drop-protection pad 2 FRUs

+ 11 14 873
Core activity
(-) Removing left drop-protection pad
(-) Installing left drop-protection pad

Hold rubber damper (4) with outer shell (3) in position.
Install screws (1) and (2).
Tightening torques
Drop-protection pad, left, to crankcase
M6 x 18 10 Nm
M6 x 30 10 Nm
Finishing work
062011 1/1
BMW-Motorrad
11 14 006 Replacing oil tank cap 18 FRUs

+ 11 14 874
0416 - Electronic Suspension Adjustment (ESA)
Preparatory work
Removing left rear trim panel
Lowering bevel gears
Removing flexible gaiter for bevel bears
Removing seat support
Removing spring strut
Draining engine oil
Removing oil-level/oil-temperature sensor
Core activity
(-) Removing oil-tank cap
Disengage cable (1) for the oxygen sensor from holder (2).
Remove screws (1) and remove holder (2) for the breather line.
Disengage oil-tank cap (3).
062011 1/4
BMW-Motorrad
Open clip (1) with pliers (No. 17 5 500).

Disconnect oil return hose (2).
Remove oil-tank cap (3).
(-) Replacing oil tank cap

Transfer holders (1) to new oil tank cap (2).
Remove oil return pipe (3) with O-ring (4).
Check O-ring (4); replace if necessary.
Install oil return pipe (3) with O-ring (4) in new oil tank cap (2).
Tightening torques
Return adapter in oil reservoir cap
M16 x 1.5 6 Nm
(-) Installing oil-tank cap

Apply a thin bead of sealing compound to the sealing face of the
engine block (arrow).

777
062011 2/4
BMW-Motorrad
Clean the sealing face of oil-tank cap (3).

Install oil-tank cap (3)
Connect oil return hose (2) with clip (1).
Install clip (1) with pliers (No. 17 5 500).
Install oil-tank cap (3)

Hold bracket for breather line (2) in position and install screws (1).
Tightening torques
Cover of oil tank to crankcase
M6 x 25 tighten in
diagonally
opposite
sequence
10 Nm
Finishing work
062011 3/4
BMW-Motorrad
Installing oil-level/oil-temperature sensor

Installing spring strut
Installing seat support
Swinging bevel gears up
Installing left rear trim panel
062011 4/4
BMW-Motorrad
11 14 075 Replacing engine-block cover, left 2 FRUs

+ 11 14 858
Preparatory work
Core activity
(-) Removing crankshaft cover
Remove screws (1).
Remove crankshaft cover (2) with sealing ring (3).
(-) Installing crankshaft cover

Position sealing ring (1) in the groove (arrow) of crankshaft cover (2).
Clean the sealing face (arrow).

Place crankshaft cover (2) with sealing ring (3) in position.
Install screws (1).
Tightening torques
Crankshaft cover to crankcase
M6 x 25 10 Nm
Finishing work
062011 1/2
BMW-Motorrad
062011 2/2
BMW-Motorrad
11 14 085 Replacing right engine-block cover 6 FRUs

+ 11 14 859
Preparatory work
Disengaging right stowage compartment
Core activity
(-) Removing right crankcase cover
Remove screws (1).
Remove crankcase cover (1) with gasket (2).

Remove sleeves (3).
(-) Removing right crankcase cover

Install the following components from the old right crankcase cover in
the new cover:
Only remove screws (1)
Check damper (3) for damage; replace if necessary.
Retaining plate (2) and damper (3)
Install new screws (1).
Tightening torques
Vibration damper to clutch cover
062011 1/3
BMW-Motorrad

Micro-encapsulated
(-) Installing right crankcase cover

Clean the sealing face.
Install crankcase cover (1) with gasket (2).
Install new screws (1) but do not tighten.
Tighten screws (1) to (13) in the specified sequence to the specified

initial torque.
Tightening torques
Clutch cover to crankcase (initial torque)
M6 x 25, Replace screw Initial torque, 3 Nm
Tighten screws (5) to (13) in the specified sequence to jointing torque
and final torque.
Tightening torques
Clutch cover to crankcase
062011 2/3
BMW-Motorrad
M6 x 25 Closing torque,
3 Nm
Final torque, 90°
Tighten screws (1) to (4) in the specified sequence to jointing torque
and final torque.
Tightening torques
Clutch cover to crankcase
M6 x 25 Closing torque,
3 Nm
Final torque, 30°
Finishing work
Securing right stowage compartment
062011 3/3
BMW-Motorrad
11 15 001 Replacing breather tube for crankcase 6 FRUs

+ 11 15 552
Preparatory work
Removing left and right intake air pipes
Core activity
(-) Removing breather tube for crankcase
Open clip (1) with pliers (No. 17 5 571) and disconnect breather hose
(2).
(-) Installing breather tube for crankcase

Connect breather hose (2) and close hose clip (1) with pliers (No. 17 5
571).
Finishing work
Installing left and right intake air pipes
062011 1/2
BMW-Motorrad
062011 2/2
BMW-Motorrad
11 31 080 Removing/installing or replacing timing-chain tensioner 4 FRUs

+ 11 31 780
Preparatory work
Core activity
(-) Removing timing-chain tensioner
Remove screws (1) and remove cover (2) with sealing ring (3).
Remove timing-chain tensioner (4).
(-) Installing timing chain tensioner

Position sealing ring (1) in the groove (arrow) of cover (2).
Install timing-chain tensioner (4).

Install cover (2) with sealing ring (3) and install screws (1).
Tightening torques
Cover of chain tensioner to cylinder head
M6 x 20 8 Nm
062011 1/2
BMW-Motorrad
Finishing work
062011 2/2
BMW-Motorrad
11 31 101 Replacing timing chain tensioning rail

+ 11 31 783
Preparatory work
Removing air guide
Setting engine to TDC
Locking engine at TDC
Removing timing-chain tensioner
Removing bearing cap for camshafts
Removing O-rings for camshaft bearing cap
Core activity
062011 1/5
BMW-Motorrad


Remove screws (1).
(-) Removing timing-chain tensioning rail

Remove pivot-bearing screw (1).
062011 2/5
BMW-Motorrad
Lift out timing-chain tensioning rail (1).
(-) Installing timing-chain tensioner rail

Insert timing chain tensioning rail (1) from above.
Install pivot bearing screw (1).
Tightening torques
Timing-chain rail to crankcase
M6 x 30 8 Nm
062011 3/5
BMW-Motorrad

(2).
the engine block.

777
Install screws (1).
Tightening torques
M6 x 30 10 Nm

Tightening torques
M6 x 30 10 Nm

camshafts.
062011 4/5
BMW-Motorrad
Finishing work
Installing O-rings for camshaft bearing cap
Installing bearing cap for camshafts
Installing timing chain tensioner
Removing locating pin
062011 5/5
BMW-Motorrad
11 31 112 Replacing timing chain slide rails

+ 11 31 784
Preparatory work
Removing air guide
Core activity
062011 1/5
BMW-Motorrad


Remove screws (1).
(-) Removing timing chain slide rail

Remove pivot-bearing screw (1).
062011 2/5
BMW-Motorrad
Work timing-chain slide rail (1) up to remove.
(-) Installing timing-chain slide rail

Insert timing chain slide rail (1) from above.
Install pivot bearing screw (1).
Tightening torques
Timing-chain rail to crankcase
M6 x 30 8 Nm
062011 3/5
BMW-Motorrad

(2).
the engine block.

777
Install screws (1).
Tightening torques
M6 x 30 10 Nm

Tightening torques
M6 x 30 10 Nm

camshafts.
062011 4/5
BMW-Motorrad
Finishing work
062011 5/5
BMW-Motorrad
11 31 125 Replacing chain guide 17 FRUs

+ 11 31 786
Preparatory work
Removing air guide
Core activity
(-) Removing cylinder head cover
Remove screws (2) with seals (3).
Remove cylinder-head cover (1) with gasket (2).
Remove seal (1).
062011 1/4
BMW-Motorrad
(-) Removing top guide for timing chain

Remove nuts (1).
Remove guide (2).
(-) Installing top guide for timing chain

Install guide (2).
(-) Installing cylinder head cover

Check the gasket for damage; replace if necessary.
Apply surface sealant to the corners (arrows) of the half moons.

777
062011 2/4
BMW-Motorrad

Clean the sealing faces (arrows) on the cylinder head.
Lay large gasket (1) in position on the cylinder head, noting the
position of the tabs (2) inside the cylinder head.
Place gasket (3) in position.
Place cylinder-head cover (1) in position.

Make sure that gaskets (2) and (3) do not slip out of position and are
not pinched out of shape.
Install screws (2) with seals (3).
Tightening torques
Cylinder head cover to cylinder head (camshaft bearing cap)
M6 x 20 10 Nm
Finishing work
062011 3/4
BMW-Motorrad

062011 4/4
BMW-Motorrad
11 31 539 Replacing all camshafts (cylinder-head cover removed) 10 FRUs

Preparatory work
Core activity
(-) Replacing camshafts

Clamp camshafts (1) in a vice fitted with protective jaws.
Remove screws (2).
Remove camshaft sprockets (3).
Position camshaft sprockets (3) on new camshafts (1) in such a way
that the pins (arrow) engage the bores.
Tightening torques
Sprocket to camshaft
M10 x 1 x 30, Replace screw Initial torque,
40 Nm
Final torque, 60°

camshafts.
062011 1/2
BMW-Motorrad
Bring inlet camshaft (2) and exhaust camshaft (1) to top dead centre of
cylinder No. 1.
The recesses (arrows) of both camshafts are slightly offset toward the
top and in line.
Engage inlet camshaft (2) and exhaust camshaft (1) in timing chain
(3).
Finishing work
Checking valve clearance
062011 2/2
BMW-Motorrad
11 34 001 Checking valve clearance 20 FRUs

+ 11 34 501
Preparatory work
Removing air guide
Core activity
(-) Checking valve clearance
Test
Use a feeler gauge (1) to check the valve clearance by measuring
between the cams and the valve bucket.
Technical data
Inlet valve Engine 0.13...0.23 mm
clearance cold max 35 °
C
Exhaust valve Engine 0.23...0.33 mm
C
Check cylinder 1.
Check all the remaining cylinders as described below, using the
crankshaft to turn the engine counter-clockwise until each cylinder at
turn is at valve overlap:
Cylinder 5
Cylinder 3
Cylinder 6
Cylinder 2
Cylinder 4
Noting measured results
Note down the measured results on a record sheet.
062011 1/2
BMW-Motorrad
Result: Valve clearance is outside specified range.

Measure:
=> 11 34 504, Adjusting valve clearance (cylinder-head cover removed)
(Billed as a separate item)
Finishing work
Setting countdown distance
062011 2/2
BMW-Motorrad
11 34 502 Checking valve clearance (for maintenance) 18 FRUs
Preparatory work
Removing air guide
Core activity
(-) Checking valve clearance
Test
Use a feeler gauge (1) to check the valve clearance by measuring
between the cams and the valve bucket.
Technical data
Inlet valve Engine 0.13...0.23 mm
C
Exhaust valve Engine 0.23...0.33 mm
C
Check cylinder 1.
Check all the remaining cylinders as described below, using the
crankshaft to turn the engine counter-clockwise until each cylinder at
turn is at valve overlap:
Cylinder 5
Cylinder 3
Cylinder 6
Cylinder 2
Cylinder 4
Noting measured results
Note down the measured results on a record sheet.
062011 1/2
BMW-Motorrad
Result: Valve clearance is outside specified range.

Measure:
=> 11 34 504, Adjusting valve clearance (cylinder-head cover removed)
Finishing work
Setting countdown distance
062011 2/2
BMW-Motorrad
11 34 504 Adjusting valve clearance (cylinder-head cover removed) 13 FRUs

Preparatory work
Removing camshafts
Core activity
(-) Adjusting valve clearance
Removing bucket tappet
Attention
Friction faces in the engine have to run in against each other. If
components are mixed up they have to run in again. This results in
accelerated wear.
Do not mix up the bucket tappets.
Remove bucket tappet (1).
Note
Make a note of which bucket tappets belong to which valve.
Check the thickness of the bucket tappet with a caliper gauge.

If measured valve play is not correct, calculate the thickness of the
new bucket tappet.
Installing bucket tappet
Attention
062011 1/2
BMW-Motorrad
Friction faces in the engine have to run in against each other. If

components are mixed up they have to run in again. This results in
accelerated wear.
Do not mix up the bucket tappets.
Lubricate bucket tappet (1) with engine oil and install.
Finishing work
Installing camshafts
Rechecking valve clearance
062011 2/2
BMW-Motorrad
11 41 000 Removing/installing or replacing oil pump 31 FRUs

+ 11 41 651
Preparatory work
Draining engine oil
Removing oil pan
Removing suction pipe for engine oil
Removing sump plate
Core activity
(-) Removing oil pressure line
Remove oil filter union (1).
Remove oil pressure line (2).
(-) Removing suction pipe for oil pump

Remove screws (1).
Remove intake (2), noting O-ring (3).
062011 1/6
BMW-Motorrad
(-) Removing coolant pump

Remove screws (1).
Remove coolant pump (2), noting O-ring (3).
(-) Removing input shaft for oil pump

Remove threaded plug (1) with sealing ring (2).
Remove input shaft (3).
(-) Removing oil pump

Remove screws (1).
062011 2/6
BMW-Motorrad
Disengage circlip (2) and remove, turning the rear wheel to find the
best position for easy removal.
Turn the rear wheel to bring drive gear (1) to a position in which the
input connection (arrow) is pointing forward and down.
Push oil pump (3) to the right and down.
Use a screwdriver to pry nut (4) down.
Remove oil pump (3).
(-) Installing oil pump

Install circlip (1) between oil pump (2) and drive gear (3).
Place idler gear (4) in position.
Place oil pump (1) in position.

Using a suitable tool, carefully ease layshaft gearwheel (2) toward oil
pump.
Engage idler gear (3) in drive gear (4).
Engage circlip (5), turning the rear wheel to find the best position for
easy engagement.
062011 3/6
BMW-Motorrad
Install screws (1).
Tightening torques
Oil pump to crankcase
M6 x 50 10 Nm
(-) Installing input shaft for oil pump

Install input shaft (3).
Install threaded plug (1) with new sealing ring (2).
Tightening torques
Threaded plug (shaft for oil-pump drive) in crankcase
M10 15 Nm
(-) Installing coolant pump

Note the routing of oxygen-sensor cable (4).
Install coolant pump (2), making sure that the drive engages (arrows).
Install screws (1).
Tightening torques
Coolant pump to crankcase
M6 x 30 10 Nm
(-) Installing suction pipe for oil pump

Hold suction pipe (2) with O-ring (3) in position.
Install screws (1).
Tightening torques
Suction pipe to crankcase (return pump)
M6 x 20 10 Nm
062011 4/6
BMW-Motorrad
(-) Installing oil pressure line

Check O-rings (3) and (4) for damage; replace if necessary.
Install oil pressure line (2).
Install oil filter union (1).
Tightening torques
Oil filter union to engine
M22 x 1.5 40 Nm
Finishing work
Installing sump plate
Installing suction pipe for engine oil
Installing oil pan
062011 5/6
BMW-Motorrad

062011 6/6
BMW-Motorrad
11 51 002 Removing/installing coolant pump (without draining/refilling coolant system) 3

FRUs
+ 11 51 563
Preparatory work
=> Draining coolant, refilling/bleeding system
(Description in item: 17 00 504, Billed as a separate
item)
Core activity
(-) Removing coolant pump
Remove screws (1).
Remove coolant pump (2), noting O-ring (3).
(-) Installing coolant pump

Note the routing of oxygen-sensor cable (4).
Install coolant pump (2), making sure that the drive engages (arrows).
Install screws (1).
Tightening torques
Coolant pump to crankcase
M6 x 30 10 Nm
Finishing work
062011 1/1
BMW-Motorrad
11 61 001 Replacing intake manifold 21 FRUs

+ 11 61 600
Preparatory work
Removing fuel tank
Core activity
(-) Removing intake manifold
Disengage breather hose (1) from holder (2).
Disengage breather hoses (1) and (3) from intake manifold (4).
Remove screw (5).
Connect plug (1) for the fuel-pressure sensor.

Mark plugs (2) for the injection valves for subsequent correct
reassembly and disconnect.
Loosen screws (3) uniformly, but do not remove.
Note
Take care not to remove the screws fully, as this would damage the
captive adapter.
062011 1/6
BMW-Motorrad
Slightly raise intake manifold (1) and disengage wiring harness (2)
from holders (3).
Remove intake manifold (1) complete with sealing rings (2).
(-) Replacing intake manifold

Removing injection rail
Disengage fuel hose (1) from holder (2).
Remove screws (3).
Remove injection rail (4).
Removing throttle-valve stub assembly

Remove screws (1).
Remove retaining plate (2).
Remove throttle-valve stub assembly (3) with sealing ring (4).
062011 2/6
BMW-Motorrad
Transfer bracket (1) to new intake manifold (2).

Transfer sleeve (3) to new intake manifold (2).
Installing throttle-valve stub assembly

Install throttle-valve stub assembly (3) with sealing ring (4).
Hold retaining plate (2) in position.
Install screws (1).
Tightening torques
Throttle-valve assembly to intake assembly
T60 x 53 6 Nm
Installing injection rail

Check the O-rings (arrows); replace if necessary.
Install injection rail (4).
Install screws (3).
Secure fuel hose (1) in holder (2).
062011 3/6
BMW-Motorrad
(-) Installing intake manifold

Check sealing rings (1); replace if necessary.
Insert sealing rings (1) in intake manifold (2). Make sure that sealing
rings (1) are pressed into the retainer recesses (arrows).
Insert intake manifold (1) complete with sealing rings (2). Make sure
that sealing rings (2) do not drop out of position during installation.
Secure wiring harness (2) in holder (3) and hold intake manifold (1) in
position.
062011 4/6
BMW-Motorrad
Install screws (3) uniformly.
Tightening torques
Intake assembly to crankcase
M6 x 25 8 Nm
Connect plugs (2) for the injection valves.
Connect plug (1) for the fuel-pressure sensor.
Install screw (5).
Tightening torques
Intake assembly to crankcase
M6 x 16 8 Nm
Connect breather hoses (1) and (3) to intake manifold (4).
Secure breather hose (1) in holder (2).
Finishing work
062011 5/6
BMW-Motorrad
Install the left side panel

062011 6/6
BMW-Motorrad
11 72 101 Removing/installing or replacing line for secondary air system 14 FRUs

+ 11 72 660
Warning
Fuel is flammable and a hazard to health.
Observe all applicable safety regulations.
Preparatory work
Removing fuel tank
Core activity
(-) Removing line for secondary air system
Disconnect line (1) from distributor rail (2).
Work line (1) clear.
(-) Installing line for secondary air system

Route line (1) and connect it to distributor rail (2).
062011 1/2
BMW-Motorrad
Finishing work
062011 2/2
BMW-Motorrad
11 78 001 Replacing oxygen sensors 7 FRUs

+ 11 78 501
Warning
Risk of burns caused by the hot exhaust system.
Do not touch the exhaust system when it is hot; if necessary, allow the
exhaust system ample time to cool before proceeding.
Preparatory work
Core activity
(-) Removing left oxygen sensor
Open the cable tie (arrow).
Remove plug (1) for the oxygen sensor and disconnect.
Disengage cable (2) for the oxygen sensor from holder (3) and work it
clear.
Disengage cable (1) for the oxygen sensor between engine (2) and
gearbox (3) and work it clear.
Remove oxygen sensor (1).
062011 1/5
BMW-Motorrad
(-) Installing left oxygen sensor

Thinly lubricate threads of oxygen sensor (1).

Optimoly TA High-temperature 18 21 9 062
assembly grease 599
Install oxygen sensor (1).
Tightening torques
Oxygen sensor to exhaust manifold
M12 x 1.25 25 Nm
Thinly lubricate thread, Optimoly
TA
Route cable (1) for the oxygen sensor between engine (2) and
gearbox (3) and secure it.
Connect plug (1) for the oxygen sensor and install.
Secure the cable tie (arrow).
062011 2/5
BMW-Motorrad
(-) Removing right oxygen sensor

Open the cable tie (arrow).
Remove plug (1) for the oxygen sensor and disconnect.
clear.
clear.
Work cable (1) clear from behind coolant pump (3).
062011 3/5
BMW-Motorrad
Remove oxygen sensor (1).
(-) Installing right oxygen sensor

Thinly lubricate threads of oxygen sensor (1).

assembly grease 599
Install oxygen sensor (1).
Tightening torques
Oxygen sensor to exhaust manifold
M12 x 1.25 25 Nm
Thinly lubricate thread, Optimoly
TA
Route cable (1) behind coolant pump (3).
062011 4/5
BMW-Motorrad
Connect plug (1) for the oxygen sensor and install.

Finishing work
=> Resetting/learning adaptation values (with replacing

component) (Description in item: 61 00 503, Billed as a
separate item)
062011 5/5
BMW-Motorrad
12 00 014 Performing vehicle test with BMW Motorrad diagnostic system 3 FRUs
+ 12 00 516
Preparatory work
Core activity
(-) Connecting BMW Motorrad diagnostic system to
motorcycle
Connect the BMW Motorrad battery charger.
Note
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 13V.
Disengage diagnosis plug (1) from holder (2) and remove protective
cap (3).
Connect diagnosis plug (1) to connecting cable (4) for the diagnostic
system.
Note
See the information about the BMW Motorrad diagnostic system for all
other instructions.
(-) Performing vehicle test with BMW Motorrad diagnostic

system
Perform the vehicle test with the BMW Motorrad diagnostic system
and read out the fault memory.
Note
When working with the BMW Motorrad diagnostic system, always follow
the instructions it issues.
Follow instructions or use the diagnosis options, as applicable.
(-) Disconnecting BMW Motorrad diagnostic system from

motorcycle
Close all diagnostic programs and switch off the ignition.
Disconnect the connecting cable for the BMW Motorrad diagnostic
system from the motorcycle's diagnosis plug and screw the cap onto
the diagnosis plug.
Disconnect the BMW Motorrad battery charger from the motorcycle.
Finishing work
062011 1/1
BMW-Motorrad
12 12 011 Renewing all spark plugs 13 FRUs

+ 12 12 513
Preparatory work
Removing air guide
Core activity
(-) Removing direct ignition coils
Attention
Clean the cylinder-head cover with compressed air prior to removal.

Remove direct ignition coils (2) with puller (No. 12 3 621).
(-) Removing spark plugs

Clean the spark-plug recess with compressed air.
Remove spark plugs (1) with spark-plug wrench (No. 12 3 611).
(-) Changing spark plugs

Install new spark plugs.
062011 1/2
BMW-Motorrad
Technical data
Spark plugs, NGK LMAR8AI-8
manufacturer and
designation
(-) Installing spark plugs

Install spark plugs (1) with spark-plug wrench (No. 12 3 611).
Tightening torques
Spark plug in cylinder head
M10 x 1 12 Nm
(-) Installing direct ignition coils

Insert each direct ignition coil (2), seat it on the spark plug and make
sure it engages.
Finishing work
062011 2/2
BMW-Motorrad
12 12 509 Replace all spark plugs (as part of maintenance) 2 FRUs
Core activity
(-) Removing spark plugs
Clean the spark-plug recess with compressed air.
Remove spark plugs (1) with spark-plug wrench (No. 12 3 611).
(-) Changing spark plugs

Install new spark plugs.
Technical data
Spark plugs, NGK LMAR8AI-8
manufacturer and
designation
(-) Installing spark plugs

Install spark plugs (1) with spark-plug wrench (No. 12 3 611).
Tightening torques
Spark plug in cylinder head
M10 x 1 12 Nm
062011 1/1
BMW-Motorrad
12 13 155 Replacing direct ignition coil 10 FRUs

+ 12 13 655
Preparatory work
Removing air guide
Core activity
(-) Removing direct ignition coils
Attention
Clean the cylinder-head cover with compressed air prior to removal.

Remove direct ignition coils (2) with puller (No. 12 3 621).
(-) Installing direct ignition coils

Insert each direct ignition coil (2), seat it on the spark plug and make
sure it engages.
Finishing work
062011 1/2
BMW-Motorrad

062011 2/2
BMW-Motorrad
12 31 022 Replace generator 21 FRUs

+ 12 31 673
Preparatory work
Removing fuel tank
Core activity
(-) Removing starter
Cap (1)
Nut (2)
Positive lead (3) for the starter
Screws (4)
Remove starter (5), noting the O-ring (arrow).
(-) Removing alternator

Cap (1)
Nut (2)
Positive lead (3) for the alternator
Screws (4)
Alternator (5)
Disconnect plug (6) for the alternator.
062011 1/3
BMW-Motorrad
(-) Installing alternator


Check that judder dampers (1) are correctly positioned in the housing;
reposition if necessary.
Connect plug (6) for the alternator.

Install alternator (5).
Install screws (4).
Tightening torques
Alternator to crankcase/alternator cover
M6 x 65 20 Nm
Hold positive lead (3) for the alternator in position.
Install nut (2).
062011 2/3
BMW-Motorrad
Tightening torques
Wiring harness to alternator
M6 8 Nm
Install cap (1).
(-) Installing starter

Clean the sealing faces.
Check the O-ring (arrow) for damage; replace if necessary.
Hold starter (5) in position.
Install screws (4).
Tightening torques
Starter motor to gearbox housing
M6 x 25 10 Nm
Hold positive lead (3) for the starter in position.
Install nut (2).
Tightening torques
M6 8 Nm
Install cap (1).
Finishing work
Connecting battery
062011 3/3
BMW-Motorrad
12 41 025 Replacing starter 19 FRUs

+ 12 41 528
Preparatory work
Removing fuel tank
Core activity
(-) Removing starter
Cap (1)
Nut (2)
Positive lead (3) for the starter
Screws (4)
Remove starter (5), noting the O-ring (arrow).
(-) Installing starter

Clean the sealing faces.
Check the O-ring (arrow) for damage; replace if necessary.
Hold starter (5) in position.
Install screws (4).
Tightening torques
Starter motor to gearbox housing
062011 1/2
BMW-Motorrad
M6 x 25 10 Nm
Hold positive lead (3) for the starter in position.
Install nut (2).
Tightening torques
M6 8 Nm
Install cap (1).
Finishing work
Connecting battery
062011 2/2
BMW-Motorrad
12 61 001 Replacing oil-level/oil-temperature sensor 3 FRUs

+ 12 61 567
Additional line items for billing

12 61 502 Additional work for replacing oil-level/oil-temperature sensor (with ESA), 11 FRUs
Preparatory work
Remove the rear seat
Removing right rear trim panel
Releasing expansion tank
Removing silencer
Raising rear frame
Removing rear spring strut
Core activity
(-) Removing oil-level/oil-temperature sensor
Remove cable holder (1).
Remove and disconnect plug (2) for the oil-level/oil-temperature
sensor.
Work cable (3) for the oil-level/oil-temperature sensor clear and
disengage it from holder (4).
Remove screws (1).

Carefully work oil-level/oil-temperature sensor (2) with O-ring (3) clear
and remove.
062011 1/3
BMW-Motorrad
(-) Installing oil-level/oil-temperature sensor

Carefully work oil-level/oil-temperature sensor (2) with O-ring (3) into
position and install.
Install screws (1).
Tightening torques
Oil-level/oil-temperature sensor to oil tank cover
M6 x 16 10 Nm
Route cable (3) for the oil-level/oil-temperature sensor and secure it in

holder (4).
Connect plug (2) for oil-level/oil-temperature sensor and install.
Install cable holder (1).
Finishing work
Installing rear spring strut
Lowering rear frame
Securing silencer
Securing expansion tank
062011 2/3
BMW-Motorrad

Installing right rear trim panel

separate item)
Installing rear seat
062011 3/3
BMW-Motorrad
12 62 010 Replacing coolant-temperature sensor 5 FRUs

+ 12 62 510
Preparatory work
Core activity
(-) Removing coolant-temperature sensor
Remove coolant-temperature sensor (2) with sealing ring (3).
Seal the bore for the coolant-temperature sensor.
(-) Installing coolant-temperature sensor

Install coolant-temperature sensor (2) with new sealing ring (3).
Tightening torques
Temperature sensor to cylinder head
M12 x 1.5 15 Nm
Finishing work
062011 1/2
BMW-Motorrad

Checking coolant level
062011 2/2
BMW-Motorrad
12 72 001 Replacing crankshaft sensor 3 FRUs

+ 12 72 501
Preparatory work
Core activity
(-) Removing crankshaft sensor
Disconnect plug (1) for the crankshaft sensor.
Disengage cable (1) from holder (2).

Remove screw (3) and crankshaft sensor (4) with O-ring (5).
(-) Installing crankshaft sensor

Install crankshaft sensor (4) with O-ring (5) and screw (3).
Tightening torques
Crankshaft sensor on crankcase
M6 x 16 10 Nm
Route cable (1) and secure it in holder (2).
Connect plug (1) for the crankshaft sensor.

Close the cable ties (arrows).
062011 1/2
BMW-Motorrad
Finishing work
062011 2/2
BMW-Motorrad
12 72 020 Replacing camshaft sensor 11 FRUs

+ 12 72 520
Preparatory work
Removing air guide
Core activity
(-) Removing camshaft sensor
Remove screw (2).
Remove camshaft sensor (3) with O-ring (4).
(-) Installing camshaft sensor

Install camshaft sensor (3) with O-ring (4).
Install new screw (2).
Tightening torques
Camshaft sensor to cylinder head cover
M6 x 16, Replace screw Initial torque, 3 Nm
Final torque, 90°
Finishing work
062011 1/2
BMW-Motorrad

062011 2/2
BMW-Motorrad
13 54 017 Replacing complete throttle-valve assembly 10 FRUs

+ 13 54 521
Warning
Preparatory work
Disengaging complete intake air silencer
Core activity
(-) Removing throttle-valve stub assembly
Remove the cable ties (arrows).
Disconnect plug (1) for the throttle-valve stub assembly.
Allow cable leg (2) to dangle to one side.
Remove screws (1).

Remove retaining plate (2).
Remove throttle-valve stub assembly (3) with sealing ring (4).
(-) Installing throttle-valve stub assembly

Install throttle-valve stub assembly (3) with sealing ring (4).
Hold retaining plate (2) in position.
Install screws (1).
062011 1/2
BMW-Motorrad
Tightening torques
Throttle-valve assembly to intake assembly
T60 x 53 6 Nm
Connect plug (1) for the throttle-valve stub assembly.

Position wiring-harness leg (2).
Finishing work
Securing complete intake air silencer
062011 2/2
BMW-Motorrad
13 61 522 Programming control unit of engine management system (along with testing
software) 3 FRUs
Core activity
(-) Programming engine-management control unit
Start ISTA/P.
Start the programming routine and follow the instructions issued by the
BMW Motorrad diagnostic system.
062011 1/1
BMW-Motorrad
13 61 510 Replacing engine management control unit (not including checking/programming

software) 5 FRUs
Note
Before removal, test the control unit with the BMW Motorrad diagnostic
system and make a backup copy of the data.
Preparatory work
Removing air guide for intake air pipe, right
Disengaging expansion tank for coolant
Disengaging bracket for basic module and engine control unit
Core activity
(-) Removing engine control unit
Disconnect plugs (1) and (2) for the engine control unit.
Push back locking tabs (3) and remove engine control unit (4).
(-) Installing engine control unit
Note
Do not, under any circumstances temporarily install control units from
other vehicles by way of testing.
The possible consequences include:
Coding data could be overwritten.
The control units could malfunction.
Install engine control unit (4).

Make sure that retaining tabs (3) are latched.
Connect plugs (2) and (1) for the engine control unit.
062011 1/2
BMW-Motorrad
Finishing work
Securing bracket for basic module and engine control unit
Securing expansion tank for coolant
Installing air guide for intake air pipe, right
=> 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)
062011 2/2
BMW-Motorrad
13 62 010 Replacing intake-air temperature sensor 5 FRUs

+ 13 62 501
Preparatory work
Core activity
(-) Removing intake-air temperature sensor
Disconnect plug (1) for the intake-air temperature sensor.
Push the locking device (arrow) and remove intake-air temperature
sensor (2) with sealing ring (3).
(-) Installing intake-air temperature sensor

Install air-temperature sensor (2) with sealing ring (3). Make sure that
the locking device (arrow) engages.
Connect plug (1) for the intake-air temperature sensor.
Finishing work
062011 1/1
BMW-Motorrad
13 64 165 Renewing one injector 16 FRUs

+ 13 64 501
Warning
Preparatory work
Removing fuel tank
Core activity
(-) Removing injection rail
Disconnect plug (1) for the fuel-pressure sensor and plugs (2) for the
injection valves.
Disengage fuel hose (1) from bracket (2).

Remove screws (3).
Remove injection rail (4).
062011 1/3
BMW-Motorrad
(-) Removing one injection valve
Attention
Fuel feed lines are pressurised. Fuel escapes when a connection is
opened.
Catch escaping fuel in a suitable container.
Remove spring clip (1).

Remove injection valve (2) with O-ring (3) from injection rail (4).
(-) Installing injection valve

Lubricate O-ring (3).

Rubber care product Lubricating and 83 12 0 397
care of rubber 018
grommets, O-rings
and rubberised
components
Install injection valve (2) in injection rail (4), noting O-ring (3).
Install spring clip (1).
(-) Installing injection rail

Check the O-rings (arrows); replace if necessary.
Install injection rail (4).
Install screws (3).
Secure fuel hose (1) in holder (2).
062011 2/3
BMW-Motorrad
Connect plug (1) for the fuel-pressure sensor and plugs (2) for the
injection valves.
Finishing work

separate item)
062011 3/3
BMW-Motorrad
13 71 010 Replace intake-air silencer 7 FRUs

+ 13 71 510
0530 - Tyre pressure monitoring (RDC)
Preparatory work
Removing left and right intake air pipes
Core activity
(-) Removing intake air silencer front section
Remove screws (1).
Remove intake air silencer front section (1) with air filter (2).
(-) Removing air filter

Remove air filter (1) from intake air silencer front section (2).
062011 1/7
BMW-Motorrad
(-) Removing intake air silencer main section

Disconnect plug (1) for the RDC control unit and disengage cable (2)
from holder (3).
Disconnect plug (1) for the air-temperature sensor.

Disconnect hose (2) for the secondary air system.
Disconnect plug (1) for the secondary air system valve (SLS valve)
and disengage the cable from holder (2).
Open clip (3) and disconnect breather hose (4).
Open clip (5) with pliers (No. 17 5 571) and disconnect breather hose
(6).
062011 2/7
BMW-Motorrad
Remove clips (1) and washers (2).

Remove intake air silencer main section (3) and work hose (4) clear of
the motorcycle.
(-) Removing tyre pressure monitoring control unit (RDC

control unit)
Remove screw (1).
Remove RDC control unit (2).
(-) Removing intake-air temperature sensor

Push the locking device (arrow) and remove intake-air temperature
sensor (1) with sealing ring (2).
(-) Removing changeover valve for secondary air system

Remove screws (1).
Remove changeover valve (2), noting the O-ring (arrow).
062011 3/7
BMW-Motorrad
(-) Replacing intake air silencer

Remove rubber grommets (1), bushing (2), rubber grommet (3) and
condensate drain hose (4) from the old intake air silencer main section
and transfer them to the new component.
(-) Installing changeover valve for secondary air system

Check O-ring (arrow) for damage; replace if necessary.
Install changeover valve (2) with the O-ring (arrow).
Install screws (1).
Tightening torques
Secondary air system changeover valve to intake air silencer
PT40 x 1.5 3 Nm
(-) Installing intake-air temperature sensor

Install air-temperature sensor (1) with sealing ring (2). Make sure that
the locking device (arrow) engages.
062011 4/7
BMW-Motorrad
(-) Installing tyre pressure monitoring control unit (RDC

control unit)
Install RDC control unit (2).
Install screw (1).
Tightening torques
Tyre pressure monitoring (RDC) control unit to intake air silencer
TS4 x 10 3 Nm
(-) Installing intake air silencer main section

Install intake air silencer main section (3), working hose (4) into
position.
Install washers (2) and clips (1).
Connect breather hose (6) and close hose clip (5) with pliers (No. 17 5
571).
Connect breather hose (4) and secure hose clip (3).
Connect plug (1) for the secondary air system valve (SLS valve) and
secure the cable in holder (2).
062011 5/7
BMW-Motorrad
Install screw (3) with washer (4).
Tightening torques
Intake air silencer to frame
M6 x 25 8 Nm
Connect hose (2) for the secondary air system.
Connect plug (1) for the air-temperature sensor.
Connect plug (1) for RDC control unit and secure cable (2) in holder
(3).
(-) Installing air filter

Install air filter (1) in intake air silencer front section (2).
Make sure that the gasket (arrow) is correctly seated.
062011 6/7
BMW-Motorrad
(-) Installing intake air silencer front section

Install intake air silencer front section (1) with air filter (2).
Make sure that air filter (2) does not slip out of position and that the
retaining lugs (arrows) are engaged in holder (3).
Install screws (1).
Tightening torques
Intake air silencer to filter housing
M6 x 16 3 Nm
Finishing work
Installing left and right intake air pipes
062011 7/7
BMW-Motorrad
13 72 001 Renewing air cleaner insert 4 FRUs

+ 13 72 532
Preparatory work
Removing intake air silencer front section
Core activity
(-) Replacing air filter
Install new air filter (1) in intake air silencer front section (2).
Finishing work
Installing intake air silencer front section
062011 1/1
BMW-Motorrad
13 72 505 Replace air filter cartridge (for maintenance) 2 FRUs
Preparatory work
Removing intake air silencer front section
Core activity
(-) Replacing air filter
Install new air filter (1) in intake air silencer front section (2).
Finishing work
Installing intake air silencer front section
062011 1/1
BMW-Motorrad
16 11 030 Removing/installing fuel tank 14 FRUs

+ 16 11 533
Warning
Preparatory work
Core activity
(-) Removing fuel tank
Disconnect plug (1) for the fuel-level sensor and plug (2) for the fuel
pump.
Open the latch of the quick-action coupling of the fuel delivery line
(arrow) and disconnect fuel line (3).
Disconnect hoses (4) and (5).
Slacken screws (1) on left and right.
062011 1/4
BMW-Motorrad

Remove screws (3) with shouldered bushings (4).
Remove fuel tank (5).
(-) Installing fuel tank

Hold fuel tank (5) in position.
Install screws (3) with shouldered bushings (4).
Tightening torques
Fuel tank to main frame, rear
M8 x 120 14 Nm
Tightening torques
Fuel tank to main frame, front
M8 x 55 19 Nm
Tighten screws (1) on left and right.
Tightening torques
Tank holder, front, to main frame
M6 x 30 8 Nm
062011 2/4
BMW-Motorrad
Check O-ring of fuel delivery line (1) for damage; replace if necessary.
Attention
Lightly touching the latching pin of the female connector can cause the
connector to latch. If this happens and force is applied in an attempt to
close the male and female elements of the quick-action coupling,
damage to the O-rings can result, and the O-rings will leak.
Make sure that the latch is open/pressed when you connect the two
elements of the quick-action couplings in the fuel lines.
Open the latch for fuel delivery line (arrow) and, applying light
pressure, press male adapter of fuel delivery line (3) into the female
coupling. Release the latch and check that the delivery line is correctly
seated.
Connect plug (1) for the fuel-level sensor and plug (2) for the fuel
pump.
Route hoses (4) and (5), secure them in holders on the tank and
connect them.
Finishing work
062011 3/4
BMW-Motorrad

062011 4/4
BMW-Motorrad
16 11 531 Replacing fuel tank (fuel tank removed) 3 FRUs
Warning
Preparatory work
=> Removing/installing fuel tank (Description in item: 16
11 533, Billed as a separate item)
Core activity
(-) Draining fuel tank
Warning
Drain the fuel tank, using the commercially available special tool.
(-) Removing fuel-pump unit

Remove union nut (1) with pin wrench (No. 16 1 021).
Attention
Failure to follow the correct procedure for removing the fuel pump can
damage the gasket at the fuel-pump flange, resulting in leaks
When removing the fuel pump, do not lever against the flange of the
pump unit.
Hold fuel-pump unit (2) by tab (3) and lift it carefully out of the fuel
tank.
Remove fuel-pump unit (1) with gasket (2) from the fuel tank, making
sure that intake strainer (3) and lever-type sensor (4) do not catch in
the fuel tank and suffer damage.
(-) Removing complete fuel filler cap

Remove screws (1).
Remove outer ring with fuel filler cap (2).
062011 1/4
BMW-Motorrad
Remove retaining ring (1) for the cover of fuel tank.

Remove screws (2).
Remove filler neck (3) with gasket (4).
(-) Replacing fuel tank

Remove retaining ring (1) from the old fuel tank by applying abrupt and
firm pressure with pin wrench (No. 16 1 021).
Clean retaining ring (1) and check for damage; replace if necessary.
Install retaining ring (1) and position it with projection (2) seated in the
corresponding recess (arrow) in the fuel tank.
Remove washer (1) with bushing (2) and rubber mount (3) from the old
fuel tank and install them in the new component.
062011 2/4
BMW-Motorrad
(-) Installing complete fuel filler cap

Install filler neck (3) with gasket (4).
Install screws (2).
Tightening torques
Fuel filler cap to fuel tank
M5 x 20 3 Nm
Place retaining ring (1) for the cover of fuel tank in position.
Place outer ring with fuel filler cap (2) in position.

Install screws (1).
Tightening torques
Fuel filler cap to fuel tank
M5 x 20 3 Nm
(-) Installing fuel-pump unit

Lubricate sealing ring (2) at the seating face for the union nut.

Tyre mounting paste Assembly paste 81 22 0 433
046
Install fuel pump (1) with sealing ring (2) in the fuel tank. Take care not
to allow lever-type sensor (4) and intake strainer (3) to snag on the fuel
tank and suffer damage.
Insert sealing ring (2) in the fuel tank and install fuel pump (1).
Position fuel pump (1) in the locator (arrow).

Install union nut (2) with pin wrench (No. 16 1 021). Make sure that
retaining ring (3) does not turn at the same time.
Tightening torques
Fuel pump to fuel tank
Union nut 35 Nm
062011 3/4
BMW-Motorrad
(-) Filling fuel tank
Warning
Fill the fuel tank with fuel.
Technical data
Recommended fuel Super unleaded
grade 95 ROZ/RON
89 AKI
Finishing work
062011 4/4
BMW-Motorrad
16 14 009 Removing/installing fuel-pump unit 9 FRUs

+ 16 14 502
Warning
Preparatory work
Draining fuel tank
Core activity
pump.
Attention
pump unit.
tank.
062011 1/3
BMW-Motorrad


046

Tightening torques
Union nut 35 Nm
062011 2/3
BMW-Motorrad
Attention
seated.
pump.
Finishing work
Filling fuel tank

separate item)
062011 3/3
BMW-Motorrad
16 14 010 Replace electronics of fuel pump 7 FRUs

+ 16 14 521
Preparatory work
Core activity
(-) Removing electronic fuel pump
Disconnect plug (1) for the electronics of the fuel pump.
Remove screws (1).

Slightly lift electronics section (2) and disconnect plug (3) for the fuel
pump.
Remove electronics section (2) with sealing ring (4).
(-) Installing electronic fuel pump

Checking electrical contacts
When installing parts that were in use beforehand, check the condition
of the electrical contacts.
Test
Check the electrical contacts of the plug of the fuel-pump electronics.
Result: Significant signs of corrosion on the contacts.
Measure:
Replace the fuel-pump electronics.
062011 1/2
BMW-Motorrad
Test
Check the electrical contacts of the fuel-pump unit
Result: Significant signs of corrosion on the contacts.
Measure:
Replace the fuel-pump unit
Remove all traces of water or moisture inside the cavity and on the
plugs.
Check sealing ring (4) for damage; replace if swollen out of shape or
damaged.
Position sealing ring (4) on electronics section (2).
Connect plug (3) for the fuel pump.
Carefully install electronics section (2), making sure that sealing ring
(4) is correctly seated.
Install screws (1).
Connect plug (1) for the electronics of the fuel pump.
Finishing work
062011 2/2
BMW-Motorrad
16 14 011 Replacing fuel pump unit 11 FRUs

+ 16 14 503
Warning
Preparatory work
Draining fuel tank
Core activity
pump.
Attention
pump unit.
tank.
062011 1/4
BMW-Motorrad
(-) Replacing fuel-pump unit

Removing fuel-level sensor
Disconnect plug (1) for the fuel-level sensor.
Disengage the retaining tabs (arrows) and remove fuel-level sensor
(2).
Installing fuel-level sensor

Install fuel-level sensor (2), making sure that the retaining tabs
(arrows) engage.
Connect plug (1) for the fuel-level sensor.

062011 2/4
BMW-Motorrad

046

Tightening torques
Union nut 35 Nm
Attention
seated.
pump.
062011 3/4
BMW-Motorrad
Finishing work
Filling fuel tank
062011 4/4
BMW-Motorrad
16 14 513 Replacing fuel-level sensor (fuel-pump unit removed) 1 FRUs
Warning
Core activity
(-) Removing fuel-level sensor
Disconnect plug (1) for the fuel-level sensor.
Disengage the retaining tabs (arrows) and remove fuel-level sensor
(2).
(-) Installing fuel-level sensor

Install fuel-level sensor (2), making sure that the retaining tabs
(arrows) engage.
Connect plug (1) for the fuel-level sensor.
062011 1/1
BMW-Motorrad
17 00 010 Checking cooling system for leaks (with cooling system tester) 4 FRUs
+ 17 00 502
Warning
Take care when working on the cooling system: risk of burns if the
system is hot.
Do not work on the cooling system until it has had ample time to cool
down.
Preparatory work
Core activity
(-) Checking cooling system for leaks
Precondition
Engine cold.
Removing radiator cap

Remove cap (1).
Secure pump (No. 17 0 002) with adapter (No. 17 5 521) to the filler
neck.
Test
Pressure-test the cooling system; the pressure must remain
unchanged for at least 5 minutes.
Technical data
Cooling system Test pressure must 2 bar
test pressure remain
unchanged: min 5 min
Result: Pressure loss

Measure:
062011 1/2
BMW-Motorrad
Check for leaks and rectify.
Installing radiator cap

Install cap (1).
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
Coolant, specified level engine between MIN and
cold MAX marks on
the expansion
tank
Finishing work
062011 2/2
BMW-Motorrad
17 00 020 Checking coolant concentration

+ 17 00 503
Warning
system is hot.
down.
Core activity
(-) Checking coolant
Test
Check the ability of the coolant in the expansion tank to resist freezing
temperatures by checking the antifreeze concentration in the
expansion tank.
Technical data
Coolant, frost min −30 °C
protection
Result: Ability to resist freezing temperatures is not ensured.
Measure:
If necessary, increase the proportion of antifreeze until ability to resist
freezing temperatures is ensured.
Technical data
Coolant, total Expansion 0.5 l
capacity tank
Coolant 3.5 l
system, total
Antifreeze
Finishing work
062011 1/1
BMW-Motorrad
17 00 035 Draining coolant, refilling/bleeding system 8 FRUs

+ 17 00 504
Warning
system is hot.
down.
Preparatory work
Core activity
(-) Completely draining cooling system
Drawing off coolant from expansion tank
Remove cap (1) and draw off coolant (2) with a suitable tool, such as a
large syringe, for example.
Removing radiator cap

Remove cap (1).
062011 1/5
BMW-Motorrad
Warning
system is hot.
down.
Place a suitable container in position.

Remove screw (1).
Disconnect return line (2) for the coolant from the coolant pump, noting
O-ring (3).
Drain the coolant into the container.
(-) Filling and venting complete cooling system

Clean the tapped hole.
Check O-ring (3) for damage; replace if not in perfect condition.
Make sure that O-ring (3) is seated in the groove (arrow).
Push return line (2) for the coolant into the coolant pump.
Tightening torques
Coolant line to pump
Micro-encapsulated
Slacken screw (1).
Slacken screw (1).
062011 2/5
BMW-Motorrad
If the system is not refilled with fresh coolant, check the coolant to
ensure that the proportion of antifreeze is sufficient to ensure
resistance to freezing temperatures.
Technical data
Coolant, frost min −30 °C
protection
Fill the cooling system with coolant.
Technical data
capacity tank
Coolant 3.5 l
system, total
Antifreeze
Air escapes initially, then coolant.
Tighten screw (1).
Tightening torques
Vent screw in coolant pump
M6 x 10 8 Nm
Continue filling the cooling system with coolant.
Technical data
capacity tank
Coolant 3.5 l
system, total
Antifreeze
Air escapes initially, then coolant.
Tighten screw (1).
Tightening torques
Breather screw to cylinder head
M6 x 10 8 Nm
Completely fill the cooling system with coolant.
Filling expansion tank
Pour in coolant (2).
Technical data
Coolant, specified level engine
cold between MIN and
MAX marks on
062011 3/5
BMW-Motorrad
the expansion
tank
Install cap (1).
(-) Checking cooling system for leaks
Precondition
Engine cold.
Secure pump (No. 17 0 002) with adapter (No. 17 5 521) to the filler
neck.
Test
Pressure-test the cooling system; the pressure must remain
unchanged for at least 5 minutes.
Technical data
Cooling system Test pressure must 2 bar
test pressure remain
unchanged: min 5 min
Result: Pressure loss

Measure:
Check for leaks and rectify.
Installing radiator cap

Install cap (1).
Filling expansion tank
062011 4/5
BMW-Motorrad
Technical data
cold MAX marks on
the expansion
tank
Install cap (1).
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
cold MAX marks on
the expansion
tank
Finishing work
062011 5/5
BMW-Motorrad
17 11 001 Replacing cap for radiator 3 FRUs

+ 17 11 501
Warning
system is hot.
down.
Preparatory work
Core activity
(-) Removing radiator cap
Replace cap (1).
Finishing work
062011 1/1
BMW-Motorrad
17 11 008 Removing/installing radiator (without draining/refilling coolant system) 3 FRUs

+ 17 11 508
Preparatory work
item)
Core activity
(-) Removing complete radiator
Disconnecting coolant hose between engine and radiator at
radiator
Disconnect coolant hose (2).
Remove clip (1) and washer (2).
Releasing strut for radiator at bottom

Detach strut (3) from radiator (4).
062011 1/4
BMW-Motorrad

Remove plug (1) for the crankshaft sensor.
Remove and disconnect plug (2) for the fan.
Disengage radiator (1) complete with mounted parts from the retaining
pins (arrow) of the air guide for oil cooler on left and right and remove.
Take care not to damage the radiator and the mounted parts.
062011 2/4
BMW-Motorrad
(-) Installing complete radiator

Insert radiator (1) complete with mounted parts, seat it on the retaining
pins (arrow) of the air guide for oil cooler on left and right and install.
Take care not to damage the radiator and the mounted parts.
Install washer (2) and clip (1).
Connect plug (2) for the fan and install.

Hold plug (1) for the crankshaft sensor in position.
Securing strut for radiator at bottom

Secure strut (3) to radiator (4).
062011 3/4
BMW-Motorrad
Connecting coolant hose between engine and radiator at engine

Connect coolant hose (2).
Secure clip (1) with pliers (No. 17 5 571).
Finishing work
062011 4/4
BMW-Motorrad
17 11 038 Removing/installing or replacing dirt deflector for radiator 2 FRUs

+ 17 11 546
Core activity
(-) Removing dirt deflector
Unclip the holders (arrows) for dirt deflector (1).
Disengage dirt deflector (1) from air guide (2) and remove, noting the
holders (arrows).
(-) Installing dirt deflector

Seat dirt deflector (1) in air guide (2) and install. Make sure that the
holders (arrows) engage with an audible click.
Clip in the holders (arrows) for dirt deflector (1).
062011 1/2
BMW-Motorrad
Finishing work
062011 2/2
BMW-Motorrad
17 11 039 Removing/installing or replacing screen for radiator 5 FRUs

+ 17 11 547
Preparatory work
Removing spoiler for radiator
Removing air guide for radiator
Core activity
(-) Removing screen
Remove screws (1).
Disengage dirt screen (2) and remove.
(-) Installing screen

Hold screen (2) in position.
Install screws (1).
Tightening torques
Mesh screen and cooling-air guide to radiator
TS5 x 18 3 Nm
Finishing work
Installing air guide for radiator
Installing spoiler for radiator
062011 1/1
BMW-Motorrad
17 11 510 Replacing radiator (radiator removed) 3 FRUs
Core activity
(-) Removing spoiler for radiator
Remove screws (1).
Remove spoiler (2).
(-) Removing air guide with dirt deflector

Remove screws (1).
Disengage the holders (arrows) for dirt deflector (2).
Remove air guide (3) with dirt deflector (2).
(-) Removing screen

Remove screws (1).
Remove screen (2).
(-) Removing return line with bypass

Disconnect bypass (2) and disengage it from holder (3).
062011 1/5
BMW-Motorrad

Disconnect return line (2) from radiator (3).
(-) Removing fan

Remove screws (1).
Remove fan (2).
(-) Replacing radiator

Transfer rubber grommets (1) and inserts (2) from old to new radiator
(3).
062011 2/5
BMW-Motorrad
(-) Installing fan

Hold fan (2) in position.
Install screws (1).
Tightening torques
Radiator cowl/screen to radiator
Plastic screw, TS5 x 18 3 Nm
(-) Installing return line with bypass

Connect return line (2) to radiator (3).
Connect bypass (2) and secure it in holder (3).

062011 3/5
BMW-Motorrad
(-) Installing screen

Hold screen (2) in position.
Install screws (1).
Tightening torques
TS5 x 18 3 Nm
(-) Installing air guide with dirt deflector

Place air guide (3) with dirt deflector (2) in position.
Secure the holders (arrows) for dirt deflector (2).
Install screws (1).
Tightening torques
TS5 x 18 3 Nm
(-) Installing spoiler for radiator

Install spoiler (2).
Install screws (1) on left and right.
062011 4/5
BMW-Motorrad
Finishing work
062011 5/5
BMW-Motorrad
17 12 098 Replacing coolant hose from cylinder head (without draining/ refilling coolant
system) 2 FRUs
+ 17 12 758
Warning
system is hot.
down.
Core activity
(-) Removing coolant hose from cylinder head
Disconnect coolant hose (2) from adapter (3).
(-) Disconnecting feed line for coolant

Remove screw (1).
Disconnect feed line (2) for the coolant from the coolant pump, noting
O-ring (3).
(-) Replacing coolant hose from cylinder head

Transfer clip (1) with pliers (No. 17 5 571) to new coolant hose (2).
062011 1/2
BMW-Motorrad
(-) Connecting feed line for coolant

Check O-ring (3) for damage; replace if not in perfect condition.
Make sure that O-ring (3) is seated in the groove (arrow).
Push feed line (2) for the coolant into the coolant pump.
Tightening torques
Coolant line to pump
Micro-encapsulated
(-) Installing coolant hose from cylinder head

Connect coolant hose (2) to adapter (3).
Finishing work
item)
062011 2/2
BMW-Motorrad
17 12 100 Replacing coolant hose from radiator (without draining/ refilling coolant system) 2
FRUs
+ 17 12 600
Warning
system is hot.
down.
Core activity
(-) Removing coolant hose from radiator
Release clips (1) and (2) with pliers (No. 17 5 571).
Disconnect bypass line (3).
Disconnect coolant hose (4) from radiator (5).
(-) Replacing coolant hose from radiator

Transfer clip (1) with pliers (No. 17 5 571) to new coolant hose (2).
(-) Installing coolant hose from radiator

Connect coolant hose (4) to radiator (5).
The lug (arrow) engages the recess of the hose.
Connect bypass line (3).
Secure clips (1) and (2) with pliers (No. 17 5 571).
062011 1/2
BMW-Motorrad
Finishing work
item)
062011 2/2
BMW-Motorrad
17 12 105 Replacing coolant hose to radiator (without draining/ refilling coolant system) 2
FRUs
+ 17 12 605
Warning
system is hot.
down.
Preparatory work
Core activity
(-) Removing coolant hose to radiator
Open clips (1) with pliers(No. 17 5 571).
Disconnect coolant hose (2) from adapter (3) and radiator (4).
(-) Replacing coolant hose to radiator

Transfer clips (1) with pliers (No. 17 5 571) to new coolant hose (2).
(-) Installing coolant hose to radiator

Connect coolant hose (2) to adapter (3) and radiator (4).
Close clips (1) with pliers (No. 17 5 571).
062011 1/2
BMW-Motorrad
Finishing work

item)
062011 2/2
BMW-Motorrad
17 12 200 Replacing coolant hose from expansion tank 4 FRUs

+ 17 12 755
Warning
system is hot.
down.
Preparatory work
Core activity
(-) Drawing off coolant from expansion tank
(-) Removing coolant hose for expansion tank

Release clips (1) and (2) with pliers (No. 17 5 571).
Disconnect hose (3) from expansion tank (4) and use suitable means
to catch the remaining coolant as it escapes.
Disconnect hose (3) from filler neck (5).
Remove hose (3).
(-) Replacing coolant hose for expansion tank

Transfer clips (1) with pliers (No. 17 5 571) to new coolant hose (2).
062011 1/2
BMW-Motorrad
(-) Installing coolant hose for expansion tank

Connect hose (3) to expansion tank (4).
Connect hose (3) to filler neck (5).
Secure hose (3) in holder (6).
(-) Filling expansion tank

Technical data
cold MAX marks on
the expansion
tank
Install cap (1).
Finishing work
062011 2/2
BMW-Motorrad
17 13 001 Replace expansion tank 4 FRUs

+ 17 13 501
Warning
system is hot.
down.
Preparatory work
Core activity
(-) Drawing off coolant from expansion tank
(-) Removing expansion tank for coolant

Remove screw (3).
Disengage expansion tank (4).
Seal off hose (1) with hose clamp (No. 13 3 010).

Disconnect hose (1).
Remove expansion tank (3).
062011 1/3
BMW-Motorrad
(-) Installing expansion tank for coolant

Connect hose (1) to expansion tank (3) in such a way that the lug
(arrow) engages the recess of the hose.
Close clip (2) with pliers (No. 17 5 571).
Remove hose clamp (No. 13 3 010).
Engage expansion tank (4).

Install screw (3).
Tightening torques
Expansion tank to front panel carrier
Special thread for light alloy, 5 x 6 Nm
30
16
(-) Filling expansion tank

Technical data
cold MAX marks on
the expansion
tank
062011 2/3
BMW-Motorrad
Install cap (1).
Finishing work
062011 3/3
BMW-Motorrad
17 21 000 Removing/installing or replacing oil cooler

+ 17 21 501
Preparatory work
Removing right hand protector
Removing right speaker
Removing right mirror
Removing finisher of air guide, right
Removing top section of fairing, right
Removing air guide for intake air pipe, left
Removing left hand protector
Removing left speaker
Removing finisher of air guide, left
Removing top section of fairing, left
Removing cover of instrument panel
Disengaging left and right windscreen holders
Removing top cover
Removing cover for windscreen adjuster
Removing air guide for oil cooler
Removing headlight
Removing oil cooler from front panel carrier
Core activity
(-) Removing oil cooler
Close off feed hose (1) and return hose (2) with hose clamps (No. 13 3
010).
Open clip (1) and disconnect feed line (2) from oil cooler (3).
Open clip (4) and disconnect return line (5) from oil cooler (3).
062011 1/3
BMW-Motorrad
(-) Replacing oil cooler

Transfer rubber mounts (1) to new oil cooler (2).
(-) Installing oil cooler

Connect return line (5) to oil cooler (3).
Connect feed line (2) to oil cooler (3).
Remove the hose clamps (No. 13 3 010) from feed line (1) and return
line (2).
062011 2/3
BMW-Motorrad
Finishing work
Installing oil cooler in front panel carrier
Installing headlight
Installing air guide for oil cooler
Installing cover for windscreen adjuster
Installing top cover
Securing left and right windscreen holders
Installing cover of instrument panel
Checking headlight beam throw
Installing top section of fairing, left
Installing finisher of air guide, left
Installing left mirror
Installing left speaker
Installing left hand protector
Installing air guide for intake air pipe, left
Installing finisher of air guide, right
Installing right mirror
Installing right speaker
Installing right hand protector
062011 3/3
BMW-Motorrad
17 22 035 Removing/installing or replacing oil-cooler line, flow

+ 17 22 501
Preparatory work
Removing left mirror
Removing headlight
Removing fuel tank
Core activity
(-) Removing oil cooler line, feed
Place a suitable tray underneath the oil cooler to catch escaping oil.
Open clip (1) and disconnect oil cooler line (2) from oil cooler (3).
062011 1/4
BMW-Motorrad

Unclip oil cooler line (1) from holder (2).
Unclip oil cooler line (1) from the holders (arrows).
Remove screw (1).

Disconnect oil cooler line (2) and unclip it from the holder (arrow).
Remove sealing ring (3) from oil cooler line (2).
Work oil cooler line (2) to the rear until clear of the motorcycle and
remove.
Remove all oil stains from the vehicle.
(-) Installing oil cooler line, feed
062011 2/4
BMW-Motorrad
Manoeuvre oil cooler line (2) into position on the motorcycle.

Install sealing ring (3) on oil cooler line (2).
Connect oil cooler line (2) and clip the holder (arrow) to oil cooler line
(2).
Install screw (1).
Tightening torques
M6 x 20 10 Nm
Clip oil cooler line (1) of the oil cooler into holder (2) and secure it with
a cable tie (arrow).
Clip oil cooler line (1) into the holders (arrows).
Connect oil cooler line (2) to oil cooler (3) and close new clip (1) with
pliers (No. 13 1 500).
Finishing work
062011 3/4
BMW-Motorrad

Installing top section of fairing, right
062011 4/4
BMW-Motorrad
17 22 050 Removing/installing or replacing oil-cooler line, return

+ 17 22 502
Preparatory work
Removing headlight
Removing fuel tank
Core activity
(-) Removing oil cooler line, return
Place a suitable tray underneath the oil cooler to catch escaping oil.
Open clip (1) and disconnect oil cooler line (2) from oil cooler (3).
062011 1/4
BMW-Motorrad

Unclip oil cooler line (1) from holder (2).
Unclip oil cooler line (1) from the holders (arrows).
Remove screw (1).

Disconnect oil cooler line (2) and unclip it from the holder (arrow).
Remove sealing ring (3) from oil cooler line (2).
Work oil cooler line (2) to the rear until clear of the motorcycle and
remove.
Remove all oil stains from the vehicle.
(-) Installing oil cooler line, return
062011 2/4
BMW-Motorrad
Manoeuvre oil cooler line (2) into position on the motorcycle.

Install sealing ring (3) on oil cooler line (2).
Connect oil cooler line (2) and clip the holder (arrow) to oil cooler line
(2).
Install screw (1).
Tightening torques
M6 x 20 10 Nm
Clip oil cooler line (1) into the holders (arrows).
Clip oil cooler line (1) of the oil cooler into holder (2) and secure it with
a cable tie (arrow).
Connect oil cooler line (2) to oil cooler (3) and close new clip (1) with
pliers (No. 13 1 500).
Finishing work
062011 3/4
BMW-Motorrad

062011 4/4
BMW-Motorrad
17 40 000 Removing/installing or replacing fan 3 FRUs

+ 17 40 500
Preparatory work
Core activity
(-) Removing fan
Remove plug (1) for the crankshaft sensor.
Remove and disconnect plug (2) for the fan.
Remove screws (1).
Remove screws (1).

Remove fan (2).
(-) Installing fan

Install fan (2).
Install screws (1).
062011 1/2
BMW-Motorrad
Tightening torques
Install screws (1).
Tightening torques
Connect plug (2) for the fan and install.

Hold plug (1) for the crankshaft sensor in position.
Finishing work
062011 2/2
BMW-Motorrad
18 51 000 Replacing silencer 3 FRUs

+ 18 51 500
Warning
Preparatory work
Core activity
(-) Disengaging clamp on left silencer
Slacken screw (1) until clamp (2) is loose.
(-) Removing left silencer

Remove screw (1) with thrust washer (2).
Remove silencer (3).
(-) Replacing silencer

Remove clamp (1) from silencer (2).
Transfer retaining clamp (3) to new silencer (2).
062011 1/3
BMW-Motorrad
(-) Installing left silencer

Lubricating clamp for silencer
Thinly lubricate the inner face (arrow) of clamp (1).

assembly grease 599
Slip clamp (1) on to silencer pipe (2).
Install silencer (3), slipping the guide (arrow) on to holder (4).

Install screw (1) with thrust washer (2).
Tightening torques
Silencer to bracket
M8 x 35 19 Nm
(-) Securing clamp on left silencer

Aligning silencer
When installing silencers (1), make sure that they are
installed on the same level (A)
relative to tyre (2) parallel (B)
and with the outlets (arrows) forming a slightly V-shaped pattern (C).
062011 2/3
BMW-Motorrad
Align clamp (2) with the retaining lug (arrow).

Tighten screw (1).
Tightening torques
Clamp to silencer and exhaust manifold
M8 x 40 30 Nm
Finishing work
062011 3/3
BMW-Motorrad
18 51 001 Replacing exhaust manifold

+ 18 51 502
Warning
Preparatory work
Core activity
(-) Removing exhaust manifold, left
Remove gaskets (3).
(-) Removing exhaust manifold, right
062011 1/3
BMW-Motorrad

Remove gaskets (3).
(-) Replacing exhaust manifold

Transfer flat nut (1) to new left-hand exhaust manifold (2).
Transfer flat nut (3) to new right-hand exhaust manifold (4).
(-) Installing exhaust manifold, right

Tightening torques
M7 14 Nm
(-) Installing exhaust manifold, left

Tightening torques
M7 14 Nm
062011 2/3
BMW-Motorrad
Finishing work
062011 3/3
BMW-Motorrad
21 21 000 Removing and installing or replacing clutch 10 FRUs

+ 21 21 606
Preparatory work
Removing right crankcase cover
Core activity
(-) Removing clutch
Engage 6th gear and turn the rear wheel to turn clutch (1) until conrod
(2) of cylinder No. 5 is no longer visible.
Removing pressure plate

Screws (1)
Springs (3)
Pressure plate (4)
Thrust piece (5)
Removing plate cluster

Friction plate (1) with large inside diameter
Steel plate (2) with large inside diameter
062011 1/7
BMW-Motorrad

Steel plates (3)
Friction plates (4)

Release spring (5)
Plate for release spring (6) with
Removing driver
Remove circlip (1) with suitable pliers.
062011 2/7
BMW-Motorrad
Engage 6th gear on the motorcycle and apply the rear brake.
Remove nut (1).
Remove driver (2).
Remove bearing bushing (1) and clutch cage (2)

Remove thrust washer (3).
(-) Installing clutch

Bring tensioning gear of countershaft (1) and gearwheel of
countershaft (2) into alignment with each other.
Install thrust washer (3).

Position clutch cage (2) with bearing bushing (1) on gearbox shaft (4).
062011 3/7
BMW-Motorrad
Push clutch cage (1) onto the gearbox shaft until tensioning gear (2)
engages the following gearwheels:
Tensioning gear of countershaft (3)
Gearwheel of countershaft (4)
Crankshaft gear (5)
Drive gear for oil pump (6)
Turn tensioning gear (1) by using the bore (arrow) to insert a suitable
tool (2) and push in complete clutch cage (3).
Check that the gearwheels of crankshaft (1) and tensioning gear of

countershaft (2) are flush with the gearwheel of clutch cage (3).
Installing driver
Install driver (2).
062011 4/7
BMW-Motorrad
Engage 6th gear on the motorcycle and apply the rear brake.
Install nut (1).
Tightening torques
Clutch to gearbox input shaft
M20 x 1.5 160 Nm
Install circlip (1) with suitable pliers.
Installing plate cluster
Attention
Clutch plates can burn if installed dry.
Immerse the new clutch-plate stack in clean engine oil before installing.
The plate cluster is made up of different friction plates installed in a

certain sequence:
Friction plates (1) with large inside diameter
Friction plates (4)

Plate for release spring (6)
Release spring (5) with the curvature (arrow) toward the inside
062011 5/7
BMW-Motorrad
Install the following components in alternate sequence:

Steel plates (3)
Friction plates (4)
Install friction plate (1) with large inside diameter.
Installing pressure plate

Install friction plate (1) with large inside diameter and steel plate (2)
with large inside diameter on pressure plate (3).

Thrust piece (5)
Pressure plate (4) complete
Springs (3)
Lightly lubricate screws (1) and engage the threads.
Install screws and tighten to specified torque in diagonally opposite
sequence.
Tightening torques
Pressure plate to clutch hub
062011 6/7
BMW-Motorrad
M6 10 Nm
Finishing work
Installing right crankcase cover
062011 7/7
BMW-Motorrad
21 21 140 Removing and installing or replacing lined plates 9 FRUs

+ 21 21 609
Preparatory work
Core activity
(-) Removing pressure plate
Screws (1)
Springs (3)
Pressure plate (4)
Thrust piece (5)
(-) Removing plate cluster

Steel plate (2) with large inside diameter

Steel plates (3)
Friction plates (4)
062011 1/4
BMW-Motorrad

Release spring (5)
Plate for release spring (6) with
(-) Installing plate cluster
Attention
Clutch plates can burn if installed dry.
Immerse the new clutch-plate stack in clean engine oil before installing.
The plate cluster is made up of different friction plates installed in a

certain sequence:
Friction plates (1) with large inside diameter
Friction plates (4)

Plate for release spring (6)
Release spring (5) with the curvature (arrow) toward the inside
062011 2/4
BMW-Motorrad
Install the following components in alternate sequence:

Steel plates (3)
Friction plates (4)
Install friction plate (1) with large inside diameter.
(-) Installing pressure plate

Install friction plate (1) with large inside diameter and steel plate (2)
with large inside diameter on pressure plate (3).

Thrust piece (5)
Pressure plate (4) complete
Springs (3)
Lightly lubricate screws (1) and engage the threads.
Install screws and tighten to specified torque in diagonally opposite
sequence.
062011 3/4
BMW-Motorrad
Tightening torques
Pressure plate to clutch hub
M6 10 Nm
Finishing work
062011 4/4
BMW-Motorrad
21 52 005 Bleeding hydraulic clutch system 3 FRUs

+ 21 52 506
Preparatory work
Core activity
(-) Draining clutch system
Remove grubscrew (1) and install bleed screw (2) and tighten until
hand-tight.
Note
Oder the bleed screw and dust cap through the electronic parts
catalogue (ETK).
Remove screws (1) and remove reservoir cap (2) and diaphragm (3).
Clean reservoir, diaphragm (3) and cap (2).
Attention
Any mixture of oil, brake fluid and clutch fluid, even if the quantities
involved are minute, can attack and damage seals.
Always use separate sets of syringes and hoses for the individual
fluids, in order to avoid the risk of one fluid contaminating another.
Use syringe (No. 34 2 551) to draw the clutch fluid out of the clutch-
fluid reservoir.
Connect syringe (No. 34 2 551) to bleed screw (1) and secure it with a
cable tie (arrow).
Back off bleed screw (1).
Use syringe (No. 34 2 551) to extract hydraulic fluid through bleed
screw (1) until the line is empty.
Slightly tighten bleed screw (1).
Remove the cable tie (arrow) and disconnect syringe (No. 34 2 551)
from bleed screw (1).
(-) Filling clutch system
Note
Oder the bleed screw and dust cap through the electronic parts
062011 1/3
BMW-Motorrad
catalogue (ETK).
Attention
Any mixture of oil, brake fluid and clutch fluid, even if the quantities
involved are minute, can attack and damage seals.
Always use separate sets of syringes and hoses for the individual
fluids, in order to avoid the risk of one fluid contaminating another.
Fill syringe (No. 34 2 551) to capacity with hydraulic fluid.

Connect syringe (No. 34 2 551) to bleed screw (1) and secure it with a
cable tie (arrow).
Back off bleed screw (1).
Use syringe (No. 34 2 551) to inject hydraulic fluid into the system
through bleed screw (1) until the fluid level in the reservoir is correct.
Technical data
Clutch fluid level with new Max mark on
clutch reservoir
liner,
motorcycle
upright
and
handlebars
centred
Vitamol V10
Tighten breather screw (1).
Tightening torques
Bleed screw/grubscrew to clutch slave cylinder
M5 3 Nm
Disconnect syringe (No. 34 2 551) from bleed screw (1).
Motorcycle upright, handlebars turned all the way to the right.
Repeatedly pull the clutch lever until the pressure point is perceptible.
Repeat the procedure with the handlebars turned all the way to the
left.
Correct the level in the clutch fluid reservoir by drawing off excess fluid
or topping up with fresh hydraulic fluid, as necessary.
Technical data
Clutch fluid level with new Max mark on
clutch reservoir
liner,
motorcycle
upright
and
handlebars
centred
062011 2/3
BMW-Motorrad
Vitamol V10
Wipe the rim of the reservoir, diaphragm (3) and cap (2) to remove
clutch fluid, carefully reassemble the components and install.
Install screws (1).
Remove bleed screw (2) and install grubscrew (1).
Tightening torques
Bleed screw/grubscrew to clutch slave cylinder
M5 3 Nm
Finishing work
062011 3/3
BMW-Motorrad
21 52 014 Replacing clutch line (without bleeding system)

+ 21 52 514
Preparatory work
Removing fuel tank
Draining clutch system
Core activity
(-) Removing clutch line
Open rubber retaining band (1).
Remove banjo bolt (2) with sealing rings (3).
Disengage clutch line (4) from handlebar fitting (5).
Open rubber retaining bands (1).

Remove screw (2) and remove clip (3).
Unclip clutch line (4) from holder (5).
062011 1/4
BMW-Motorrad
Unclip clutch line (1) at GT marking rings (arrows) from holder (2).
Unclip clutch line (1) from holders (3) and (4).

Disengage clutch line (3) from slave cylinder (4) and remove.
(-) Installing clutch line

Route clutch line (3), position it correctly and hold it in position at slave
cylinder (4).
Install banjo bolt (1) with new sealing rings (2).
Tightening torques
Clutch line to clutch slave cylinder
Banjo bolt, M10 x 1 18 Nm
062011 2/4
BMW-Motorrad

Align shift lever (2) with the mark on the selector shaft (arrow) and slip
it into position.
Install screw (1).
Tightening torques
Shift lever to gearbox selector shaft
M6 x 25 8 Nm
Click shift lever (1) up and down, making sure that there is adequate
clearance between shift lever (1) and clutch line (2).
If the clearance between clutch line and shift lever is not adequate,
reposition the clutch line.
Clip clutch line (1) centred at printed GT marking rings (arrows) into
holder (2).
Clip clutch line (1) into holders (3) and (4).
Clip clutch line (4) into holder (5).

Hold clip (3) in position and install screw (2), turning clip (3) counter-
clockwise and counter-holding.
Tightening torques
Clamp with clutch line to frame steering head
M6 x 15 8 Nm
Close rubber retaining bands (1).
062011 3/4
BMW-Motorrad
Hold clutch line (1) in position at handlebar fitting (2).

Install banjo bolt (3) with new sealing rings (4), but do not tighten at
this point.
Position clutch line (1) at the stop (arrow) and tighten banjo bolt (1).
Tightening torques
Clutch line to clutch lever fitting
Close rubber retaining band (5).
Finishing work
=> Bleeding hydraulic clutch system (Description in

item: 21 52 506, Billed as a separate item)
062011 4/4
BMW-Motorrad
23 00 020 Removing/installing gearbox 22 FRUs

+ 23 00 659
Preparatory work
Removing clutch
Disengaging gearbox potentiometer
Removing clutch slave cylinder
Removing pushrod
Disengaging mounted parts from gearbox
Core activity
(-) Removing gearbox
Attention
Components can be damaged by hard or sharp-edged objects.
Avoid scratching the components; use masking tape if necessary.
062011 1/4
BMW-Motorrad
Remove complete gearbox (1).
Remove housing gasket (1).
(-) Installing gearbox

Clean sealing faces (1) on engine block and gearbox.
Make sure that reamed pins (2) are correctly installed.
Place housing gasket (3) in position.
062011 2/4
BMW-Motorrad
When installing gearbox (1), note breather hose (2) and drain hose (3)
and route them correctly.
Install complete gearbox (1).

Make sure that all gearbox components can be slipped easily into the
corresponding bearing seats in the engine block.
Tightening torques
Gearbox to crankcase
M8 x 30 19 Nm
M8 x 125 19 Nm
Finishing work
Securing mounted parts to gearbox
Installing pushrod
Securing clutch slave cylinder
Securing gearbox potentiometer
062011 3/4
BMW-Motorrad

Installing clutch
062011 4/4
BMW-Motorrad
23 14 051 Replacing potentiometer for gear indicator 6 FRUs

+ 23 14 507
Preparatory work
Core activity
(-) Removing gearbox potentiometer
Disconnect plug (1) for the gearbox potentiometer and work cable (2)
clear of the motorcycle.
Remove screws (3).
Remove gearbox potentiometer (4) and O-ring (5).
(-) Installing gearbox potentiometer

Install gearbox potentiometer (4) with O-ring (5), noting O-ring (5).
Install screws (3).
Tightening torques
Gearbox potentiometer to selector-drum carrier
M5 x 14 5 Nm
Route cable (2) in the motorcycle and connect plug (1) for the gearbox
potentiometer.
Finishing work

separate item)
062011 1/2
BMW-Motorrad
062011 2/2
BMW-Motorrad
23 41 300 Removing/installing or replacing gearshift lever 3 FRUs

+ 23 41 551
Core activity
(-) Removing gearshift lever
Remove retaining clip (1).
Disengage selector rod (2) from shift lever (3) and remove.
Slacken screws (1) and remove screw (2).

Lift footrest plate (3).
Remove gearshift lever (4) with washer (5).
(-) Replacing gearshift lever

Remove shouldered bushing (1) from shift lever (2) and check for
damage; replace if necessary.
Lubricate shouldered bushing (1) and install in new shift lever (2).

(-) Installing gearshift lever

Clean tapped hole for screw (2).
Install shift lever (4) with washer (5), making sure that the components
do not slip out of position.
Hold footrest plate (3) in position.
062011 1/2
BMW-Motorrad
Make sure that gearshift lever (4) with washer (5) do not slip out of
position.
Install new screw (2) and screws (1).
Tightening torques
Footrest plate to frame
M8 x 25 28 Nm
Micro-encapsulated
Seat selector rod (2) on shift lever (3).

Install retaining clip (1).
Finishing work
062011 2/2
BMW-Motorrad
23 41 310 Adjusting gearshift lever 2 FRUs

+ 23 41 510
Preparatory work
Core activity
(-) Checking and, if necessary, adjusting position of gearshift
lever
Check the position of the shift lever on the selector shaft.
Make sure that the mark (arrow) is aligned with the gap on the shift
lever.
Check the ease of movement of the components of the gearshift
linkage; remove, clean and lubricate if necessary.

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.
Test
Result: When not touched, the gearshift lever is not on a level with the
062011 1/2
BMW-Motorrad
rider's toe joint.

Measure:
Installing gearshift lever
Slacken nuts (1) and (2).
Correct position of shift lever (3) by turning selector rod (4).
Technical data
Selector-rod rod- Screw-in screwed in at least
end setting depth in ball 3 full threads
socket and
rod end
Tighten nuts (1) and (2).
Tightening torques
Ball end/rod end to selector rod
Ball end, Left-hand thread, M6 8 Nm
Rod end, M6 8 Nm
Check the clearance between the shift lever and the side stand;
correct the setting if necessary.
Have the customer take the motorcycle for a test ride to check the
setting; readjust if necessary.
Note
A poorly adjusted shift lever has a negative effect on the shiftability of the
gearbox.
Have the customer take the motorcycle for a test ride to check the
setting; readjust if necessary.
Finishing work
062011 2/2
BMW-Motorrad
23 41 325 Replacing selector rod on pedals 3 FRUs

+ 23 41 555
Preparatory work
Core activity
(-) Removing selector rod
Remove screw (1) and remove shift lever (2) with washer (3).
Remove retaining clip (1).

Disengage selector rod (2) from shift lever (3) and remove.
(-) Adjusting selector rod length

Slacken nuts (1) and (2).
Adjust length (A).
Technical data
Basic setting of +0.5
273.9 −0.5 mm
selector rod
Tighten nuts (1) and (2).
Tightening torques
Ball end/rod end to selector rod
Ball end, Left-hand thread, M6 8 Nm
Rod end, M6 8 Nm
062011 1/2
BMW-Motorrad
(-) Installing selector rod

Install selector rod (2) and engage it on shift lever (3).
Install retaining clip (1).
Hold shift lever (2) with washer (3) in position and install screw (1).
Tightening torques
Selector rod to shift lever
M8 x 30 19 Nm
Finishing work
062011 2/2
BMW-Motorrad
31 48 001 Replacing front spring strut 20 FRUs

+ 31 48 512
Additional line items for billing

31 48 510 Additional work for replacing front spring strut (with ESA), 1 FRUs
Preparatory work
Removing fuel tank
Disengaging front brake hose
Releasing pressure modulator
Core activity
(-) Releasing spring strut at bottom
Remove screw (1) for spring strut (2).
(-) Raising front suspension
Precondition
Motorcycle is secured so that it cannot drop or topple.
Remove nut (1).
062011 1/6
BMW-Motorrad
Release collared nut (1) and remove quick-release axle (2).
Lift front suspension (1) on scissor-type lifter (No. 00 1 571), noting oil
cooler (2).
Carefully lower leading link (3).
(-) Removing spring strut

Remove and disconnect plug (1) for the ESA spring strut.
Work cable (2) clear of the motorcycle.
062011 2/6
BMW-Motorrad
Remove screw (1).

Remove spring strut (2).
(-) Replacing spring strut

Install bushing (1) with collar (arrow) on left in forward direction of
travel in spring strut (2).
(-) Installing spring strut

Lubricate the fitted head of screw (1).

Install spring strut (2).
Install screw (1).
Tightening torques
Spring strut, front, to frame and leading link
M12 x 1.5 x 60, Replace screw 50 Nm
Micro-encapsulated
Lubricate the fitted head,
Staburags NBU 30 PTM
Route cable (2) into position.
Connect and install plug (1) for the ESA spring strut.
062011 3/6
BMW-Motorrad
(-) Lowering front suspension

Lower front suspension (1) on scissor-type lifter (No. 00 1 571), and at
the same time guide the leading link (2) into position.
Clean quick-release axle (2) and lubricate the shank.

assembly grease 599
Install quick-release axle (2).
Tightening torques
Leading link (quick-release axle) to frame
M24 x 1.25 Initial torque,
Lubricate thread, Optimoly TA 15 Nm
Loosen
Final torque, 7 Nm
Attention
Overtightening the locknut of the quick-release axle can result in
component damage.
Be sure to apply only the specified torque when tightening the collared
nut of the quick-release axle.
Install collared nut (1) with socket wrench insert (No. 33 6 641),
counter-holding with Allen key (No. 33 6 642).
062011 4/6
BMW-Motorrad
Tightening torques
Locknut on quick-release axle/bearing stud
M24 x 1.25 145 Nm
Install nut (1).
Tightening torques
Nut on leading-link quick-release axle
M14 x 1.5 30 Nm
(-) Securing spring strut at bottom

Lubricate the fitted head of screw (1).

Install screw (1) for spring strut (2).
Tightening torques
Spring strut, front, to frame and leading link
Micro-encapsulated
Finishing work
Securing pressure modulator
Securing front brake hose
062011 5/6
BMW-Motorrad

062011 6/6
BMW-Motorrad
32 71 001 Replacing top steering bridge

+ 32 71 501
Preparatory work
Covering cover for fuel tank
Covering instrument panel
Closing equalising bore of front brake
Removing BMW badge with carrier
Removing nut of handlebar bridge
Disconnecting plugs for ignition switch/steering lock and ring
aerial
Core activity
(-) Removing handlebar bridge
Remove screws (1).
Separate handlebar, right (2) from handlebar bridge (3).
Allow handlebar, right (2) to dangle to one side. Make sure that no
brake fluid escapes.
Remove screws (4) and remove handlebar bridge (3).
Allow handlebar, left (5) to dangle to one side. Make sure that no
clutch fluid escapes.
(-) Replacing top handlebar bridge

Removing ignition switch/steering lock with ring aerial
Lay handlebar bridge (1) on a padded rest.
Remove screws (2).
Remove screws (3) and remove ignition switch (4).
Attention
Drill pilot holes into non-removable screws (1) and then continue
drilling out the holes until the screw heads come off.
062011 1/3
BMW-Motorrad
Technical data
Ignition Pilot hole min 5 mm
switch/steering diameter 4 mm
lock - drilling depth Diameter for 5 mm
for drilling out non- drilling out
removable screws fully 8.5 mm
Use compressed air to remove metal particles.
Remove steering lock (2) with ring aerial (3).
Use a stud remover to remove shanks of non-removable screws (4).
Clean the threads.

Install steering lock (2) with ring aerial (3) in new handlebar bridge (4).
Install non-removable screws (1) with socket wrench insert (No. 51 0
531).
Tightening torques
Ignition and steering lock to handlebar yoke
Micro-encapsulated
Hold ignition switch (3) in position and install screws (2).

Install screws (1).
(-) Installing handlebar bridge

Position left handlebar (5) on handlebar bridge (3).
Install screws (4).
Tightening torques
Stub handlebar to handlebar bridge
M8 x 25 19 Nm
Position right handlebar (2) on handlebar bridge (3).
Install screws (1).
062011 2/3
BMW-Motorrad
Tightening torques
M8 x 25 19 Nm
Finishing work
Connecting plugs for ignition switch/steering lock and ring aerial
Installing handlebars
Installing BMW badge with carrier
Opening equalising bore of front brake
Removing blanket covering instrument panel
Removing blanket covering fuel tank
062011 3/3
BMW-Motorrad
32 71 063 Renewing handlebar weight 2 FRUs

+ 32 71 515
Core activity
(-) Removing handlebar weight
Remove screw (1).
Remove handlebar weight (2).
(-) Installing handlebar weight

Hold handlebar weight (2) in position.
Install screw (1).
Tightening torques
Handlebar weight to handlebar half
M8 x 35 19 Nm
On the throttle twistgrip side make sure that the twist tube rotates
freely.
Finishing work
062011 1/1
BMW-Motorrad
32 71 150 Removing/installing or replacing handlebar, left

+ 32 71 525
Preparatory work
Removing handlebar weight
Removing left grip unit
Removing handlebar lever fitting for clutch
aerial
Core activity
(-) Removing left handlebar
Remove screws (1).
Remove handlebar (2) from handlebar bridge (3).
(-) Removing left handlebar

Position handlebar (2) on handlebar bridge (3).
Install screws (1).
Tightening torques
M8 x 25 19 Nm
Finishing work
062011 1/2
BMW-Motorrad
Installing handlebar lever fitting for clutch

Installing left grip unit
Installing handlebar weight
062011 2/2
BMW-Motorrad
32 71 160 Removing/installing or replacing handlebar, right

+ 32 71 527
Preparatory work
Removing right multifunction switch
Removing throttle twistgrip
Removing handbrake lever fitting
aerial
Core activity
(-) Removing right handlebar
Remove screws (1).
Remove handlebar (2) from handlebar bridge (3).
(-) Installing right handlebar

Position handlebar (2) on handlebar bridge (3).
Install screws (1).
Tightening torques
M8 x 25 19 Nm
Finishing work
Installing handbrake fitting
062011 1/2
BMW-Motorrad
Installing throttle twistgrip

Installing right multifunction switch
062011 2/2
BMW-Motorrad
32 72 001 Replacing throttle twistgrip 3 FRUs

+ 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
Throttle twistgrip to handlebar
M3.5 x 32 2 Nm
Finishing work
Installing right multifunction switch

separate item)
062011 1/1
BMW-Motorrad
32 72 064 Replacing handlebar fitting for clutch actuation (without bleeding system) 2 FRUs
+ 32 72 664
Preparatory work
=> Bleeding hydraulic clutch system (Description in
Core activity
(-) Disengaging clutch switch
Remove screw (1).
Remove clutch switch (2), noting locating point (3).
(-) Removing handlebar fitting for clutch actuation

Open the retaining strap (arrow).
Remove banjo bolt (1) with sealing washers (2).
Disconnect clutch hose (3).
Remove screws (1) and clamp (2).

Remove clutch lever fitting (3).
(-) Installing handlebar fitting for clutch
062011 1/2
BMW-Motorrad
Hold clutch lever fitting (3) in position.

Hold clamp (2) in position and align with clutch fitting (3) at the mark
(arrow).
Install screws (1).
Tightening torques
Handlebar fittings to handlebars
M5 x 20 5 Nm
Hold clutch hose (3) in position.

Install banjo bolt (1) with new sealing washers (2).
Tightening torques
Clutch line to clutch lever fitting
Close the retaining strap (arrow).
(-) Securing clutch switch

Install clutch switch (2) with the white mark (arrow) pointing down,
noting locating point (3).
Install screw (1).
Tightening torques
Clutch switch to handlebar fitting
M2 x 18 0.3 Nm
Finishing work
062011 2/2
BMW-Motorrad
32 72 070 Replace clutch lever 2 FRUs

+ 32 72 627
Core activity
(-) Removing clutch lever
Remove nut (1).
Pull screw (2) up to remove.
Pull out lever unit (3), noting rubber sleeve (4).
Remove sleeve (1) from lever (2).

Remove lever mount with pushrod (3) and spring (4).
(-) Installing clutch lever

Seat spring (4) and lever pivot with pushrod (3) in lever (2).
Install sleeve (1) and lubricate.

Teflon spray Gearbox shift shaft, 83 23 0 154
foot-operated 884
selector shaft
Lubricate screw (2).

Teflon spray 83 23 0 154
Gearbox shift shaft,
884
foot-operated
062011 1/2
BMW-Motorrad
selector shaft
Install lever unit (3), making sure that pushrod (5) engages in piston
seat (6) and that rubber sleeve (4) is correctly positioned.
Install screw (2) with new nut (1).
Tightening torques
Handlebar lever to fitting
M5, Replace nut 7 Nm
Mechanical thread lock
Finishing work
062011 2/2
BMW-Motorrad
32 72 097 Replacing left handlebar grip

+ 32 72 632
Preparatory work
Core activity
(-) Removing left multifunction switch
Disengage the retaining tabs (arrows).
Remove cover (1).
Working in the following sequence, disconnect and remove the
following plugs:
(2), 4-pin
(3) for the grip heating
(4), 8-pin
Push up retainer (1).

Remove multifunction switch (2) from grip (3) and remove plug (4) for
the heated grip.
(-) Disengaging multi-controller

Remove screws (1).
Lift bracket (2) and work the cable from plug (3) for the heated grip
clear.
Remove bracket (2) and multi-controller (4) from grip (5).
062011 1/3
BMW-Motorrad
(-) Securing multi-controller

Position multi-controller (4) on grip (5). Make sure that the retainers
(arrows) and recesses (6) engage.
Work the cable of plug (3) for the heated grip through bracket (2).
Hold bracket (2) in position and install screws (1), noting the grip-
heating cable.
Tightening torques
Multi-controller to grip
RS2.5 x 20 1.5 Nm
(-) Installing left multifunction switch

Push multifunction switch (2) on to grip (3) and install plug (4) for the
heated grip.
Retainer (1) engages.
Check that the grip-heating cable is correctly routed and does not
project into the grip tube.
Working in the following sequence, install and connect the plugs:

(4), 8-pin
(2), 4-pin
Install cover (1).
Make sure that the retaining tabs (arrows) engage.
062011 2/3
BMW-Motorrad
Finishing work
062011 3/3
BMW-Motorrad
32 72 119 Replacing handbrake lever 2 FRUs

+ 32 72 637
Core activity
(-) Removing handbrake lever
Remove nut (1).
Pull screw (2) up to remove.
Pull out lever unit (3), noting rubber sleeve (4).
Remove sleeve (1) from lever (2).

Remove lever mount with pushrod (3) and spring (4).
(-) Installing handbrake lever

Seat spring (4) and lever pivot with pushrod (3) in lever (2).
Install sleeve (1) and lubricate.

Teflon spray Gearbox shift shaft, 83 23 0 154
foot-operated 884
selector shaft
Lubricate screw (2).

Teflon spray 83 23 0 154
Gearbox shift shaft,
884
foot-operated
062011 1/2
BMW-Motorrad
selector shaft
Install lever unit (3), making sure that pushrod (5) engages in piston
seat (6) and that rubber sleeve (4) is correctly positioned.
Install screw (2) with new nut (1).
Tightening torques
Handlebar lever to fitting
M5, Replace nut 7 Nm
Finishing work
062011 2/2
BMW-Motorrad
32 72 120 Replace handbrake fittings 4 FRUs

+ 32 72 638
Attention
Brake fluid attacks paintwork, plastic and rubber parts.
Do not allow brake fluid to come into contact with paintwork, plastic or
rubber parts.
Preparatory work
Draining brake fluid reservoir on handbrake fitting
Core activity
(-) Removing handbrake fitting
Remove banjo bolt (1) with sealing washers (2).
Remove brake hose (3).
Remove screws (1) and clamp (2).

Remove handbrake fitting (3).
(-) Installing handbrake fitting

Hold handbrake fitting (3) in position.
Hold clamp (2) in position and align with handbrake fitting (3) at the
mark (arrow).
Install screws (1).
Tightening torques
Handlebar fittings to handlebars
M5 x 20 5 Nm
062011 1/2
BMW-Motorrad
Hold brake hose (3) in position.

Install banjo bolt (1) with new sealing washers (2).
Tightening torques
Brake hose with banjo bolt to components
M10 x 1 24 Nm
Finishing work
Filling and bleeding front brake system
062011 2/2
BMW-Motorrad
32 76 000 Replacing steering damper 15 FRUs

+ 32 76 500
Preparatory work
Removing fuel tank
Core activity
(-) Removing steering damper
Position handlebars (1) so that screw (2) is accessible.
Remove screw (2) and remove corrugated washer (3).
Remove nut (4), while counter-holding at ball head (5).
Remove steering damper (6).
(-) Installing steering damper

Clean the threads in steering damper (6).
Position handlebars (1) so that hole for screw of steering damper (6) is
accessible.
Hold steering damper (6) with corrugated washer (3) in position and
install screw (2).
Tightening torques
Steering damper to steering unit
Micro-encapsulated
Install nut (4), counter-holding at ball head (5).
062011 1/2
BMW-Motorrad
Tightening torques
Steering damper to frame
M8 19 Nm
Finishing work
062011 2/2
BMW-Motorrad
33 35 000 Replacing rear wheel swinging arm 13 FRUs

+ 33 35 501
Preparatory work
Core activity
(-) Removing universal shaft
Work flexible gaiter (1) to the rear to remove.
Use a suitable tool to press universal shaft (1) to the rear.
Ease universal shaft (1) out of swinging arm (2).
062011 1/9
BMW-Motorrad
(-) Removing rear wheel swinging arm

Secure swinging arm (1) with ratchet strap (2) to footrest bracket (3).
Remove spray-guard clip (1) from link strut (2).
Remove nut (1) and screw (2) with washer (3).

Pivot link strut (4) down.
062011 2/9
BMW-Motorrad

Pivot relay plates (4) down.
Slacken screw (1), but do not remove.
Remove screw (1) and screws (2) for bearing stud (3).
Install a suitable screw (1) and tighten it until it can still just be gripped
well by puller (No. 33 1 671).
Mount pull rod (No. 13 5 251) and impact weight (No. 13 5 253) with
puller (No. 33 1 671) on screw (1).
Remove bearing stud (2).
Slacken locknut (1) and remove with bearing stud (2).
062011 3/9
BMW-Motorrad
Remove ratchet strap (1) from footrest bracket (3) and lower swinging
arm (2).
Turn swinging arm (2) slightly and work it to the rear to remove.
(-) Replacing swinging arm

Hold relay plates (1) in position on new swinging arm.

The marks (arrows) are at the top and face in the forward direction of
travel.
062011 4/9
BMW-Motorrad
Install screw (2) with washer (3) and new nut (1).
Tightening torques
Relay plate to swinging arm and relay lever
M12 x 1.5 x 75 - 10.9, Replace nut 50 Nm
Affix masking tape to new swinging arm (1) at the areas indicated
(arrows).
Install flexible gaiter (1) and plastic insert (2) in the new swinging arm.
The retainers (arrows) snap into position.
Transfer flexible gaiter (1) and plastic inserts (2) and (3) to the new
swinging arm.
(-) Installing rear swinging arm
062011 5/9
BMW-Motorrad
Turn swinging arm (2) slightly and carefully work it into position in the
main frame.
Lift swinging arm (2) and secure it with ratchet strap (1) to footrest
bracket (3).
Slightly lubricate bearing stud (3) where shown here.

Align swinging arm (4) and install bearing stud (3).
Install screws (2).
Tightening torques
Bearing stud, swinging arm to frame, left
M6 x 16 9 Nm
Install screw (1).
Tightening torques
Capping screw, bearing stud, left
M6 x 8 9 Nm
Clean bearing stud (2) and lubricate at threads and bearing seat.

assembly grease 599
Align the swinging arm and install bearing stud (2).
Tightening torques
Floating bearing stud (swinging arm) to frame
M24 x 1.25 Initial torque,
Lubricate thread and bearing seat, 20 Nm
Optimoly TA Loosen
Final torque, 7 Nm
Tighten locknut (1) with socket wrench insert (No. 33 6 641), while
counter-holding bearing stud (2) with Allen key (No. 33 6 642).
062011 6/9
BMW-Motorrad
Tightening torques
Locknut (bearing stud) to frame
M24 x 1.25 145 Nm
Swing relay plates (4) up and hold in position.
Install screw (2) with washer (3) and nut (1).
Tightening torques
Deflectors to spring strut
M10 x 70 - 10.9, Replace nut 42 Nm
Swing link strut (4) up and hold it in position.

Tightening torques
Clip spray-protection clip (1) to link strut (2).
Tighten screw (1).
Tightening torques
Spring strut/link strut to frame
Micro-encapsulated
062011 7/9
BMW-Motorrad
Remove ratchet strap (2) from swinging arm (1) and footrest bracket
(3).
Remove the adhesive tapes (arrow) from swinging arm (1).
(-) Installing universal shaft

Lubricate the splines (arrows) of universal shaft (1).

assembly grease 599
062011 8/9
BMW-Motorrad
Insert universal shaft (1) into swinging arm (2).
Turn universal shaft (1) until the splines (arrows) engage.

Slide universal shaft (1) into gearbox output shaft (2) until seated.
Work flexible gaiter (1) forward on to gearbox cover (2).

Finishing work
062011 9/9
BMW-Motorrad
33 35 001 Replacing swinging-arm bearing

+ 33 35 502
Preparatory work
Core activity
(-) Replacing swinging-arm bearing
Attention
Install reaction support (No. 00 8 572), support ring (No. 36 6 610) and
internal puller 2 1/2 (No. 00 8 571).
Heat the part of the swinging arm surrounding the bearing.
Technical data
Release/mating 80 °C
temperature,
swinging-arm
bearing
Remove bearing (1).
Install new bearing (1) with drift (No. 33 5 700) until flush.
Install the second bearing in the same way.
(-) Removing deflector panels
062011 1/4
BMW-Motorrad
Remove deflector panels (1).
(-) Removing relay bearing
Attention
Use a suitable tool to remove shaft sealing rings (1).

Remove bearing bushing (2).
Remove needle roller bearing (3) with drift (No. 36 3 700) and bushing
(No. 33 2 533).
062011 2/4
BMW-Motorrad
(-) Installing relay bearing
Attention
Position the swinging arm on bushing (No. 33 2 533).

Install needle roller bearing (3) with drift (No. 36 3 700).
Install bearing bushing (2).

Bearing bushing (2) is centred in the mount.
Install shaft sealing rings (1).
(-) Installing deflector panels

Hold relay plates (1) in position.
The marks (arrows) are at the top and face in the forward direction of
travel.
062011 3/4
BMW-Motorrad
Tightening torques
Finishing work
062011 4/4
BMW-Motorrad
33 54 000 Replacing rear spring strut 11 FRUs

+ 33 54 500
Preparatory work
Removing right rear trim panel
Releasing expansion tank
Removing silencer
Raising rear frame
Core activity
(-) Removing rear spring strut
Disengage deflectors (4) from spring strut (5).
Remove and disconnect plugs (1) and (2) for ESA spring strut and
work them clear of the motorcycle.
Remove screw (1).

Remove spring strut (2).
062011 1/3
BMW-Motorrad
(-) Installing rear spring strut

Install spring strut (5).
Hold deflectors (4) in position on spring strut (5).
Tightening torques
Deflectors to spring strut
M10 x 70 - 10.9, Replace nut 42 Nm

Work spring strut (2) into position in rear frame (3) and install by
moving rear frame (3).
Lubricate new screw (1) and install.
Tightening torques
Micro-encapsulated
Work plugs (1) and (2) for ESA spring strut into position, connect and
install.
062011 2/3
BMW-Motorrad
Finishing work
Lowering rear frame
Securing silencer
Securing expansion tank
Installing right rear trim panel
Preparation for initialising/calibrating new parts
062011 3/3
BMW-Motorrad
33 54 005 Replacing link strut 3 FRUs

+ 33 54 508
Preparatory work
Core activity
(-) Removing link strut
Unclip spray guard (1) from link strut (2).

Pivot link strut (4) down.
Remove screw (1).

Remove link strut (2).
(-) Installing link strut

Install link strut (2).
062011 1/2
BMW-Motorrad
Tightening torques
Micro-encapsulated
Swing link strut (4) up and hold it in position.

Tightening torques
Clip spray guard (1) (black) to link strut (2).
Finishing work
062011 2/2
BMW-Motorrad
33 73 000 Removing/installing or replacing universal shaft 5 FRUs

+ 33 73 500
Preparatory work
Core activity
(-) Removing universal shaft
Work flexible gaiter (1) to the rear to remove.
Use a suitable tool to press universal shaft (1) to the rear.
Ease universal shaft (1) out of swinging arm (2).
062011 1/3
BMW-Motorrad
(-) Installing universal shaft

Lubricate the splines (arrows) of universal shaft (1).

assembly grease 599
Ease universal shaft (1) into swinging arm (2), moving the swinging
arm back and forth slightly to facilitate installation.
Turn universal shaft (1) until the splines (arrows) engage.

Slide universal shaft (1) into gearbox output shaft (2) until seated.
Work flexible gaiter (1) forward on to gearbox cover (2).

062011 2/3
BMW-Motorrad
Finishing work
062011 3/3
BMW-Motorrad
33 74 000 Oil change in rear bevel gears 4 FRUs

+ 33 74 500
Preparatory work
Core activity
(-) Changing oil in bevel gears
Note
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.
Removing oil filler plug, bevel gears
Remove oil filler plug (1) with O-ring (2).
Removing drain plug, bevel gears

Remove drain plug (1) with O-ring (2).
Allow all the oil to drain off.
Filling bevel gears with oil (oil change)

Installing drain plug, bevel gears
062011 1/2
BMW-Motorrad
Install drain plug (1) with O-ring (2).
Tightening torques
Drain plug in bevel gears
M12 x 1 20 Nm
Use syringe (No. 34 2 551) to inject the gear oil slowly through the filler
neck into the housing.
Technical data
Bevel gears, oil oil change 180 ml
capacity Fluids and lubricants
Castrol SAF-XO
Installing oil filler plug, bevel gears

Install oil filler plug (1) with O-ring (2).
Tightening torques
Oil filler screw in cover of bevel gears
M12 x 1 20 Nm
Finishing work
062011 2/2
BMW-Motorrad
33 74 001 Removing/installing rear bevel gears 7 FRUs

+ 33 74 501
Warning
Failure/breakage of the knuckle lever would cause the tail section to
drop suddenly.
If a component that is part of the rear suspension has to be replaced
because of an external effect/impact, it is important to replace the
knuckle lever as well.
Preparatory work
Core activity
(-) Removing bevel gears
Lower bevel gears (1), unclipping flexible gaiter (2).
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) with bearing stud (2) and sealing ring (3), counter-
holding bearing stud (4).
062011 1/4
BMW-Motorrad
Remove bearing stud (4), if necessary using a suitable tool to drive it

out.
Separate bevel gears (1) from universal shaft (2) and remove.
When setting down bevel gears always keep the assembly upright,
never lay it flat.
(-) Removing flexible gaiter for bevel bears

Remove flexible gaiter (1) with clips (2) and (3).
062011 2/4
BMW-Motorrad
(-) Installing bevel gears

Hold bevel gears (5) in position.
Clean the tapped hole in bearing stud (4).
Install bearing stud (4).

Install bearing stud (2) with sealing ring (3).
Install new screw (1), while counter-holding at bearing stud (4).
Tightening torques
Bevel gears to swinging arm
M12 x 1.5 x 80 - 10.9, Replace 100 Nm
screw
Micro-encapsulated
Installing cover of bevel gears

Install new cover (1).

Lubricate the splines of universal shaft (6) and the shaft of bevel gears
(5).

assembly grease 599
Check that plastic inserts (1) and (2) are correctly seated in flexible
gaiter (3).
062011 3/4
BMW-Motorrad
Lubricate the mating faces (arrows) of flexible gaiter (3).

Introduce flexible gaiter (3) into the swinging arm and make sure that
lug (4) engages the swinging arm.
Swing bevel gears (5) up and introduce the shaft of the bevel gears
into universal shaft (6).
Engage flexible gaiter (3) in the threaded ring of bevel gears (5).
Check the seat of flexible gaiter (3).
Finishing work
062011 4/4
BMW-Motorrad
34 00 010 Change brake fluid in entire system 8 FRUs

+ 34 00 504
Core activity
(-) Changing brake fluid, front, and bleeding brake system
Warning
Air can be drawn into the system through the fluid replenishing hole if
the fluid level in the reservoir is too low; the system has to be bled
again if this happens.
Make sure that the fluid replenishing bore is always under the surface
of the brake fluid throughout the entire process of fluid changing/system
bleeding.
Note
This description applies for brake filling and bleeding units with vacuum
extraction. If other devices are used, comply with the manufacturer's
instructions.
Set the brake lever to maximum span.

Attention
rubber parts.
Draw off the old brake fluid.
Removing front brake pads

Remove screws (1) and remove brake-pad spring (2).
062011 1/8
BMW-Motorrad
Remove split-pin keeper (1) and locking pin (2).

Remove brake pads (3).
Repeat this procedure on the other side.
In the left and right brake calipers, insert piston resetting device (No.
34 1 531) with locator (No. 34 1 532).
Force the left and right pistons fully back with the piston resetting
device.
Draw off the excess brake fluid and clean the reservoir.
Turn the handlebars to a position in which the brake fluid reservoir is

horizontal.
Warning
Brake fluid is hygroscopic, which means that its boiling point drops
once the container has been opened.
Use only new brake fluid from freshly opened containers.
Top up with fresh brake fluid to the MAX mark (arrow).
062011 2/8
BMW-Motorrad
Brake fluid Hydraulic systems

Connect the brake bleeding device to bleed screw (1) in the handbrake
cylinder.
Slightly open bleed screw (1).
Continue bleeding the brake system until the fresh brake fluid emerges
clear and free from bubbles.
Close bleed screw (1).
Tightening torques
Bleed screw to handlebar fitting
M5 2.2 Nm
Connect the brake bleeding device to bleed screw (1) in the left brake
caliper.
Continue bleeding the brake system until fresh brake fluid emerges.
Warning
The brake-bleeding process might have been interrupted even though
air remained in the system. On account of the vacuum extraction
process, it is not possible to tell whether the brake fluid extracted from
the system is free of bubbles.
On conclusion of the process, bleed the system manually (without
vacuum extraction) until you are sure that the brake fluid expelled from
Close bleed screw (1) of the left brake caliper.
Tightening torques
Bleed screw in front brake caliper
M7 8 Nm
Repeat the fluid-change procedure/procedure for bleeding the
brakes at the right brake caliper.

Again connect the brake bleeding device to bleed screw (1) in the
handbrake cylinder.
062011 3/8
BMW-Motorrad

Tightening torques
M5 2.2 Nm
Fit adapter 25 (No. 34 1 535) to the left and right of resetting device
(No. 34 1 531) and screw the resetting device together.
Pull the handbrake lever until the brake pistons are in contact with the
piston resetting device.
This simulates the thickness of new brake pads and brake discs.

horizontal.
Expand the piston resetting device on left and right.
This forces back the brake pistons so that the brake pads can be
installed.
Remove the piston resetting device and locators left and right from the
brake calipers.
Wipe the rim of the reservoir, diaphragm (3) and reservoir cap (2) to
remove brake fluid and carefully reassemble the components.
Install screws (1).
Installing front brake pads

Install brake pads (3).
062011 4/8
BMW-Motorrad
Install locking pin (2) with the bore (arrow) facing up and secure it with
split-pin keeper (1).
Hold brake-pad spring (2) in position and install screws (1).
Tightening torques
Sheet metal spring on front brake caliper
M4 3 Nm
Bedding in brake pads

Once the work has been completed, seat the pads against the brake
discs and check operation of the brake system.
Test
Check brake pressure by operating the brakes.
Result: Low brake pressure
Measure:
Repeat the brake bleeding procedure without removing the brake
pads.
(-) Change the brake fluid, rear, and bleed the brake system
Warning
Note
instructions.
062011 5/8
BMW-Motorrad
Draining rear reservoir

Disengage reservoir (1) from bracket (2).
Attention
rubber parts.
Remove cap (3) while counter-holding reservoir (1).

Remove flexible gaiter (4).
Draw off the brake fluid from reservoir (1).
Press brake caliper (1) against the brake disc to force the pistons
back.
Draw off the excess brake fluid that was forced back into the reservoir.
Warning
Top up with fresh brake fluid to the (MAX) mark.

Connect the brake bleeding device to bleed screw (1) in the brake
caliper.
Warning
bleeding.
062011 6/8
BMW-Motorrad
Warning
Close bleed screw (1) and remove the brake bleeding device.
Tightening torques
Bleed screw, rear, in banjo bolt
14 Nm
Filling rear reservoir
Warning

Clean all components.

Install diaphragm (4).
Install cap (3) while counter-holding reservoir (1).
Secure reservoir (1) in bracket (2).
Test
Measure:
Repeat the brake-bleeding process.
Finishing work
062011 7/8
BMW-Motorrad
062011 8/8
BMW-Motorrad
34 00 033 Bleeding front brake system 4 FRUs

+ 34 00 507
Core activity
(-) Filling and bleeding front brake system
Warning
bleeding.
Note
instructions.

Attention
rubber parts.

horizontal.
Warning
062011 1/3
BMW-Motorrad

cylinder.
Tightening torques
M5 2.2 Nm
caliper.
Warning
Tightening torques
M7 8 Nm
handbrake cylinder.
062011 2/3
BMW-Motorrad
Tightening torques
M5 2.2 Nm

horizontal.
Install screws (1).

Test
Measure:
pads.
Finishing work
062011 3/3
BMW-Motorrad
34 00 035 Bleeding rear brake system 3 FRUs

+ 34 00 509
Core activity
(-) Bleeding rear brake system
Warning
Note
instructions.

Attention
rubber parts.

back.
Warning
062011 1/3
BMW-Motorrad

caliper.
Slightly open the bleed screw.
Warning
bleeding.
Warning
Close the bleed screw and remove the brake bleeding device.
Tightening torques
14 Nm
Warning
062011 2/3
BMW-Motorrad


Test
Measure:
Finishing work
062011 3/3
BMW-Motorrad
34 00 048 Changing brake fluid, front brakes 6 FRUs

+ 34 00 548
Core activity
(-) Changing brake fluid, front, and bleeding brake system
Warning
bleeding.
Note
instructions.

Attention
rubber parts.

062011 1/5
BMW-Motorrad

In the left and right brake calipers, insert piston resetting device (No.
34 1 531) with locator (No. 34 1 532).
Force the left and right pistons fully back with the piston resetting
device.
Draw off the excess brake fluid and clean the reservoir.

horizontal.
Warning
062011 2/5
BMW-Motorrad

cylinder.
Tightening torques
M5 2.2 Nm
caliper.
Warning
Tightening torques
M7 8 Nm

handbrake cylinder.
062011 3/5
BMW-Motorrad

Tightening torques
M5 2.2 Nm
Fit adapter 25 (No. 34 1 535) to the left and right of resetting device
(No. 34 1 531) and screw the resetting device together.
Pull the handbrake lever until the brake pistons are in contact with the
piston resetting device.
This simulates the thickness of new brake pads and brake discs.

horizontal.
Expand the piston resetting device on left and right.
This forces back the brake pistons so that the brake pads can be
installed.
Remove the piston resetting device and locators left and right from the
brake calipers.
Install screws (1).

062011 4/5
BMW-Motorrad
Tightening torques
M4 3 Nm

Test
Measure:
pads.
Finishing work
062011 5/5
BMW-Motorrad
34 00 049 Changing brake fluid, rear brakes 3 FRUs

+ 34 00 549
Core activity
(-) Change the brake fluid, rear, and bleed the brake system
Warning
Note
instructions.

Attention
rubber parts.

back.
Warning
062011 1/3
BMW-Motorrad

caliper.
Warning
bleeding.
Warning
Close bleed screw (1) and remove the brake bleeding device.
Tightening torques
14 Nm
Warning
062011 2/3
BMW-Motorrad


Test
Measure:
Finishing work
062011 3/3
BMW-Motorrad
34 11 001 Measuring front brake-disc run-out 4 FRUs

+ 34 11 844
Preparatory work
Releasing left and right front brake calipers
Core activity
(-) Checking front brake discs for runout
Precondition
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.
Test
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 runout
Raise the front wheel clear of the ground so that it can turn freely.
Install dial gauge (No. 00 2 510) in dial-gauge holder (No. 34 2 524)
and install measuring adapter (No. 34 2 510).
Install the dial-gauge holder with screw (1).
Align dial gauge in such a way that the measuring adapter is in contact
with the brake disc close to the outer circumference and the dial gauge
is slightly preloaded.
Test
Set the dial gauge to "0".
Slowly turn the wheel through at least one complete revolution and
062011 1/2
BMW-Motorrad
observe the dial gauge reading.

The sum of the positive and negative dial-gauge readings is the total
runout.
Technical data
Brake disc lateral At max 0.15 mm
runout, front circumference
Result: Lateral runout is excessive.
Measure:
Check positioning of the brake disc/wheel rim.
Check the wheel rim for damage.
If necessary, check the brake disc.
Finishing work
Securing front brake calipers, left and right
062011 2/2
BMW-Motorrad
34 11 008 Replacing front brake pads 3 FRUs

+ 34 11 832
Core activity
(-) Replacing front brake pads

Install piston resetting device (No. 34 1 531) and locator (No. 34 1

532) in the left and right brake calipers.
Push back the brake pistons.

062011 1/2
BMW-Motorrad
Tightening torques
M4 3 Nm
Finishing work
062011 2/2
BMW-Motorrad
34 11 060 Replacing front brake caliper (without bleeding brakes) 3 FRUs

+ 34 11 560
Preparatory work
Draining front brake system
Core activity
(-) Removing front brake caliper
Attention
rubber parts.

Remove screws (3).
Remove brake caliper (4).
(-) Installing front brake caliper

Secure brake caliper (5) with screws (4).
Tightening torques
Front brake caliper to wheel carrier
M8 x 30 - 10.9 28 Nm
Install brake pipe (3) with banjo bolt (1) and new sealing rings (2).
Tightening torques
M10 x 1 24 Nm
Finishing work
=> Bleeding front brake system (Description in item: 34

062011 1/1
BMW-Motorrad
34 11 220 Removing/installing front brake discs 11 FRUs

+ 34 11 840
Preparatory work
Remove the complete front-wheel cover
Installing front-wheel stand
Removing front wheel
Core activity
(-) Removing front left brake disc
Remove screws (1).
Remove brake disc (2) and sensor ring (3).
(-) Removing front right brake disc

Remove screws (1).
Remove brake disc (2).
(-) Installing front left brake disc

Clean the tapped holes in the wheel rim.
Lay sensor ring (3) on the wheel rim.
Lay brake disc (2) on the wheel rim with the wide flats (arrow) of the
rivets to the outside and position it correctly.
Tightening torques
Brake disc to front wheel
Flat-head screw, M8 x 27 - 10.9,
Replace screw tighten in
diagonally
062011 1/2
BMW-Motorrad
Micro-encapsulated opposite
sequence
19 Nm
(-) Installing front right brake disc

Tightening torques
Flat-head screw, M8 x 27 - 10.9, tighten in
Replace screw diagonally
sequence
19 Nm
Finishing work
Install the front wheel
Removing front-wheel stand
Installing complete front-wheel cover
062011 2/2
BMW-Motorrad
34 21 200 Replacing rear brake pads 2 FRUs

+ 34 21 769
Core activity
(-) Removing rear brake pads
Press brake caliper (1) against the brake disc to force back the brake
pistons.
(-) Installing rear brake pads

Install brake pads (4). Make sure that they are engaged in the guide
(arrow) at the brake caliper (1).
Install locking pin (3) and secure it with split-pin keeper (2).
Finishing work
062011 1/1
BMW-Motorrad
34 21 301 Removing/installing rear brake disc 7 FRUs

+ 34 21 772
Preparatory work
Core activity
(-) Removing rear brake disc
Remove screws (1).
(-) Install the rear brake disc

Install sensor ring (3) and brake disc (2) and position them correctly.
Tightening torques
Brake disc to wheel carrier
M8 x 15.5, Replace screw tighten by stages
Micro-encapsulated in diagonally
opposite
sequence
Initial torque,
12 Nm
Final torque, 30 Nm
Finishing work
062011 1/1
BMW-Motorrad
34 31 002 Replacing footbrake cylinder (without bleeding brakes)

+ 34 31 502
Attention
rubber parts.
Attention
Stretched, twisted or incorrectly fitted brake lines can become worn and
start to leak.
Do not bend or clamp brake lines.
When fitting, check that they are correctly installed and secured and
are not stretched, bent or clamped. Make sure that clearance relative to
all other components is adequate in all situations.
Preparatory work
Draining rear brake system
Core activity
(-) Removing footbrake cylinder
Disengage union screw (1).
Disengage brake line (2) from footbrake cylinder (3).
Remove locking clip (1).

Open clip (2) and disconnect hose (3).
Remove screws (4) and remove footbrake cylinder (5).
(-) Installing footbrake cylinder
062011 1/2
BMW-Motorrad
Clean the threads.

Hold footbrake cylinder (5) in position and install new screws (4).
Tightening torques
Footbrake cylinder to rear frame
Micro-encapsulated
Connect hose (3) and close hose clip (2) with pliers (No. 13 1 500).
Install locking clip (1).
Hold brake line (2) in position at footbrake cylinder (3) and tighten
union screw (1).
Tightening torques
Brake line with union screw to components
M10 x 1, M12 x 1 14 Nm
Finishing work
=> Bleeding rear brake system (Description in item: 34
062011 2/2
BMW-Motorrad
34 32 038 Replacing rear brake hose to brake caliper (without bleeding brakes)
+ 34 32 538
Attention
rubber parts.
Attention
start to leak.
Preparatory work
Core activity
(-) Removing rear brake hose
Disengage brake hose (2) from connector (3) for brake hose.
Unclip holder (1) from brake hose (2).

Remove screw (3).
Disengage brake hose (2) from frame (4).
062011 1/3
BMW-Motorrad
Disengage brake hose (3) from brake caliper (4).
Unclip holder (1) from brake hose (2).

Work brake hose (2) to the rear and disengage it from bracket (3) for
the thrust link and holder (4) for the brake hose.
(-) Installing rear brake hose

Seat brake hose (2) in bracket (3) for the thrust link and bracket (4) for
the brake hose.
Position brake hose (2) and clip in holder (1).
Hold brake hose (3) in position at brake caliper (4).

Install banjo bolt (1) with new sealing rings (2).
Tightening torques
M10 x 1 24 Nm
062011 2/3
BMW-Motorrad
Hold brake hose (2) in position at frame (4).

Align brake hose (2) and install screw (3).
Tightening torques
Brake hose, rear, to frame
M6 x 25 8 Nm
Clip holder (1) to brake hose (2).
Hold brake line (2) in position at connector (3) for brake hose and
secure union screw (1).
Tightening torques
M10 x 1, M12 x 1 14 Nm
Finishing work
062011 3/3
BMW-Motorrad
34 32 040 Replacing front brake line to pressure modulator (without bleeding brakes)
+ 34 32 640
Attention
rubber parts.
Attention
start to leak.
Preparatory work
Removing fuel tank
Core activity
(-) Removing brake line to pressure modulator
Unclip holder (1) from brake line (2).
062011 1/3
BMW-Motorrad

Unclip brake line (2) from holder (3) and remove.
(-) Installing brake line to pressure modulator

Work brake line (2) into position and route it correctly.
Clip brake pipe (2) into holder (3).
Tighten union screw (1).
Tightening torques
M10 x 1, M12 x 1 14 Nm
Clip brake line (2) into holder (1).

Tighten down union screw (3).
Tightening torques
M10 x 1, M12 x 1 14 Nm
062011 2/3
BMW-Motorrad
Finishing work
062011 3/3
BMW-Motorrad
34 32 044 Replacing front brake line from pressure modulator (without bleeding brakes)
+ 34 32 644
Attention
rubber parts.
Preparatory work
Core activity
(-) Removing brake line from pressure modulator
Unclip holder (1).
Slacken union screws (2) and (3).
Work brake line (4) clear and remove.
(-) Installing brake line from pressure modulator

Hold union screws (2) and (3) in position and tighten.
Tightening torques
M10 x 1, M12 x 1 14 Nm
Clip in holder (1).
Finishing work
062011 1/2
BMW-Motorrad

062011 2/2
BMW-Motorrad
34 32 050 Replacing rear brake line to pressure modulator (without bleeding brakes)
+ 34 32 650
Attention
rubber parts.
Preparatory work
Removing fuel tank
Core activity
(-) Removing brake line to pressure modulator
Disengage brake line (2) from pressure modulator (3).

Disengage brake line (2) from footbrake cylinder (3).
062011 1/4
BMW-Motorrad
Remove bracket (1).

Unclip brake hose (2) from holder (3).

Disengage brake line (1) and suspension wiring harness (3).
Remove brake line (1).
(-) Installing brake line to pressure modulator

Position brake line (1) and suspension harness adapter (3) and secure
with cable ties (arrows).
062011 2/4
BMW-Motorrad
Clip brake pipe (2) into holder (3).

Install bracket (1).
Hold brake line (2) in position at pressure modulator (3) and tighten
union screw (1).
Tightening torques
M10 x 1, M12 x 1 14 Nm
Hold brake line (2) in position at footbrake cylinder (3) and tighten
union screw (1).
Tightening torques
M10 x 1, M12 x 1 14 Nm
Finishing work
062011 3/4
BMW-Motorrad

062011 4/4
BMW-Motorrad
34 32 051 Replacing rear brake line from pressure modulator (without bleeding brakes)
+ 34 32 651
Attention
rubber parts.
Preparatory work
Removing fuel tank
Core activity
(-) Removing brake line from pressure modulator
Attention
start to leak.

Disengage brake line (2) from pressure modulator (3).

Disengage brake line (2) from connector (3) for brake hose.
062011 1/4
BMW-Motorrad

Unclip brake line (1) from holder (2) and remove.
(-) Installing brake line from pressure modulator

062011 2/4
BMW-Motorrad

Hold brake line (2) in position at connector (3) for brake hose and
secure union screw (1).
Tightening torques
M10 x 1, M12 x 1 14 Nm
Hold brake line (2) in position at pressure modulator (3) and tighten
union screw (1).
Tightening torques
M10 x 1, M12 x 1 14 Nm
Finishing work
062011 3/4
BMW-Motorrad

062011 4/4
BMW-Motorrad
34 32 499 Replacing hose, rear, to reservoir

+ 34 32 525
Attention
rubber parts.
Preparatory work
Core activity
(-) Removing rear hose to reservoir
Open clips (1) and remove hose (2).
(-) Installing rear hose to reservoir

Install hose (2) and close clips (1) with pliers (No. 13 1 500).
Slowly top up with brake fluid to the (MAX) mark on the reservoir,
making sure that the air is expelled from hose (2).

Lightly tap hose (2) to enable the residual air to escape from hose (2)
to the reservoir.
Repeatedly depress the footbrake lever.
Top up with fresh brake fluid, if necessary.
Finishing work
062011 1/1
BMW-Motorrad
34 51 011 Replacing pressure modulator (without bleeding/testing software/ programming) 7

FRUs
+ 34 51 511
Attention
rubber parts.
Note
Preparatory work
=> Change brake fluid in entire system (Description in
Core activity
(-) Removing pressure modulator
Remove and disconnect plug (1) for the wheel-speed sensor and plug
(2) for the ESA spring strut.
Disconnect plug (3) for the pressure modulator.
Allow cable leg (4) to dangle to one side.
Disconnecting brake lines from pressure modulator

Slacken union screws (1) and (2).
Disconnect the following brake lines:
Note
Use the protective cap from a bleed screw to seal the brake pipes.
(3) for control circuit, front wheel

(4) for brake circuit, front wheel
(5) for brake circuit, rear wheel
(6) for control circuit, rear wheel
062011 1/4
BMW-Motorrad
Remove nut (1) and remove brake line (2).

Remove nuts (3).
Remove pressure modulator (4) with the bracket.
(-) Replacing pressure modulator

Remove the following components and transfer them to the new
pressure modulator:
Screw (1) with washer
Screws (2)
Holder (3)
Tighten screws (1) and (2) to the specified tightening torque.
Tightening torques
Pressure modulator to bracket
M6 x 12 8 Nm
M6 x 25 8 Nm
(-) Installing pressure modulator

Hold pressure modulator (4) with the bracket in position.
Install nuts (3).
Tightening torques
Bracket for pressure modulator to vibration damper
M6 8 Nm
Hold brake line (2) in position and install nut (1).
062011 2/4
BMW-Motorrad
Tightening torques
Brake line, front, to bracket for pressure modulator
M6 8 Nm
Connecting brake lines to pressure modulator
Attention
start to leak.
Connect the following brake lines:

(6) for control circuit, rear wheel
(5) for brake circuit, rear wheel
(4) for brake circuit, front wheel
(3) for control circuit, front wheel
Tighten union screws (1) and (2).
Tightening torques
M10 x 1, M12 x 1 14 Nm
Route cable leg (4).

Connect plug (3) for the pressure modulator.
Connect and install plug (1) for the wheel-speed sensor and plug (2)
for the ESA spring strut.
Finishing work
062011 3/4
BMW-Motorrad


as a separate item)
062011 4/4
BMW-Motorrad
35 21 000 Removing/installing or replacing footbrake lever 3 FRUs

+ 35 21 531
Core activity
(-) Removing footbrake lever
Disengage tension spring (1) from footbrake lever (2).
Remove locking clip (1).

Remove screw (2) with bushing (3) and remove footbrake lever (4)
with washer (5).
(-) Installing footbrake lever

Introduce footbrake lever (4) into adapter (6) of the footbrake cylinder
and hold it in position with washer (5).
Lubricate bushing (3).

Install bushing (3) and new screw (2).
Tightening torques
Footbrake lever to frame
M8 x 45 - 10.9, Replace screw 28 Nm
Micro-encapsulated
Install locking clip (1).
Engage tension spring (1) in footbrake lever (2).
062011 1/2
BMW-Motorrad
Finishing work
Adjusting play of footbrake lever
062011 2/2
BMW-Motorrad
36 20 510 Replacing RDC control unit (without checking software/programming) 4 FRUs

Note
Preparatory work
Core activity
(-) Removing tyre pressure monitoring control unit (RDC
control unit)
Disconnect plug (1) for the RDC control unit.
Remove screw (2).
Remove RDC control unit (3).
(-) Installing tyre pressure monitoring control unit (RDC

control unit)
Install RDC control unit (3).
Install screw (2).
Tightening torques
Tyre pressure monitoring (RDC) control unit to intake air silencer
TS4 x 10 3 Nm
Connect plug (1) for the RDC control unit.
Finishing work
062011 1/2
BMW-Motorrad


062011 2/2
BMW-Motorrad
36 20 554 Replacing front RDC sensor (tyre removed) 2 FRUs

Core activity
(-) Removing front tyre pressure monitoring sensor (RDC
sensor)
Remove screw (1).
Remove RDC sensor (2).
(-) Install the front tyre pressure monitoring sensor (RDC

sensor)
Clean the seat and the threaded bore for the RDC sensor.
Parallel RDC sensor (1) with the wheel rim such that the plastic body
does not touch the wheel rim.
When installing, make sure that RDC sensor (2) and RDC label (3) on
the rim are aligned and install screw (1).
Tightening torques
RDC sensor to wheel rim
M8 x 25, use thread-locking 9 Nm
compound for repair
Loctite 243
Finishing work
062011 1/2
BMW-Motorrad

Teaching tyre pressure monitoring (RDC) sensor to control unit
062011 2/2
BMW-Motorrad
36 20 555 Replacing rear RDC sensor (tyre removed) 2 FRUs

Core activity
(-) Remove the rear tyre pressure monitoring sensor (RDC
sensor)
Remove screw (1).
(-) Replacing rear tyre pressure monitoring sensor (RDC

sensor)
Clean the seat and the threaded bore for the RDC sensor.
When installing, make sure that RDC sensor (2) and RDC label (3) on
the rim are aligned and install screw (1).
Tightening torques
compound for repair
Loctite 243
Finishing work
062011 1/2
BMW-Motorrad

Teaching tyre pressure monitoring (RDC) sensor to control unit
062011 2/2
BMW-Motorrad
36 23 001 Replacing wheel-speed sensor, front 8 FRUs

+ 36 23 601
Preparatory work
Core activity
(-) Removing front wheel-speed sensor
Remove plug (1) for the wheel-speed sensor and disconnect.
Work cable (2) clear of the motorcycle.

Remove screws (1).

Remove cable guide (2) and disengage cable (3).
062011 1/3
BMW-Motorrad
Remove screw (1).

Remove wheel-speed sensor (2).
(-) Installing front wheel-speed sensor

Install wheel-speed sensor (2).
Tightening torques
Wheel-speed sensor to wheel carrier/ rear brake caliper
Micro-encapsulated
When routing cable (1) for the wheel-speed sensor, make sure that
with the front wheel installed, the cable cannot chafe against sensor
ring (2).
062011 2/3
BMW-Motorrad

Secure cable (3) in cable guide (2) and hold cable guide (2) in position.
Tightening torques
Cable guide to wheel carrier
Micro-encapsulated
Secure cable (1) in holder (2).


Connect plug (1) for wheel-speed sensor and install.
Finishing work
062011 3/3
BMW-Motorrad
36 23 002 Replacing wheel-speed sensor, rear 4 FRUs

+ 36 23 602
Preparatory work
Core activity
(-) Removing rear wheel-speed sensor
Remove plug (1) for the wheel-speed sensor and disconnect.

Disengage cable (1) from holder (2) and work it clear.
062011 1/3
BMW-Motorrad

Remove screw (3).
Remove wheel-speed sensor (4).
(-) Installing rear wheel-speed sensor

Install wheel-speed sensor (4).
Tightening torques
Wheel-speed sensor to wheel carrier/ rear brake caliper
Micro-encapsulated
062011 2/3
BMW-Motorrad

Connect plug (1) for wheel-speed sensor and install.

Finishing work
062011 3/3
BMW-Motorrad
36 23 003 Replacing sensor ring, front 8 FRUs

+ 36 23 603
Preparatory work
Core activity
(-) Removing front sensor ring
Remove screws (1).
(-) Installing front sensor ring

Lay sensor ring (3) on the wheel rim.
Tightening torques
Flat-head screw, M8 x 27 - 10.9, tighten in
Replace screw diagonally
sequence
19 Nm
Finishing work
062011 1/1
BMW-Motorrad
36 23 004 Replacing sensor ring, rear 7 FRUs

+ 36 23 604
Preparatory work
Core activity
(-) Removing rear sensor ring
Remove screws (1).
(-) Installing rear sensor ring

Install sensor ring (3) and brake disc (2) and position them correctly.
Tightening torques
Brake disc to wheel carrier
M8 x 15.5, Replace screw tighten by stages
Micro-encapsulated in diagonally
opposite
sequence
Initial torque,
12 Nm
Final torque, 30 Nm
Finishing work
062011 1/1
BMW-Motorrad
36 30 300 Removing/installing front wheel 5 FRUs

+ 36 30 628
Preparatory work
Core activity
(-) Removing front wheel
Attention
The left axle clamping screw locates the threaded bush in the front
suspension. If the threaded bush is not correctly aligned the gap
between the ABS sensor ring and the ABS sensor will not be correct
and this can cause the ABS to malfunction or allow the ABS sensor to
be damaged.
In order to ensure that the threaded bush remains correctly aligned, do
not slacken or remove the left axle camping screw.
Slacken screw (1).

Remove quick-release axle (2) with hexagon (No. 36 3 691).
Remove front wheel (3).
(-) Install the front wheel

Clean and lubricate quick-release axle (2).

assembly grease 599
Install front wheel (3).
Install quick-release axle (2) with hexagon (No. 36 3 691) and tighten.
Tightening torques
Quick-release axle in threaded bush (wheel carrier)
M24 x 1.5 50 Nm
Tighten screw (1).
Tightening torques
Clamping screw for quick-release axle to wheel carrier
M8 x 30 19 Nm
Finishing work
062011 1/2
BMW-Motorrad

062011 2/2
BMW-Motorrad
36 30 320 Removing/installing rear wheel 3 FRUs

+ 36 30 629
Preparatory work
Core activity
(-) Remove the rear wheel
Remove screws (1).
Disengage rear wheel (2) and remove.
(-) Installing rear wheel

Install rear wheel (2).
Install screws (1).
Tightening torques
Rear wheel to wheel flange
M10 x 1.25 x 40 tighten in
diagonally
opposite
sequence
60 Nm
Finishing work
062011 1/1
BMW-Motorrad
36 30 508 Balancing front wheel (statically) (wheel removed) 1 FRUs
Core activity
(-) Static balancing of front wheel
Align balancer (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.
Place the front wheel on the balancer and allow it to come to rest.
Clean the attachment points for the adhesive weights.
Affix adhesive weights (3) opposite the heaviest point of the wheel.
Technical data
Permissible front- max 5 g
wheel imbalance
Balancing weight max 80 g
for front wheel
Weight must be
divided equally
across both sides
and weights
attached to rim on
left and right.
Repeat the balancing procedure as a check.
062011 1/1
BMW-Motorrad
36 30 518 Balancing rear wheel (statically) (wheel removed) 2 FRUs
Core activity
(-) Static balancing of rear wheel
Install balancing adapter (No. 36 5 561) with wheel studs (1).
(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.
Technical data
Permissible rear- max 45 g
wheel imbalance
for rear wheel
Weight must be
divided equally
across both sides
and weights
attached to rim on
left and right.
062011 1/1
BMW-Motorrad
36 30 601 Replacing rim for front wheel (wheel removed) 6 FRUs

Preparatory work
Removing front left brake disc
Removing front right brake disc
Core activity
(-) Removing front tyre
Pry off the tyre opposite (arrow) the valve/tyre pressure monitoring
sensor (RDC sensor).
Apply the lever to the rim at RDC sticker (1), to prevent the tyre bead
from damaging the RDC sensor.
Remove the tyre with commercially available tools.
(-) Removing front tyre pressure monitoring sensor (RDC

sensor)
Remove screw (1).
(-) Checking battery of tyre-pressure monitoring sensor (RDC

sensor)
Test
Check the battery of the RDC sensor with RDC test tool (No. 61 1
671).
062011 1/3
BMW-Motorrad
Result: Battery too weak

Measure:
Replace the RDC sensor.
(-) Installing front tyre pressure monitoring sensor (RDC

sensor)
Affix RDC label (3) at the position of RDC sensor (2).

Install screw (1).
Tightening torques
compound for repair
Loctite 243
(-) Installing front tyre
Attention
Use commercially available tools and work to the manufacturer's
062011 2/3
BMW-Motorrad
specifications to fit the tyres, and make sure that the direction-of-
rotation arrows on tyre and rim point in the same direction.
Test
Inflate the tyre to test pressure and check the valve for leaks.
Technical data
Wheel valve test 4 bar
pressure
Result: Valve leaking
Measure:
Replace the valve insert.
Result: Valve leaktight
Measure:
Correct the tyre pressure.
Technical data
Tyre pressure, front Tyre cold 2.9 bar
Finishing work
Installing front left brake disc
Installing front right brake disc
Static balancing of front wheel
062011 3/3
BMW-Motorrad
36 30 611 Replacing rim for rear wheel (wheel removed)

Core activity
(-) Removing rear tyre
(-) Remove the rear tyre pressure monitoring sensor (RDC

sensor)
Remove screw (1).
(-) Checking battery of tyre-pressure monitoring sensor (RDC

sensor)
Test
671).

Measure:
062011 1/3
BMW-Motorrad
Replace the RDC sensor.
(-) Installing rear tyre pressure monitoring sensor (RDC

sensor)
Affix RDC label (3) at the position of RDC sensor (2).

Install screw (1).
Tightening torques
compound for repair
Loctite 243
(-) Installing rear tyre
Attention

Test
Technical data
pressure
Measure:
062011 2/3
BMW-Motorrad
Measure:
Technical data
Tyre pressure, rear Tyre cold 2.9 bar
Check the tyre and make sure the line is at a uniform distance from the
rim flange all the way round.
Finishing work
Static balancing of rear wheel
062011 3/3
BMW-Motorrad
36 31 851 Renewing front wheel bearing (wheel removed)
Preparatory work
Removing radial shaft sealing rings, left and right
Core activity
(-) Removing wheel bearings
Place support ring (No. 31 4 800) between the wheel hub on the right
side of the wheel and reaction support (No. 00 8 572).
Heat the bearing seat.
Technical data
Release 100 °C
temperature, front
wheel bearing
Use reaction support (No. 00 8 572) and internal puller (No. 00 8 573)
to remove the wheel bearing.
Remove spacing bushing (1).
Heat the left bearing seat (detail).
Technical data
Release 100 °C
temperature, front
wheel bearing
Drive out the left wheel bearing with drift (No. 11 6 732) 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 bearing (1) into the bearing seat.
Install long spindle with pull-in nut (No. 36 5 551) washer without
thread (No. 36 5 554) and washers with thread (No. 36 5 553):
Washer (A) dia. 47 mm
Washer (B) with thread dia. 25 mm
062011 1/2
BMW-Motorrad
Washer (C) with thread dia. 47 mm

Pull in 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 bearing (1).
Introduce bearing (3) into the bearing seat.
Install washer (A) and pull-in nut.
Pull in bearing (3) until seated against spacing bushing (2).
Finishing work
Installing radial shaft sealing rings, left and right
062011 2/2
BMW-Motorrad
36 32 501 Renewing front tyre (wheel removed) 3 FRUs

Core activity
(-) Remove the front tyre
Attention
(-) Checking battery of front tyre-pressure monitoring sensor

(RDC sensor)
Test
671).

Measure:
=> 36 20 554, Replacing front RDC sensor (tyre removed) (Billed as a
separate item)
(-) Installing front tyre
Attention

Test
062011 1/2
BMW-Motorrad
Technical data
pressure
Measure:
Measure:
Technical data
Tyre pressure, front Tyre cold 2.9 bar
(-) Static balancing of front wheel

(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.
Place the front wheel on the balancer and allow it to come to rest.
Technical data
Permissible front- max 5 g
wheel imbalance
for front wheel
Weight must be
divided equally
across both sides
and weights
attached to rim on
left and right.
Finishing work
062011 2/2
BMW-Motorrad
36 32 511 Removing rear tyre (wheel removed) 3 FRUs

Core activity
(-) Removing rear tyre
Attention
(-) Checking battery of rear tyre-pressure monitoring sensor

(RDC sensor)
Test
671).

Measure:
=> 36 20 555, Replacing rear RDC sensor (tyre removed) (Billed as a
separate item)
(-) Installing rear tyre
Attention

Test
062011 1/3
BMW-Motorrad
Technical data
pressure
Measure:
Measure:
Technical data
Tyre pressure, rear Tyre cold 2.9 bar
Check the tyre and make sure the line is at a uniform distance from the
rim flange all the way round.
(-) Static balancing of rear wheel

Install balancing adapter (No. 36 5 561) with wheel studs (1).
(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.
Technical data
Permissible rear- max 45 g
wheel imbalance
for rear wheel
Weight must be
divided equally
across both sides
and weights
attached to rim on
left and right.
062011 2/3
BMW-Motorrad
062011 3/3
BMW-Motorrad
46 52 000 Removing/installing or replacing centre stand 4 FRUs

+ 46 52 502
Preparatory work
Installing engine lifter
Core activity
(-) Removing tension springs of centre stand
Warning
Components are spring-loaded. Risk of injury caused by flying parts.
Proceed with care when decreasing or increasing spring tension.
Remove tension springs (1), using hook (No. 46 5 721).

Remove attachment plate (2).
(-) Removing centre stand

Remove centre-stand axle (1) with O-rings (2).

Remove centre stand (3).
062011 1/3
BMW-Motorrad
(-) Installing centre stand

Check O-rings (2) and bearing bushings (4) for damage; replace if
necessary.
Lubricate bearing bushings (4) and centre-stand axle between
(arrows) O-rings (2).

Klüberplex BE 11-462 Lubricant 83 22 0 397
761
Install centre stand (3).
Install centre-stand axle (1) with O-rings (2).
Make sure that centre-stand axle (1) is installed with catch in recess
(arrows) of centre stand (3).
(-) Installing tension springs of centre stand

Install attachment plate (2).
Warning
Install tension springs (1), using hook (No. 46 5 721).
062011 2/3
BMW-Motorrad
Finishing work
Removing engine lifter
062011 3/3
BMW-Motorrad
46 52 009 Removing/installing or cleaning/ lubricating centre stand 4 FRUs

+ 46 52 509
Preparatory work
Installing engine lifter
Removing tension springs of centre stand
Core activity
(-) Removing centre stand
Remove centre-stand axle (1) with O-rings (2).

Remove centre stand (3).
(-) Installing centre stand

Check O-rings (2) and bearing bushings (4) for damage; replace if
necessary.
Lubricate bearing bushings (4) and centre-stand axle between
(arrows) O-rings (2).

761
Install centre stand (3).
Install centre-stand axle (1) with O-rings (2).
062011 1/2
BMW-Motorrad
Make sure that centre-stand axle (1) is installed with catch in recess
(arrows) of centre stand (3).
Finishing work
Installing tension springs of centre stand
Removing engine lifter
062011 2/2
BMW-Motorrad
46 53 000 Removing/installing or replacing side stand 5 FRUs

+ 46 53 601
Preparatory work
Disengaging side-stand switch
Core activity
(-) Removing side-stand pivot mount with side stand
Warning

Remove screws (3).
Remove the side-stand pivot mount with side stand (4).
(-) Removing side stand

Remove screw (1).
Remove side stand (2) from pivot mount (3).
(-) Checking bearing bushing
Test
Check bearing bushing (1) for scores, damage, etc.
Result: Bearing bushing is worn.
062011 1/2
BMW-Motorrad
Measure:
=> 46 53 501, Replacing pivot mount for side stand (side stand removed)
(-) Installing side stand

Lubricate screw (1) and side stand (2) at the points indicated (arrows).

761
Insert pivot mount (3) into side stand (2).
Install new screw (1) and tighten.
Tightening torques
Side stand to pivot mount
Micro-encapsulated
(-) Installing side-stand pivot mount with side stand

Hold the side-stand pivot mount with side stand (4) in position.
Tightening torques
Pivot mount (side stand) to frame
Micro-encapsulated
Warning
Engage tension springs (1), using hook (No. 46 5 721).
Finishing work
Securing side-stand switch
062011 2/2
BMW-Motorrad
46 53 005 Removing/installing/cleaning and lubricating side stand 5 FRUs

+ 46 53 505
Preparatory work
Disengaging side-stand switch
Removing side-stand pivot mount with side stand
Core activity
(-) Removing side stand
Remove screw (1).
Remove side stand (2) from pivot mount (3).
(-) Checking bearing bushing
Test
Check bearing bushing (1) for scores, damage, etc.
Result: Bearing bushing is worn.

Measure:
=> 46 53 501, Replacing pivot mount for side stand (side stand removed)
(-) Installing side stand

Lubricate screw (1) and side stand (2) at the points indicated (arrows).

761
062011 1/2
BMW-Motorrad
Insert pivot mount (3) into side stand (2).

Install new screw (1) and tighten.
Tightening torques
Side stand to pivot mount
Micro-encapsulated
Finishing work
Installing side-stand pivot mount with side stand
Securing side-stand switch
062011 2/2
BMW-Motorrad
46 53 011 Renewing tension spring for prop stand 2 FRUs

+ 46 53 602
Warning
Core activity
(-) Removing tension springs of side stand
Remove tension springs (1) from attachment plate (2).
(-) Installing tension springs of side stand

Insert tension springs (1) into attachment plate (2).
Engage tension springs (1), using hook (No. 46 5 721).
Finishing work
062011 1/1
BMW-Motorrad
46 53 501 Replacing pivot mount for side stand (side stand removed) 1 FRUs
Core activity
(-) Replacing bearing bushing of side stand
Replace bearing bushing (1), using a suitable tool.
Lubricate new bearing bushing (1).

761
Finishing work
062011 1/1
BMW-Motorrad
46 54 200 Removing and installing or replacing complete luggage carrier 4 FRUs

+ 46 54 505
Preparatory work
Removing complete luggage carrier
Core activity
(-) Removing luggage carrier
Remove screws (1).
Remove grab handles (2) left and (3) right from luggage carrier (4).
(-) Installing luggage carrier

Hold grab handles (2) left and (3) right in position on luggage carrier
(4).
Make sure that the latching devices (arrows) engage in luggage carrier
(4).
Tightening torques
Grab handle to luggage carrier
Micro-encapsulated
Finishing work
Installing complete luggage carrier
062011 1/1
BMW-Motorrad
46 54 315 Replacing rear (trunk/boot) lid 3 FRUs

+ 46 54 510
Core activity
(-) Removing case lid
Disengage holding strap (1) from bracket (2).
Remove screws (1) and screw (2) with nut (3).

Remove mating piece (4) with flat nut (5).
Repeat this procedure with the other hinge.
Remove cover (6).
(-) Disassembling case lid

Remove body-bound rivet (1).
Remove screws (2).
Remove cover (3).
Remove flat nuts (1).

Remove cover (2).
062011 1/3
BMW-Motorrad
(-) Assembling case lid

Install flat nuts (1).
Insert cover (2) in such a way that it is held in place by the lug (arrow).
Hold cover panel (3) in position.

Install screws (2).
Install body-bound rivet (1).
(-) Installing case lid

Place lid (6) in position and align it correctly.
Hold mating piece (4) in position and install screw (1) for flat nut (5).
Hold nut (3) in position, locate it and install screw (2).
Repeat this procedure with the other hinge.
062011 2/3
BMW-Motorrad
Engage holding strap (1) on bracket (2).
Finishing work
062011 3/3
BMW-Motorrad
46 61 000 Removing/installing front-wheel cover 2 FRUs

+ 46 61 500
Core activity
(-) Removing front-wheel cover (front section)
Remove screws (1) on left and right.
Remove front-wheel cover (front section) (2).
(-) Disassembling front-wheel cover (front section)

Remove flat nuts (1) from front-wheel cover (front section) (2).
(-) Assembling front-wheel cover (front section)

Install flat nuts (1) in front-wheel cover (front section) (2).
(-) Installing front-wheel cover (front section)

Install front-wheel cover (front section) (2).
Install screws (1) on left and right.
062011 1/2
BMW-Motorrad
Tightening torques
Front-wheel cover, front, to front-wheel cover, rear
M5 x 12 2.5 Nm
Finishing work
062011 2/2
BMW-Motorrad
46 61 008 Removing/installing rear front-wheel cover 2 FRUs

+ 46 61 502
Core activity
(-) Remove the complete front-wheel cover
Remove screws (1).
Remove complete front-wheel cover (2).
(-) Disassembling front-wheel cover (rear section)

Remove screws (1).
Remove front-wheel cover (front section) (2) from front-wheel cover
(rear section) (3).
(-) Assembling front-wheel cover (rear section)

Position front-wheel cover (front section) (2) on front-wheel cover (rear
section) (3).
Install screws (1).
Tightening torques
Front-wheel cover, front, to front-wheel cover, rear
M5 x 12 2.5 Nm
(-) Installing complete front-wheel cover

Place complete front-wheel cover (2) in position.
Install screws (1).
062011 1/2
BMW-Motorrad
Tightening torques
Front-wheel cover to wheel carrier
M6 x 12 2.5 Nm
Finishing work
062011 2/2
BMW-Motorrad
46 63 001 Replacing compartment cover for navigation device 1 FRUs

+ 46 63 981
Core activity
(-) Removing compartment cover for navigation device
Using a suitable tool, disengage compartment cover (1) and remove,
noting the retaining lugs (arrows).
(-) Installing compartment cover for navigation device

Install compartment cover (1), noting the retaining lugs (arrows).
Finishing work
062011 1/1
BMW-Motorrad
46 63 002 Replacing gearbox cover 2 FRUs

+ 46 63 975
Core activity
(-) Removing gearbox cover
Remove screws (1).
Remove gearbox cover (2).
(-) Replacing gearbox cover

Transfer rubber buffer (1) with bushings (2) and (3) from old to new
gearbox cover (4).
Installing designation for gearbox cover

Peel backing film (1) from designation (2).
Position designation (2) with pins (arrows) on gearbox cover (3) and
press it firmly into place.
(-) Installing gearbox cover

Hold gearbox cover (2) in position.
Install screws (1).
062011 1/2
BMW-Motorrad
Finishing work
062011 2/2
BMW-Motorrad
46 63 019 Replacing tail cover, centre section 4 FRUs

+ 46 63 982
0603 - Anti-theft alarm (DWA)
Preparatory work
Core activity
(-) Removing tail cover centre panel
Remove screws (1).
Remove tail cover (2).
(-) Installing tail cover centre panel

Hold tail cover (2) in position.
Install screws (1).
Finishing work
062011 1/1
BMW-Motorrad
46 63 028 Replacing left or right hand protector 3 FRUs

+ 46 63 628
Preparatory work
Core activity
(-) Removing left hand protector
Precondition
Windscreen is raised.
Remove screws (1).

Disengage hand protector (2) from the guides (arrows) and remove.
(-) Replacing left hand protector

Removing cover for tweeter
Disengage the retaining tabs (arrows) and remove cover (1).
Removing left speaker grille

Remove screw (1).
Disengage the retaining tabs (arrows) and remove speaker grille (2).
062011 1/3
BMW-Motorrad
Replace the hand protector.

Installing left speaker grille
Install speaker grille (2), making sure that the retaining tabs (arrows)
engage.
Install screw (1).
Installing cover for tweeter

Install cover (1), making sure that the retaining tabs (arrows) engage.
(-) Installing left hand protector
Precondition
Windscreen is raised.
Install hand protector (2), making sure that it is engaged in the guides
(arrows).
062011 2/3
BMW-Motorrad
Install screws (1).
Finishing work
062011 3/3
BMW-Motorrad
46 63 031 Removing/installing windscreen 2 FRUs

+ 46 63 830
Core activity
(-) Removing windscreen
Remove screws (1) and remove covers (2).
Remove windscreen (3).
(-) Installing windscreen

Hold windscreen (3) in position.
Hold covers (2) in position and install screws (1).
Tightening torques
Standard screws for trim panels/body panels
M5 2.5 Nm
Finishing work
062011 1/1
BMW-Motorrad
46 63 032 Replace holders for windscreen, left and right 3 FRUs

+ 46 63 971
Preparatory work
Removing windscreen
Removing cross brace for windscreen
Core activity
(-) Removing left and right holders for windscreen
Retaining clips (1) with collar
Retainers (2)
Pin, long (3)
Pin, short (4)
Holder for windscreen, left (5)
Holder for windscreen, right (6)
(-) Installing left and right windscreen holders

Clean and lubricate pins (3) and (4).

MP 3 paste High-performance 07 55 9 062
Holder for windscreen, right (6)
Holder for windscreen, left (5)
Pin, short (4)
Pin, long (3)
Retainers (2)
Retaining clips (1) with collar
Finishing work
Installing cross brace for windscreen
Installing windscreen
062011 1/1
BMW-Motorrad
46 63 189 Replacing top section of fairing, right 3 FRUs

+ 46 63 987
Preparatory work
Core activity
(-) Removing top section of fairing, right
Remove screws (1).
Remove screw (1).

Remove top section of fairing (2), noting the retaining lugs (arrows).
(-) Replacing right top section of fairing

Transfer rubber buffer (1), flat nuts (2) and rubber nut (3) from old to
new top section of fairing (4).
062011 1/2
BMW-Motorrad
(-) Installing top section of fairing, right

Install top section of fairing (2), noting the retaining lugs (arrows).
Install screw (1).
Install screws (1).
Finishing work
062011 2/2
BMW-Motorrad
46 63 190 Replacing top section of fairing, left 3 FRUs

+ 46 63 853
Preparatory work
Core activity
(-) Removing top section of fairing, left
Remove screws (1).
Remove screw (1).

Remove top section of fairing (2), noting the retaining lugs (arrows).
(-) Replacing left top section of fairing

Transfer rubber buffer (1), flat nuts (2) and rubber nut (3) from old to
new top section of fairing (4).
062011 1/2
BMW-Motorrad
(-) Installing top section of fairing, left

Install top section of fairing (2), noting the retaining lugs (arrows).
Install screw (1).
Install screws (1).
Finishing work
062011 2/2
BMW-Motorrad
46 63 200 Replacing fuel-tank cover, middle 4 FRUs

+ 46 63 860
Preparatory work
Core activity
(-) Removing centre cover of fuel tank
Remove screw (1).

Remove cover (2).
(-) Replacing centre cover of fuel tank

Transfer the following components from old to new cover (1):
Bushings (2)
Rubber grommets (3)
Flat nuts (4)
062011 1/2
BMW-Motorrad
(-) Installing centre cover of fuel tank

Place cover (2) in position.
Install screw (1).
Finishing work
062011 2/2
BMW-Motorrad
46 63 217 Replace front carriers, left and right

+ 46 63 717
Preparatory work
Removing right side panel
Removing windscreen
Removing top cover
Removing inner trim with instrument panel
Removing windscreen adjuster
Removing headlight
Disengaging expansion tank for coolant
Removing height sensor, front
Removing fuel tank
Removing horn
062011 1/8
BMW-Motorrad
Core activity
(-) Removing left front panel carrier
Unclip feed line (1) of the oil cooler from bracket (2).
Unclip return line (3) of the oil cooler from bracket (4).
Remove plug (5) for the clutch switch.
Remove and disconnect plug (1) for the multi-controller.

Remove screws (2) and remove plug (3) for the multifunction switch.
Remove the cable ties (arrows) and disengage wiring harness (4).
Remove the cable ties (arrows) and disengage wiring harness (1).
Remove screws (1) and (2) and disengage front panel carrier (3).
062011 2/8
BMW-Motorrad
Work left front panel carrier (1) clear, noting feed line (2) and return
line (3) of oil cooler (4).
Remove oil cooler (4) with rubber mounts (5) from right front panel
carrier (6) and allow it to dangle to one side.
(-) Removing right front panel carrier

Remove the cable ties (arrows) and disengage wiring harness (1) from
front panel carrier (1).
Remove screws (1), raise front panel carrier (2) and unclip cable (3)
for the ignition switch.
062011 3/8
BMW-Motorrad
(-) Replacing front panel carrier, left

Remove screws (1) and remove bracket (2) for the speaker from front
panel carrier (3).
Transfer the following parts to new front panel carrier (1) :

Bracket (2) for the cable ties
Bracket (3) for the flow line to oil cooler
Bracket (4) for the return line from oil cooler
Rubber grommets (5)
Rubber plug (6)
Rubber grommet (7) with metal bushing.
Hold bracket (2) for speaker in position on new front panel carrier (3)
and install screws (1).
Tightening torques
Bracket for speaker to front panel carrier
M5 x 16 10 Nm
(-) Replacing front panel carrier, right

Remove screws (1) and remove bracket (2) for the speaker from front
panel carrier (3).
Remove screw (4) and remove earthing strap (5) for the aerial.
062011 4/8
BMW-Motorrad
Transfer the following parts to new front panel carrier (1) :

Rubber grommet (2) with metal bushing
Rubber plug (3)
Rubber grommet (4)
Bracket (5) for cable ties.
Hold bracket (2) for speaker in position on new front panel carrier (3)
and install screws (1).
Tightening torques
Bracket for speaker to front panel carrier
M5 x 16 10 Nm
Hold earthing strap (5) for the aerial in position and install screw (4).
Tightening torques
Earthing strap (aerial) to front panel carrier
M6 x 12 8 Nm
(-) Installing right front panel carrier

Hold front panel carrier (2) in position, clip cable (3) for the ignition
switch to the inside of front panel carrier (2) and install screws (1).
Tightening torques
Front panel carrier to main frame
M6 x 20 8 Nm
062011 5/8
BMW-Motorrad
Route wiring harness (1) to front panel carrier (2) and secure it with the
cable ties (arrows).
(-) Installing left front panel carrier

Work left front panel carrier (1) into position, noting feed line (2) and
return line (3) of oil cooler (4).
Work oil cooler (4) with rubber mounts (5) into position from below
between right front panel carrier (6) and left front panel carrier (1).
Hold front panel carrier (3) in position, install screws (1) to secure the
front panel carrier to the front panel carrier and screws (2) to secure
the front panel carrier to the main frame.
Tightening torques
Front panel carrier to front panel carrier
25
Front panel carrier to main frame
M6 x 20 8 Nm
062011 6/8
BMW-Motorrad
Route wiring harness (1) and secure it with the cable ties (arrows).
Route wiring harness (4) and secure it with the cable ties (arrows).
Hold plug (3) for the multifunction switch in position and install screws
(2).
Connect and install plug (1) for the multi-controller.
Clip return line (3) of the oil cooler into holder (4) and secure it with a
cable tie (arrow).
Clip flow line (1) of the oil cooler into holder (2) and secure it with a
cable tie (arrow).
Finishing work
Installing horn
Installing height sensor, front
Securing expansion tank for coolant
Installing windscreen adjuster
062011 7/8
BMW-Motorrad
Installing inner trim with instrument panel

Installing right side panel
062011 8/8
BMW-Motorrad
46 63 222 Removing/installing or replacing left or right radiator cowl 2 FRUs

+ 46 63 867
Core activity
(-) Removing left radiator cowl
Remove screws (1).
Disengage radiator cowl (2) from the rubber grommet (arrow) and
remove.
(-) Replacing left radiator cowl

Transfer flat nuts (1) from old to new radiator cowl (2).
(-) Installing left radiator cowl

Hold radiator cowl (2) in position, engage it in the rubber grommet
(arrow) and install.
Install screws (1).
Finishing work
062011 1/1
BMW-Motorrad
46 63 265 Removing/installing or replacing cover for instruments 3 FRUs

+ 46 63 928
Preparatory work
Core activity
(-) Removing cover of instrument panel
Remove screws (1).
Use a suitable tool to push back retainers (2) and disengage cover (3)
at top.
Remove cover (3), noting the retainers (arrows).
(-) Replacing cover for instruments

Using a suitable tool, disengage compartment cover (1) and remove it
from old cover (2) for the instruments, noting the retaining lugs
(arrows).
Install compartment cover (1) in new cover (2) for the instruments,
noting the retaining lugs (arrows).
(-) Installing cover of instrument panel

Install cover (1), noting the retainers (arrows).
Press on cover (1) at top.
Retainers (2) engage with an audible click.
Install screws (3).
062011 1/2
BMW-Motorrad
Finishing work
062011 2/2
BMW-Motorrad
46 63 274 Renewing wind deflector plate 4 FRUs

+ 46 63 884
Preparatory work
Core activity
(-) Removing left slipstream deflector
Remove screws (1).
Remove complete slipstream deflector (2).
(-) Installing left slipstream deflector

Install complete slipstream deflector (2).
Install screws (1).
Finishing work
062011 1/1
BMW-Motorrad
46 63 303 Replacing left stowage-compartment lid 2 FRUs

+ 46 63 988
Core activity
(-) Removing left stowage-compartment lid
Open the stowage compartment.
Press the retainers (arrows) down and remove swivels (1) and spring
(2).
Remove stowage-compartment lid (3).
(-) Installing left stowage-compartment lid

Hold damper (4) in position.
Install stowage-compartment lid (3), positioning it with the groove
(arrow) at damper (4).
Insert spring (2) with long end toward lid (3) and install swivels (1).
Finishing work
062011 1/1
BMW-Motorrad
46 63 321 Replacing left or right rear trim panel 3 FRUs

+ 46 63 896
Preparatory work
Remove the front-seat trimmer, left
Removing cover for case carrier, left
Core activity
(-) Removing left rear trim panel
Remove screws (1).
Remove rear trim panel (1), noting the retaining lugs (arrows).
(-) Installing left rear trim panel

Install rear trim panel (1), noting the retaining lugs (arrows).
Install screws (1).
062011 1/2
BMW-Motorrad
Finishing work
Installing cover for case carrier, left
Install the front-seat trimmer, left
062011 2/2
BMW-Motorrad
46 63 333 Replacing side panel, left 4 FRUs

+ 46 63 900
Preparatory work
Core activity
(-) Removing left side panel
Turn slipstream deflector (1) to one side.
Remove screw (2).
Remove screws (1).
Remove screws (1).

Remove side panel (2).
(-) Replacing side panel, left

Transfer flat nuts (1) and rubber grommet (2) to new side panel (3).
062011 1/3
BMW-Motorrad
(-) Install the BMW badge

Seat the pins (arrow) of the BMW badge (1) in small bores (2) of the
trim panel.
Press BMW badge (1) firmly against the trim panel.
(-) Installing designation for side panel

Peel backing films (1) off designations (2) and (3).
Hold designations (2) and (3) in position and press on firmly.
(-) Install the left side panel

Install side panel (2).
Install screws (1).
062011 2/3
BMW-Motorrad
Install screws (1).

Install screw (2).
Finishing work
062011 3/3
BMW-Motorrad
46 63 334 Replacing side panel, right 4 FRUs

+ 46 63 901
Preparatory work
Core activity
(-) Remove the right side panel
Remove screw (2).
Remove screws (1).
Remove screws (1).

Remove side panel (2).
(-) Replacing right side panel

Transfer flat nuts (1) and rubber grommet (2) to new side panel (3).
062011 1/3
BMW-Motorrad
(-) Install the BMW badge

Seat the pins (arrow) of the BMW badge (1) in small bores (2) of the
trim panel.
Press BMW badge (1) firmly against the trim panel.
(-) Installing designation for side panel

Peel backing films (1) off designations (2) and (3).
Hold designations (2) and (3) in position and press on firmly.
(-) Install the right side panel

Install side panel (2).
Install screws (1).
062011 2/3
BMW-Motorrad
Install screws (1).

Install screw (2).
Finishing work
062011 3/3
BMW-Motorrad
46 63 340 Replacing interior trim for full fairing, left 5 FRUs

+ 46 63 906
Preparatory work
Core activity
(-) Removing inner trim for left side panel
Disengage complete ambient-temperature sensor (1) from inner trim
(2).
Remove screws (1) with bushings (2).

Remove screw (3).
Disconnect plug (1) for the operating unit.

Remove screw (2).
Remove inner trim (3) for the side panel.
062011 1/4
BMW-Motorrad
(-) Replacing left inner trim for side panel

Removing operating unit for audio system
Remove screws (1).
Remove operating unit (2).
Removing left slipstream deflector

Remove screws (1).
Remove slipstream deflector (2).
Transfer rubber grommet (1), flat nuts (2) and rubber guides (3) to new
inner trim (4).
Installing left slipstream deflector

Install slipstream deflector (2).
Install screws (1).
062011 2/4
BMW-Motorrad
Installing operating unit for audio system

Install operating unit (2), making sure that the operating unit is located
in the catch (arrow).
Install screws (1).
Tightening torques
Operating unit for audio system to fairing side panel
TS4 x 10 1.5 Nm
(-) Installing inner trim for left side panel

Install inner trim (3) for the side panel.
Install screw (2).
Connect plug (1) for the operating unit.
Install screws (1) with bushings (2).

Install screw (3).
062011 3/4
BMW-Motorrad
Secure complete ambient-temperature sensor (1) in inner trim (2).
Finishing work
062011 4/4
BMW-Motorrad
46 63 343 Replace inner cover for instruments 7 FRUs

+ 46 63 907
Preparatory work
Removing windscreen
Removing top cover
Core activity
(-) Removing inner trim with instrument panel
Remove screws (1) and screws (2) with washers (3).
Disengage plug (1) for windscreen adjuster from the holder (arrow).
Disconnect plug (2) for the instrument panel.
Remove inner trim (3) with the instrument panel.
(-) Removing instrument panel

Remove screws (1).
Remove instrument panel (2) from inner trim (3).
062011 1/3
BMW-Motorrad
(-) Replacing inner trim

Transfer the following components to new inner trim (4):
Flat nuts (1)
Bushings (2)
Rubber grommets (3)
(-) Installing instrument panel

Install instrument panel (2) in inner trim (3).
Install screws (1).
Tightening torques
Instrument panel to inner trim
M6 x 16 5 Nm
(-) Installing inner trim with instrument panel

Install inner trim (3) with the instrument panel.
Connect plug (2) for the instrument panel.
Secure plug (1) for windscreen adjuster in the holder (arrow).
062011 2/3
BMW-Motorrad
Install screws (1) and screws (2) with washers (3).
Finishing work
062011 3/3
BMW-Motorrad
46 63 345 Replacing interior trim for full fairing, right 5 FRUs

+ 46 63 908
Preparatory work
Core activity
(-) Removing inner trim for right side panel
Remove screw (3).
Remove screw (1).

Disconnect plug (2) for the on-board socket.
(-) Replacing right inner trim for side panel

Removing right slipstream deflector
Remove screws (1).
Remove slipstream deflector (2).
062011 1/4
BMW-Motorrad
Removing on-board socket from inner trim

Remove nut (1).
Remove on-board socket (2).
Transfer rubber grommet (1), flat nuts (2) and rubber guides (3) from
old to new inner trim (4).
Installing on-board socket in interior trim

Install on-board socket (2), noting the locator (arrows).
Tighten nut (1).
062011 2/4
BMW-Motorrad
Installing right slipstream deflector

Install slipstream deflector (2).
Install screws (1).
(-) Installing inner trim for right side panel

Connect plug (2) for the on-board socket.
Install screw (1).

Install screw (3).
062011 3/4
BMW-Motorrad
Finishing work
062011 4/4
BMW-Motorrad
46 63 352 Replacing side panel, bottom right 2 FRUs

+ 46 63 989
Core activity
(-) Removing right bottom side panel
Remove screws (1).
Remove bottom side panel (2), disengaging the hook (arrow).
(-) Installing right bottom side panel

Install bottom side panel (2), engaging the hook (arrow).
Install screws (1).
Finishing work
062011 1/1
BMW-Motorrad
46 63 353 Replacing side panel, bottom left 2 FRUs

+ 46 63 990
Core activity
(-) Removing left bottom side panel
Remove screws (1).
Remove bottom side panel (2), disengaging the hook (arrow).
(-) Installing left bottom side panel

Install bottom side panel (2), engaging the hook (arrow).
Install screws (1).
Finishing work
062011 1/1
BMW-Motorrad
46 71 061 Renewing complete left or right front footrest 2 FRUs

+ 46 71 810
Warning
Core activity
(-) Removing front footrest
Remove circlip (1) and pin (2).
Remove sleeve (3) and spring (4).
Remove complete footrest (5).
(-) Installing front footrest

Lubricate pin (2).

Install complete footrest (5).
Install spring (4) with sleeve (3).
Install pin (2) and circlip (1).
Finishing work
062011 1/1
BMW-Motorrad
46 71 299 Renewing left footrest plate 3 FRUs

+ 46 71 829
Core activity
(-) Removing left footrest plate
Remove screws (1) and screw (2).
Secure gearshift lever (3) so that it cannot fall out.
Remove footrest plate (4), removing washer (5).
(-) Replacing left footrest plate

Removing front footrest
Removing rear footrest

Remove the following components and install them in the new footrest
plate:
062011 1/3
BMW-Motorrad
Buffer (1)
Screws (2)
Cover (3)
Installing rear footrest

Lubricate pin (2).

Installing front footrest

Lubricate pin (2).

(-) Installing left footrest plate

Hold shift lever (1) in position with washer (2), making sure that the
components do not slip out of position.
062011 2/3
BMW-Motorrad

Hold footrest plate (4) in position, noting washer (5) and gearshift lever
(3), making sure that they do not slip out of position.
Tightening torques
M8 x 25 28 Nm
Micro-encapsulated
Finishing work
062011 3/3
BMW-Motorrad
46 71 312 Renewing right footrest plate 3 FRUs

+ 46 71 830
Core activity
(-) Removing right footrest plate
Remove screws (1) and screw (2).
Remove footrest plate (3).
(-) Replacing right footrest plate

Removing front footrest
Removing rear footrest

Remove screws (1) and cover (2) and install them in the new footrest
plate.
062011 1/3
BMW-Motorrad
Installing rear footrest

Lubricate pin (2).

Installing front footrest

Lubricate pin (2).

(-) Installing right footrest plate

Hold footrest plate (3) in position.
Tightening torques
M8 x 25 28 Nm
062011 2/3
BMW-Motorrad

Micro-encapsulated
Finishing work
062011 3/3
BMW-Motorrad
51 16 041 Replace mirror glass

+ 51 16 541
Core activity
(-) Removing mirror glass
Turn mirror glass (1) inward.
Using a suitable tool, unclip mirror glass (1) from the tabs (arrows) of
mirror holder (2).
Carefully remove mirror glass (1).
(-) Installing mirror glass

Position mirror glass (1) on adjuster unit (2) and press on all round,
taking care to apply pressure to mirror glass (1) only at adjuster unit
(2).
Finishing work
062011 1/1
BMW-Motorrad
51 16 044 Replacing mirror, left 3 FRUs

+ 51 16 554
Preparatory work
Core activity
(-) Removing left mirror
Remove screws (1).
Remove mirror (2).
(-) Installing left mirror

Install mirror (2).
Install screws (1).
Tightening torques
Mirror to front panel carrier
M6 x 25 5 Nm
Finishing work
062011 1/1
BMW-Motorrad
51 16 045 Replacing mirror, right 3 FRUs

+ 51 16 555
Preparatory work
Core activity
(-) Removing right mirror
Disconnect plug (1) for the aerial and work cable (2) clear of the
motorcycle.
Remove screw (1) for the earthing strap.

Remove screws (2).
Remove mirror (3) with cable (4).
(-) Installing right mirror

Install mirror (3) with cable (4).
Install screws (2).
Tightening torques
Mirror to front panel carrier
M6 x 25 5 Nm
Install screw (1) for the earthing strap.
062011 1/2
BMW-Motorrad
Work cable (2) into position and connect plug (1) for the aerial.
Finishing work
062011 2/2
BMW-Motorrad
51 25 120 Replace lock barrel for stowage-compartment lid 4 FRUs

+ 51 25 620
Preparatory work
Core activity
(-) Removing lock barrel for stowage compartment
Insert ignition key (1) in lock barrel (2) and turn lock barrel (2) to the
open position.
Using a suitable provisional tool such as a length of wire, for example,
press the locking pawl (arrow) in.
Remove lock barrel (2) with ignition key (1).
(-) Installing lock barrel for stowage compartment

Lubricate lock barrel (2).

Grease for lock cylinders Lubricating grease 81 22 9 407
421
Install lock barrel (2) with ignition key (1).
Make sure that the locking pawl (arrow) engages.
Finishing work
062011 1/1
BMW-Motorrad
61 00 002 Testing software 3 FRUs

+ 61 00 502
Preparatory work
Core activity
motorcycle
Note
cap (3).
system.
Note
other instructions.
(-) Checking software

Start ISTA/P.
Read out the software release.
Perform diagnosis. Rectify faults, if found, before starting
programming/coding.
=> Programming control unit of engine management system

(along with testing software) (Description in item: 13 61 522, Billed
as a separate item)
=> Programming control units of vehicle (along with testing
software) (Description in item: 61 00 510, Billed as a separate
item)
motorcycle
the diagnosis plug.
Finishing work
062011 1/2
BMW-Motorrad
062011 2/2
BMW-Motorrad
61 00 003 Resetting/learning adaptation values (with replacing component) 3 FRUs

+ 61 00 503
Core activity
motorcycle
Note
cap (3).
system.
Note
other instructions.
(-) Reading fault memory with BMW Motorrad diagnostic

system and resetting adaptation values
After replacing the component, be sure to read the fault memories of
the control units with the BMW Motorrad diagnostic system and rectify
the corresponding faults, if any. You must also reset the adaptation
values. From this point on, follow the instructions issued by the BMW
Motorrad diagnostic system. This is the only way of ensuring correct
operation of the motorcycle.

motorcycle
the diagnosis plug.
Finishing work
062011 1/1
BMW-Motorrad
61 00 510 Programming control units of vehicle (along with testing software)
Core activity
(-) Programming vehicle control unit
Start the programming routine and follow the instructions issued by the
BMW Motorrad diagnostic system.
062011 1/1
BMW-Motorrad
61 11 013 Wiring-harness repair WT FRUs

+ 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 approximately the length of a
shrink-on hose, 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.
Note
The cables are not colour-coded; instead, they have code numbers to
ensure the universal usability of the repair kits.
Slip a shrink-fit hose (1) onto each of the cores.

Use stripping pliers (No. 61 9 043) to strip the ends of all the wires.
Seat the ends of the wires in push-in connectors of the correct cross-
section size.
The crimp connectors always have to be crimped on to both the
insulation and the stranded cable (detail).
Use crimping pliers (No. 61 0 651) and crimping head (No. 61 0 652)
to crimp on the connectors.
Slide the shrink-on hose into position over the connector and use a
hot-air gun to heat the hose.
The shrink-on hose contracts, tightens round the surface of the cable
and turns transparent. At the same time, hot glue (arrow) escapes and
forms a seal around the repair.
062011 1/2
BMW-Motorrad
Wrap fibre-reinforced insulating tape (No. 61 0 631) around the repair.

If possible, secure the repaired cable to the frame.
062011 2/2
BMW-Motorrad
61 21 011 Renewing battery 2 FRUs

+ 61 21 522
Preparatory work
Core activity
(-) Removing battery
Attention
Disconnection in the wrong sequence increases the risk of short-
circuits.
Always proceed in the correct sequence.
Remove screw (1) and disconnect negative lead from negative

terminal of battery (2).
Remove protective cap (3) for positive terminal of battery.
Remove nut (4) and screw (5) and disconnect positive lead from
positive terminal of battery (6).
Remove screws (1) and holder (2).

Remove battery (3).
(-) Recharge the battery

Set the BMW Motorrad battery charger to the correct charging
characteristic.
Workshop equipment
BMW Motorrad battery charger (version for Europe without GB)
BMW Motorrad battery charger (GB/AUS/NZL version)
BMW Motorrad battery charger (Japan version)
BMW Motorrad battery charger (USA/CAN version)
Charge the battery with the BMW Motorrad battery charger, taking
care to comply with the instructions for use.
(-) Installing battery

Install battery (3).
Install holder (2) and screws (1).
Tightening torques
062011 1/2
BMW-Motorrad
Battery holder to rear carrier

M5 x 10 3 Nm
Attention
Connection in the wrong sequence increases the risk of short-circuits.
Always proceed in the correct sequence.
Position positive lead at positive terminal of battery (6), install screw

(5) and nut (4).
Tightening torques
Wiring harness to battery
M6 x 20 3.5 Nm
Install protective cap (3) for positive terminal.
Hold negative lead in position at negative terminal of battery (2) and
install screw (1).
Tightening torques
Wiring harness to battery
M6 x 20 3.5 Nm
Finishing work
=> Checking or restoring system time (Description in
062011 2/2
BMW-Motorrad
61 21 019 Charging battery 2 FRUs

+ 61 21 523
Core activity
(-) Checking battery charge state
Attention
Standard, commercially available chargers connected to the on-board
socket could cause irreparable damage to the on-board electronics and
themselves.
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 or sockets, if
connected.
Test
Switch on the ignition.
Control units switch on.
Switch off the ignition.
Technical data
Deactivation delay if no 60 s
for 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 power supply.
Note
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
≤7 V
Undervoltage in on-
062011 1/2
BMW-Motorrad
board system
Charge the battery with the BMW Motorrad battery charger, taking
care to comply with the instructions for use.
Finishing work
062011 2/2
BMW-Motorrad
61 31 001 Replacing multi-controller 17 FRUs

+ 61 31 950
Attention
Any attempt to open the unit will result in damage to the printed circuits,
which are lacquer-sealed.
The top and bottom parts of the switch unit are set in their relative
positions by the manufacturer: do not attempt to separate the two parts
of the switch.
Preparatory work
Removing fuel tank
Removing left multifunction switch
Core activity
(-) Removing multi-controller
Disconnect plug (1) for the multi-controller and disengage cable (2).
062011 1/3
BMW-Motorrad
Remove screws (1).

Lift bracket (2) and work the cable from plug (3) for the heated grip
clear.
Remove bracket (2) and multi-controller (4) from grip (5).
(-) Installing multi-controller

Position multi-controller (4) on grip (5). Make sure that the retainers
(arrows) and recesses (6) engage.
Work the cable of plug (3) for the heated grip through bracket (2).
Hold bracket (2) in position and install screws (1), noting the grip-
heating cable.
Tightening torques
Multi-controller to grip
RS2.5 x 20 1.5 Nm
Connect plug (1) for the multi-controller and route cable (2).
062011 2/3
BMW-Motorrad
Finishing work
Installing left multifunction switch
062011 3/3
BMW-Motorrad
61 31 063 Renewing complete multi-function switch on left handlebar 16 FRUs

+ 61 31 904
Attention
Any attempt to open the unit will result in damage to the printed circuits,
which are lacquer-sealed.
The top and bottom parts of the switch unit are set in their relative
positions by the manufacturer: do not attempt to separate the two parts
of the switch.
Preparatory work
Removing fuel tank
Core activity
(-) Removing left grip unit
Remove cable holder (1) and the cable tie (arrow).
062011 1/6
BMW-Motorrad
Pull rubber grip (1) to the side and remove screw (2).
Remove complete grip unit (3) from the handlebar.
Note
Carefully pull off the grip unit because it can catch on the anti-chafing
film, making it difficult to move.
(-) Removing left multifunction switch

Disconnect plug (1) for the multifunction switch and disengage cable
(2).
Disengage the retaining tabs (arrows).

Remove cover (1).
Working in the following sequence, disconnect and remove the
following plugs:
(2) small
(4) large
062011 2/6
BMW-Motorrad
Push up retainer (1).

Remove multifunction switch (2) from grip (3) and remove plug (4) for
the heated grip.
(-) Installing left multifunction switch

Push multifunction switch (2) on to grip (3) and install plug (4) for the
heated grip.
Retainer (1) engages.
Check that the grip-heating cable is correctly routed and does not
project into the grip tube.
Working in the following sequence, install and connect the plugs:

(4) large
(2) small
Install cover (1).
Make sure that the retaining tabs (arrows) engage.
062011 3/6
BMW-Motorrad
Route cable (2) and connect plug (1) for the multifunction switch.
(-) Installing left grip unit
Test
Check the condition of anti-chafing film (1)
Result: Protective film is damaged, out of position or missing.

Measure:
Replacing protective film on handlebar
Remove old protective film (1).
Provisionally install grip unit (1) and mark the position of the edge
(arrow) on the handlebar.
Remove grip unit (1).
062011 4/6
BMW-Motorrad
Clean the area where the protective film will be applied.

Apply protective film (1), noting the mark (arrow) for alignment and
taking care not to affix the film over the mark.
Push complete grip unit (3) on to the handlebar.

Pull rubber grip (1) to the side and install screw (2).
Tightening torques
Handlebar grip, left, to handlebar
M3.5 x 32 2 Nm
Secure cable holder (1) and the cable tie (arrow).
062011 5/6
BMW-Motorrad
Finishing work
062011 6/6
BMW-Motorrad
61 31 073 Renewing complete multi-function switch on right handlebar 2 FRUs

+ 61 31 905
Core activity
(-) Removing right multifunction switch
Disconnecting plug for throttle twistgrip
Disconnect plug (1) for the throttle twistgrip.
Remove screw (1).

Ease cover (2) down slightly until the multifunction switch is open
(arrow).
Push cover (2) forward and up, noting retaining catches (3).
Disconnect and remove plug (1) for the heated grip and plug (2) for the
multifunction switch.
Remove screw (3).
Remove multifunction switch (4).
062011 1/3
BMW-Motorrad
(-) Installing right multifunction switch

Hold multifunction switch (4) in position.
Attention
Overtightened screws can lead to component damage.
Do not exceed the specified tightening torque.
Install screw (3).
Tightening torques
Multifunction switch to grip unit
PT 2.5 x 15 0.4 Nm
Install and connect plug (2) for the multifunction switch and plug (1) for
the heated handlebar grips.
Position cover (2) and push backwards and down, paying attention to
retaining catches (3).
Push cover (2) up until the multifunction switch is closed.
Attention
Overtightened screws can lead to component damage.
Do not exceed the specified tightening torque.
Install screw (1).
Tightening torques
062011 2/3
BMW-Motorrad
Cover to multifunction switch

PT2.5 x 15 0.4 Nm
Connecting plug for throttle twistgrip

Connect plug (1) for the throttle twistgrip.
Finishing work
062011 3/3
BMW-Motorrad
61 31 295 Removing/installing or replacing clutch switch 15 FRUs

+ 61 31 911
Preparatory work
Removing fuel tank
Core activity
(-) Removing clutch switch
Remove plug (1) for the clutch switch and disconnect.
Release cable (2).
Remove cable holder (1) and the cable tie (arrow).
Remove screw (1).

Remove clutch switch (2), noting locating point (3).
062011 1/3
BMW-Motorrad
(-) Installing clutch switch

Install clutch switch (2) with the white mark (arrow) pointing down,
noting locating point (3).
Install screw (1).
Tightening torques
Clutch switch to handlebar fitting
M2 x 18 0.3 Nm
Secure cable holder (1) and the cable tie (arrow).

Connect plug (1) for the clutch switch and install.
062011 2/3
BMW-Motorrad
Finishing work
062011 3/3
BMW-Motorrad
61 31 302 Replacing switch for side stand 5 FRUs

+ 61 31 913
Preparatory work
Core activity
(-) Removing side-stand switch
Disconnect plug (1) for the side-stand switch and work cable (2) clear
of the motorcycle.
Disengage cable (1) from holder (2) and work it clear.

Remove circlip (1), tensioning ring (2) and washer (3).
Remove side-stand switch (4).
062011 1/2
BMW-Motorrad
(-) Installing side-stand switch

Hold side-stand switch (4) in position, making sure that switch pin (5)
is seated in bore (6).
Install washer (3), tensioning ring (2) and circlip (1).
Route cable (2) in the motorcycle and connect plug (1) for the side-
stand switch.
Finishing work
Function test, engine start suppression
062011 2/2
BMW-Motorrad
61 31 341 Replacing switch for rear-seat heating 3 FRUs

+ 61 31 949
Preparatory work
Core activity
(-) Removing switch for rear-seat heating
Remove screws (1).
Work switch cover (2) to the outside to remove.
Disconnect plug (1) for the switch.

Using a suitable tool, unlatch switch (2) on left and right (arrows).
Work switch (2) to the outside to remove.
(-) Installing switch for rear-seat heating

Install switch (2).
Connect plug (1) for the switch.
Install switch cover (1), making sure that lock barrel (2) engages
locking shaft (3).
Install screws (4).
062011 1/2
BMW-Motorrad
Finishing work
062011 2/2
BMW-Motorrad
61 31 390 Replacing starter relay 2 FRUs

+ 61 31 924
Preparatory work
Core activity
(-) Removing starter relay
Using a suitable tool, remove starter relay (1) from bracket (2).
(-) Installing starter relay

Using a suitable tool, install starter relay (1) in bracket (2).
Make sure that starter relay (1) is securely installed.
Finishing work
062011 1/1
BMW-Motorrad
61 32 000 Removing/installing or replacing ignition switch

+ 61 32 511
Preparatory work
Core activity
(-) Disconnecting plugs for ignition switch/steering lock and
ring aerial
Remove handlebars (1) from steering adapter (2).
Unclip cable holder (3).
Disconnect plugs (4) for the ignition switch/steering lock and (5) for the
ring aerial.
(-) Removing ignition switch

(-) Installing ignition switch

Tightening torques
Ignition switch to steering lock
M3 0.5 Nm
062011 1/2
BMW-Motorrad
(-) Connecting plugs for ignition switch/steering lock and ring

aerial
Clean the threads of steering adapter (2).
Connect plugs (4) for the ignition switch/steering lock and (5) for the
ring aerial.
Clip in cable holder (3).
Position handlebar bridge (1) on steering adapter (2).
Finishing work
062011 2/2
BMW-Motorrad
61 34 000 Replacing on-board socket, front

+ 61 34 550
Preparatory work
Core activity
(-) Removing inner trim for right side panel
Remove screw (3).
Remove screw (1).

(-) Removing on-board socket from inner trim

Remove nut (1).
062011 1/2
BMW-Motorrad
(-) Installing on-board socket in interior trim

Install on-board socket (2), noting the locator (arrows).
Tighten nut (1).
(-) Installing inner trim for right side panel

Install screw (1).

Install screw (3).
Finishing work
062011 2/2
BMW-Motorrad
61 34 001 Replacing on-board socket, rear

+ 61 34 551
Preparatory work
Core activity
(-) Disengaging relay and fuse carrier
Remove screws (1).
Remove relay and fuse carrier (2).
(-) Removing on-board socket, rear

Remove nut (2).
(-) Installing on-board socket, rear
062011 1/2
BMW-Motorrad
Install on-board socket (3), noting the locator (arrow).

Install nut (2).
(-) Securing relay and fuse carrier

Hold relay and fuse carrier (2) in position.
Install screws (1).
Finishing work
062011 2/2
BMW-Motorrad
61 35 012 Checking or restoring system time 2 FRUs

+ 61 35 506
Core activity
motorcycle
Note
cap (3).
system.
Note
other instructions.
(-) Reset system time with BMW Motorrad diagnostic system

Select Activities from the menu and call up the Service schedules.
Go to the Read and set service date menu option to calibrate the
calendar date in the vehicle with the calendar date of the BMW
Motorrad diagnostic system.

motorcycle
the diagnosis plug.
062011 1/1
BMW-Motorrad
61 35 026 Replacing control unit basic module (without testing software/programming) 3

FRUs
+ 61 35 653
Note
Preparatory work
Disengaging ESA control unit
Core activity
(-) Removing control unit basic module
Disconnect plug (1) for the basic module.
Push back retaining tabs (2) and remove basic module (3).
(-) Installing control unit basic module
Note
Install basic module (3).

Connect plug (1) for the basic module.
062011 1/2
BMW-Motorrad
Finishing work
Securing ESA control unit


as a separate item)
062011 2/2
BMW-Motorrad
61 35 027 Replacing control unit basic module satellite (without testing

software/programming) 3 FRUs
+ 61 35 654
Note
Preparatory work
Core activity
(-) Removing control unit basic module satellite
Push back retaining tabs (1) and remove basic module satellite (2).
Disconnect plug (3) for basic module satellite (2).
(-) Installing control unit basic module satellite
Note
Connect plug (3) to basic module satellite (2).

Install basic module satellite (2).
062011 1/2
BMW-Motorrad
Finishing work


as a separate item)
062011 2/2
BMW-Motorrad
61 35 150 Replacing ring aerial on ignition lock

+ 61 35 650
Preparatory work
aerial
Removing handlebar bridge
Core activity
(-) Removing ignition switch/steering lock with ring aerial
Lay handlebar bridge (1) on a padded rest.
Remove screws (2).
Attention
Drill pilot holes into non-removable screws (1) and then continue
drilling out the holes until the screw heads come off.
Technical data
Ignition Pilot hole min 5 mm
switch/steering diameter 4 mm
lock - drilling depth Diameter for 5 mm
for drilling out non- drilling out
removable screws fully 8.5 mm
Use compressed air to remove metal particles.
Remove steering lock (2) with ring aerial (3).
Use a stud remover to remove shanks of non-removable screws (4).
(-) Replacing ring aerial

Remove ring aerial (1) and O-ring (2).
Check O-ring (2); replace if necessary.
Position O-ring (2) and new ring aerial (1) on steering-lock (3) and
062011 1/2
BMW-Motorrad
install.
(-) Installing ignition switch/steering lock with ring aerial

Install steering lock (2) with ring aerial (3) in handlebar bridge (4).
Install new non-removable screws (1) with socket wrench insert (No.
51 0 531).
Tightening torques
Ignition and steering lock to handlebar yoke
Micro-encapsulated

Install screws (1).
Tightening torques
Ring aerial to ignition switch/steering lock
M3 0.5 Nm
Finishing work
Installing handlebar bridge
062011 2/2
BMW-Motorrad
61 35 503 Setting service-due date with BMW Motorrad diagnostic system (for maintenance)
1 FRUs
Core activity
(-) Setting service-due date
Start ISTA and perform the vehicle test.
Select Activities from the menu, call up the Service schedules and
set the service date.
062011 1/1
BMW-Motorrad
61 35 504 Setting service countdown distance with BMW Motorrad diagnostic system (for
maintenance) 1 FRUs
Core activity
(-) Setting service countdown distance
set the countdown distance.
062011 1/1
BMW-Motorrad
61 35 505 Setting service-due date and service countdown distance with BMW Motorrad
diagnostic system (for maintenance) 1 FRUs
Core activity
(-) Setting service-due date and service countdown distance
set the service date and the countdown distance.
062011 1/1
BMW-Motorrad
62 11 199 Replacing instrument cluster (without (testing software/programming) 7 FRUs

+ 62 11 510
Note
Preparatory work
Removing windscreen
Removing top cover
Removing inner trim with instrument panel
Core activity
(-) Removing instrument panel
Remove screws (1).
Remove instrument panel (2) from inner trim (3).
(-) Installing instrument panel

Install instrument panel (2) in inner trim (3).
Install screws (1).
Tightening torques
Instrument panel to inner trim
M6 x 16 5 Nm
062011 1/2
BMW-Motorrad
Finishing work
Installing inner trim with instrument panel


as a separate item)
062011 2/2
BMW-Motorrad
63 12 000 Adjust headlight 4 FRUs

+ 63 12 500
Preparatory work
Core activity
(-) Correcting headlight beam angle
Adjust the lateral angle for the high-beam headlight by turning
adjusting screw (1) with a suitable tool.
Adjust the height of the beam throw by turning adjusting screw (1) or
(2) with a suitable tool.
Finishing work
062011 1/1
BMW-Motorrad
63 12 003 Replacing height sensor, rear

+ 63 12 672
Preparatory work
Remove the front-seat trimmer, left
Core activity
(-) Removing height sensor, rear
Disconnect plug (1).
Remove screws (2) and remove sensor (3) from bracket (4).
(-) Installing height sensor, rear

Position sensor (3) on bracket (4) and install screws (2).
Connect plug (1).
Finishing work
Install the front-seat trimmer, left
Calibrating headlight
062011 1/1
BMW-Motorrad
63 12 004 Replacing height sensor, front 7 FRUs

+ 63 12 669
Preparatory work
Core activity
(-) Removing height sensor, front
Disengage actuator rod (4).
Remove screw (1) and remove sensor (2).
(-) Replacing height sensor, front

Remove screws (1).
Transfer bracket (2) to new sensor (3) and install screws (1).
062011 1/3
BMW-Motorrad
(-) Installing height sensor, front

Hold sensor (2) in position, making sure that the position of the recess
(arrow) relative to the lug (3) is correct, and install screw (1).
Tightening torques
Bracket for height sensor to front panel carrier
M6 x 20 5 Nm
Connect plug (1).

Hold actuator rod (4) in position.
Finishing work
Calibrating headlight
062011 2/3
BMW-Motorrad

062011 3/3
BMW-Motorrad
63 12 006 Replacing bracket for height sensor, front 7 FRUs

+ 63 12 671
Preparatory work
Core activity
(-) Removing height sensor, front
Disengage actuator rod (4).
Remove screw (1) and remove sensor (2).
(-) Replacing bracket for height sensor, front

Remove screws (1) and remove holder (2).
Hold new bracket (2) in position at sensor (3) and install screws (1).
062011 1/3
BMW-Motorrad
(-) Installing height sensor, front

Hold sensor (2) in position, making sure that the position of the recess
(arrow) relative to the lug (3) is correct, and install screw (1).
Tightening torques
Bracket for height sensor to front panel carrier
M6 x 20 5 Nm
Connect plug (1).

Hold actuator rod (4) in position.
Finishing work
062011 2/3
BMW-Motorrad
062011 3/3
BMW-Motorrad
63 12 091 Replacing headlight 11 FRUs

+ 63 12 637
Preparatory work
Removing top cover
Core activity
(-) Removing headlight
Remove retaining clip (1) and screw (2) with washer (3).
Disconnect plug (4) for the headlight and disengage with the cable
from holder (5).
Remove retaining clip (1) and screw (2) with washer (3).
Disconnect plug (4) for the headlight and disengage with the cable
from holder (5).
062011 1/4
BMW-Motorrad
Disengage headlight (1) from rubber grommets (2) and remove.
(-) Replacing headlight

Remove screws (1).
Remove the following components and transfer them to the new
headlight; check seals (4) for damage and replace if necessary:
Disengage side-light modules (2) and disconnect plugs (3)
Side-light modules (2) with seals (4)
Flat nuts (5)
Install screws (1).
Tightening torques
Mounted parts to headlight
1.5 Nm
Remove screws (1).
Remove headlight control unit (2) with seal (3) and xenon control unit
(4) with seal (5) and install in new headlight. Check seals (3) and (5)
for damage; replace if necessary.
Install screws (1).
Tightening torques
Mounted parts to headlight
1.5 Nm
(-) Installing headlight

Install headlight (1), seating the assembly in rubber grommets (2).
062011 2/4
BMW-Motorrad
Install retaining clip (1) and screw (2) with washer (3).
Tightening torques
Headlight to front panel carrier
M5 x 30 2.5 Nm
Connect plug (4) for the headlight and secure it with cable in holder
(5).
Install retaining clip (1) and screw (2) with washer (3).
Tightening torques
Headlight to front panel carrier
M5 x 30 2.5 Nm
Connect plug (4) for the headlight and secure it with cable in holder
(5).
Finishing work
062011 3/4
BMW-Motorrad

Preparation for initialising/calibrating new parts
062011 4/4
BMW-Motorrad
63 13 012 Renewing complete front left or right flashing turn indicator 4 FRUs
+ 63 13 501
Preparatory work
Core activity
(-) Removing front left flashing turn indicator
Disconnect plug (1) for the flashing turn indicators.
Remove screws (2).
Remove flashing turn indicators (3).
(-) Installing front left flashing turn indicator

Install flashing turn indicator (3).
Install screws (2).
Connect plug (1) for the flashing turn indicators.
Finishing work
062011 1/1
BMW-Motorrad
63 21 380 Removing and installing or replacing complete rear light 3 FRUs

+ 63 21 502
Preparatory work
Removing cover panels for rear lights, left and right
Core activity
(-) Removing rear-light unit
Disconnect plug (1) for the rear light.
Remove clips (2) and washers (3).
Remove clips (1) and washers (2) on left and right.

Remove rear light (3).
(-) Removing cover panel for rear light, centre section

Remove screws (1).
Remove cover panel (2) from rear light (3).
(-) Installing cover panel for rear light, centre section

Position cover panel (2) on rear light (3).
062011 1/2
BMW-Motorrad
Install screws (1).
Tightening torques
Cover, centre to rear-light cluster
Screw for plastic, PT40 x 15 3 Nm
(-) Install the rear-light unit

Seat rear light (3) in rubber grommets (4) and install.
Install clips (1) and washers (2) on left and right.
Install clips (2) and washers (3).

Connect plug (1) for the rear light.
Finishing work
Installing cover panels for rear lights, left and right
062011 2/2
BMW-Motorrad
65 13 011 Removing/installing or replacing left and right front speakers 3 FRUs

+ 65 13 501
Preparatory work
Core activity
(-) Removing left speaker
Disconnect plug (1) for the speaker.
Remove screws (2).
Remove speaker (3).
(-) Removing right speaker

Disconnect plug (1) for the speaker.
Remove screws (2).
Remove speaker (3).
(-) Installing left speaker

Install speaker (3).
Install screws (2).
Tightening torques
Speaker to bracket/top section of fairing
M5 x 20 2.5 Nm
Connect plug (1) for the speaker.
062011 1/2
BMW-Motorrad
(-) Installing right speaker

Install speaker (3).
Install screws (2).
Tightening torques
Speaker to bracket/top section of fairing
M5 x 20 2.5 Nm
Connect plug (1) for the speaker.
Finishing work
062011 2/2
BMW-Motorrad
65 14 505 Replacing operating unit for audio system (without (testing software/
programming) 3 FRUs
Note
Preparatory work
Core activity
(-) Removing operating unit for audio system
Remove screws (1).
Remove operating unit (2).
(-) Installing operating unit for audio system

Install operating unit (2), making sure that the operating unit is located
in the catch (arrow).
Install screws (1).
Tightening torques
Operating unit for audio system to fairing side panel
TS4 x 10 1.5 Nm
Finishing work
062011 1/2
BMW-Motorrad


as a separate item)
062011 2/2
BMW-Motorrad
65 75 020 Replace batteries for control unit of anti-theft alarm system 5 FRUs
+ 65 75 520
Preparatory work
Removing tail cover centre panel
Core activity
(-) Removing batteries in control unit for anti-theft alarm
system (DWA)
Remove screws (1) and remove cover (2).
Remove batteries (1).
(-) Installing batteries in control unit of anti-theft alarm

system
Install batteries (1), making sure that polarity is correct.
Technical data
Battery type and CR 1632 lithium
rated voltage 3V
062011 1/2
BMW-Motorrad
Check seal (3) for damage; replace if necessary.

Place cover (2) in position and install screws (1).
Finishing work
Installing tail cover centre panel
062011 2/2
BMW-Motorrad
65 75 510 Replacing control unit of anti-theft alarm (without testing software/ programming) 4
FRUs
Note
Preparatory work
Removing tail cover centre panel
Core activity
(-) Removing anti-theft alarm
Disconnect plug (1) for the anti-theft alarm and plug (2) for the central
locking system.
Remove screws (1).

Remove anti-theft alarm (2).
(-) Installing anti-theft alarm

Install anti-theft alarm (2).
Install screws (1).
Tightening torques
062011 1/2
BMW-Motorrad
Control unit (anti-theft alarm) to rear carrier

TS4 x 10 1.5 Nm
Connect plug (1) for the anti-theft alarm and plug (2) for the central
locking system.
Finishing work

as a separate item)
Installing tail cover centre panel
062011 2/2
BMW-Motorrad
65 81 050 Replacing ambient-temperature sensor 4 FRUs

+ 65 81 550
Preparatory work
Core activity
(-) Removing ambient-temperature sensor
Disengage complete ambient-temperature sensor (1) from inner trim
(2) and disconnect plug (3).
(-) Installing ambient-temperature sensor

Secure complete ambient-temperature sensor (1) in inner trim (2) and
connect plug (3).
Finishing work
062011 1/1
BMW-Motorrad
67 11 002 Replacing central-locking drive for case

+ 67 11 552
Preparatory work
Core activity
(-) Removing central-locking unit for cases
Disengage line (1) from the holder (arrow).
Disconnect plug (2) for the central-locking drive.
Remove screws (3).
Remove central-locking unit (4).
(-) Disassembling central-locking unit for cases

Remove screw (1).
Open the retainers (arrows).
Remove housing cover (2).
Remove screws (3).
062011 1/3
BMW-Motorrad
Remove central-locking drive (1) with pivot lever (2) from housing (3).
Remove lever (2) from drive (1).
(-) Assembling central-locking unit for cases

Install pivot lever (2) in central-locking drive (1).
Seat drive (1) with lever (2) in housing (3).
Lever (2) is located by the lug (arrow).
Install screws (3).

Install housing cover (2).
Install screw (1).
(-) Installing central-locking unit for cases

Hold central-locking unit (4) in position.
Install screws (3).
Connect plug (2) for the central-locking unit.
Secure line (1) in the holder (arrow).
062011 2/3
BMW-Motorrad
Finishing work
062011 3/3

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What are the steps to test compression?

What are the steps to test compression?

What are the steps to test for pressure loss?

What are the steps to test for pressure loss?

BMW-Motorrad

11 00 040 Testing compression with BMW Motorrad diagnostic system

Result: Compression loss greater than normal.

Install the right radiator cowl

Result: Pressure loss greater than maximum permissible value.

Installing complete radiator

11 00 050 Removing/installing engine 61 FRUs

Draining cooling system

Remove cap (1).

Disconnect plugs (1) for the direct ignition coils.

Remove screws (1).

Remove screw (1).

(-) Disengaging oil lines

Remove screws (1).

(-) Removing side-stand pivot mount with side stand

(-) Removing blanking plugs

Remove blanking plugs (1) from bores (2).

(-) Installing engine lifter

Tighten long screws (1).

Secure rail (No. 00 1 583) to scissor-type lifter (No. 00 1 571).

(-) Removing engine

Remove screws (1) and (2).

Remove screw (1).

Remove screws (1) with washers (2).

Protect frame (1) by applying adhesive tape (arrows).

Protect frame (1) by applying adhesive tape (arrows).

the engine and the frame.

(-) Installing engine

Hold topple preventer (3) in position.

Insert red taper elements (4).

Remove the lengths of adhesive tape (arrows).

(-) Removing engine lifter

Lower scissor-type lifter (No. 00 1 571) and remove it from engine

Remove short screws (1).

Remove long screws (1).

Remove long screw (1).

(-) Installing blanking plugs

Install blanking plugs (1) in bores (2).

Install blanking plug (1) in bore (2).

(-) Installing side-stand pivot mount with side stand

(-) Securing oil lines

(-) Securing wiring harness to engine

Connect plugs (1) for the direct ignition coils.

Install earth lead (2) with screws (1).

Connect plug (4) for the alternator.

Hold cable (3) for the starter in position.

Installing complete radiator

11 00 209 Oil change, engine, with filter 3 FRUs

Removing threaded plug, sump plate

Removing oil filter

Drain off all the engine oil.

Pouring in engine oil

Installing threaded plug, sump plate

Installing drain plug for oil pan

Pouring in engine oil