BMW K 1100 LT/RS manual

BMW AG Moto rcycle Division After Sales K 1100 LT/RS Repair Manual[...]

Published by BMW AG Motorcycle Division After Sales UX-VS-2 All rights reserved. Not to b e reprinted, translated or d uplicated either wholly or in par t without prior written permission . Errors and omissions excepted; subject t o technical amendment. Produced in Germany 5/99[...]

Introduct ion This repa ir manual w ill help you to p erform all the ma in maintenance and rep air work correctly and efficient- ly. If it is consulted regularly by worksho p personnel i t will form a useful addi tion to the theoretic al and prac- tical knowledge acquired at the BMW Training Centre. It is a contrib ution towards achieving e ven hig[...]

Usage Each chapter starts with the list of contents. The list of contents is foll owed by the Technical Data table. Chapter 00 “Maintenance and general instructions” details the handover checklist and lists all tightening torq ues and operati ng fluids . Key to sy mbols In this Worksho p Manual for the K 1200 L T model, the following symbols ar[...]

Order No. 01 71 9 799 131 UX-VS-2, 12/9 8 Printed in Germa ny Customer Registration No. Order No. Signature o f mechanic BMW Inspe ction 1 000 km / 600 mls BMW Ser vi ce 10 000 km/ 6000 miles BMW I ns pec tio n 20 000 km/ 12 000 mile s BMW Annual Serv ice Change oil when engine at regular operating temperature, renew oil filter element 1) Change oi[...]

Order No. 01 71 9 799 131 UX-VS-2, 12/9 8 Printed in Germa ny Customer Registration No. Order No. Sign ature of mec hanic BMW Pre- deli very c heck Inspect crates on receipt for signs of damage Motorcycle: – unpack – check scope of delivery – install front wheel –c o m p l e t e –c l e a n Batte ry: –r e m o v e – add battery acid –[...]

00 Maintenan ce and gen eral instruct ions ....... ..... ........ ..... ...... ....... ...... ..... 00.1 11 Motor ........ ..... ..... ........ ..... ..... ..... ...... ..... ..... ........ ..... ..... ..... ...... ..... ..... ..... ... 11.1 12 Eng ine elect rics ........ ..... ..... ..... ...... ..... ..... ..... ........ ..... ..... ...... ..... [...]

33 Rear wheel drive .. ....... ...... ..... ........ ..... ........ ..... ..... ........ ..... ..... ........ ..... ... 33.1 34 Brakes ........ ..... ........ ..... ...... ..... ..... ..... ..... ...... ....... ...... ..... ..... ..... ..... ...... ..... 34.1 36 Wheels and tyre s ....... ..... ........ ..... ..... ........ ..... ..... ........ ....[...]

00.1 Contents Page 00 Tightening torque ............. ..... ..... .... ........ ..... ..... ..... .... ........ ..... ..... ..... ....... ..... ..... ..... ....... ..... ..... .....3 Table of operating fluids ........... ..... ..... ..... ....... ..... ..... ..... ....... ..... ..... ..... ....... ..... ..... ..... ..... ....... . 10 Key to mainten[...]

00.2 Contents Page Checking function of electric switch on side stand and adjusting if necessary ............ ..... ..... ..... ........ .... ..... ..... ........ ..... .... ..... ..... ........ ..... ..... .... .. 17 Inspections I , II, III Checking clutch clearance and adjusting if ne cessary .. ....... ..... ..... ..... ....... ..... ....18 Insp[...]

00.3 00 Tightening torque Model K 1100 LT K 1100 RS Con nect io n Nm 11 En gine Freewheel Cover plate/fr eewheel cage at countershaft gear 10 Oil – water pump Oil pressur e switch 40 Temperature sensor/screw plug 9 Pressure r elief valve 40 Impeller 3 3 Pump housing to cr ankcase 10 Cover to pump housi ng 10 (3-Bon d 1209) Intermediate flange Thr[...]

00.4 Timing chain Chain tensioner 9 Slide rai l at camshaft bearing cap 9 Timing case cover Timing cas e cover 10 (3- Bond 12 09) Cover for Hall- effect signal transmitter 9 Screw pl ug 40 Clutch Clutch housing to output shaft Tighten to Release and re-tighten to Wrench angle 50° 140 50 Housing co ver 19 Alterna tor Alternator to intermediat e fla[...]

00.5 13 Fuel preparation and control Inje cti on ra il 9 Intake s tub pipe 9 Lower section of air cleaner housing 21 Intake a ir line 9 Motronic control unit 5 17 Radi ator Connect ing scr ew, tempera ture se nsor 9 Fastening, t hermostat cover 3 Radiator to frame 9 Coolant stub pipe to cylinder head 9 (w ith Loc tite 243) Temperature sensor to coo[...]

00.6 23 Tra nsmis sion Transmission cover to transmissio n 9 Machine screw for neutral s top 13 Stud bolt, selector shaft 17 (Loctite 24 3) Transmission to intermediate flange 16 Frame mounting to transmission 4 5 Bearing mount to transmission 41 (Loct ite 243) Starter motor to transmission 9 Positive lead to starter motor 5 Fixed beari ng of swing[...]

00.7 32 Steering Clamping screws for handleb ar fitting 5 Clamping screws 22 Clamping block to for k bridge 16 33 Rear wheel drive Threaded r ing 118 (clean thread + Hy lomar SQ 32M) Hexagon nut, drive be vel gear 200 (clean thread + Loctite 273) Housing cover 35 Swinging arm fixed bearing to transmission 9 Swinging arm be aring journal, loose bear[...]

00.8 34 Br akes ABS pulse wheel 4 ABS sensor front/rear 4 Brake caliperto sliding tube/rear wheel drive 40 Brake line to brake calipe r 18 Bleed screws at brake caliper front 14 Bleed screws at brake caliper rear 11 Brake hose to distributor 18 Brake hose to master brak e cylinder 18 Brake disc to front wheel 24 Brake disc to rear wheel drive 21 Fo[...]

00.9 46 Fram e Frame to engine 45 Fairing support bracket to frame 9 Suspension strut to fr ame/rear wheel drive 51 Handlebar to clamping bloc k 22 Clamping screws of fo rk bridge 15 Locking tube 65 Hexagon nut 65 Centre stand to be aring bloc k 41 Side stand to bear ing blo ck 41 Footre st plate 15 Brake line to hand brake cylinder 11 Brake line t[...]

00.10 Table of operating fluids Item Use Order number Quantity Lubric ant Optimoly MP 3 High-performance lubricating p aste 07 55 9 062 4 76 100 g tube Optimoly TA High-temper ature as sembly paste 18 21 9 062 5 99 100 g tube Silicone grease 300 , heavy Damping grease 07 58 9 058 193 10 g tube Retinax A Wheel, steer ing head and taper roller bea ri[...]

00.11 Key to maintenance intervals – Inspection at 1000 k m (600 mi les)I – BMW Service at 10,000 km (6000 miles))II – BMW Inspection at 20,000 km (12, 000 miles)II I – B MW Annual Service IV Changing eng ine oil Inspections I, II, III, I V • [RS] Remove lower section of fairing. • Change oil at operating temperature. • Oil drain pl u[...]

00.12 Changing oil in rear wheel drive Inspections I, III, IV • Drain off oil with drive at operating temperature. • Oil drain pl ug (1) • Oil f iller plug ( 2) L Not e: Fill oil only up to the b ottom-most thread turn of the filler hole. Oil content: Init ial fi lling ........ ..... ..... ..... ....... .. 0 .25 l (0.44 Imp. pt) Oil c hange s[...]

00.13 Renewing fuel filter Inspection III • If necessary, reduce fuel level with pump until fil - ter is clear. • Loosen hose clip (1) and shift toward s filter. • Detach line and remove filter together with line from the fuel tank. • Change fuel filter. L Note: Note direction of fuel flow o n filter. • Reconnect line to pump. • Install[...]

00.14 Checking brake pads, brake discs for wear and renewing if necessary Inspection II, III Fron t w hee l b rak e • Remove rear section of mudguard. • Remove brake ca lipe r. L Not e: It is not nece ssar y to releas e the brake lin e at th e brake caliper if only the bra ke pads are to be changed. • Drive out retaining pin (1). • Remove b[...]

00.15 Checking brake fluid level and cor- recting if necessary Inspections I, II, III Checking brake fluid level L Note: When checking front brake fluid level, the cove r of the brak e fluid reservoi r mus t always be hor izontal (see SI 00 027 95 (716 )). Adding brake fluid • Take off the reservoir cover together with the diaphragm L Note: When [...]

00.16 Renewing brake fluid Renewing front brake fluid • Remove the break pads e Caution: Do not tilt the bra ke caliper wh en removing or in stall- ing, or the br ake pa ds c ould be damag ed. • Take off the brake fluid reservoir cover com plete with the diaphragme. • Add br ake fluid . e Caution: While renewing the brake fluid, its le vel mu[...]

00.17 Checking function of electric switch on side stand and adjusting if nec- essary Inspections I, II, III • Place motorcycle on centre stand on even sur- face or lifting platform. • Spray sw itchi ng kinemati cs of the side stand wi th quick- actio n cleaner and fo ld in and out se veral times. • Complet ely f old out si de st and and m ar[...]

00.18 Checking clutch clearance and adjusting if necessary Inspections I, III • Detach cl utch cable at clutc h release lever (1). • Slightly pu sh back ru bber sleev e (2). • With the aid of setting gauge, B M WN o .2 135 0 0 ,set dimension “b” with ad- justing screw at clutch hand lever. Dimension “ B ” ..... 75 ± 1 mm (2.95 2 ± 0[...]

00.19 Checking increased starting speed (choke) and adjusting if n ecessary Inspections I, III Checking increased starting speed • Remove the left b attery cover. • Move the increased star ting speed devi ce up to its limit stop (stage 2). e Caution: Screw (2) i s secured wi th lacq uer and must not be reset. L Note: Stop face (1) must make con[...]

00.20 Checking valve clearance and adjusting if necessary Inspections I, III e Caution: Never un screw the spark plu gs before mea suring the valve clearance. Carbon particles may settle be- hind an exhaust valve head and fals ify the measured result . • [RS] Remove bottom sectio n of fairing . • Remove left side section of fairing. • Remove [...]

00.21 L Note: Only the bucke t tappets replaced during the 1000 km (60 0 miles) insp ection can be re-used . Installing camshafts • The camshafts are marked to e nsure they cannot be confused. e Caution: Camshaft identification. Inlet: Groove a fter the thr ust bearing Exhaust: No groove • The camshaft bearing caps are also identified. Inlet si[...]

00.22 Installing c ylinder head cover • Screw fitted bolt, BM W No. 11 1 980 , (ar row) into inner hole at the front. • Press centring pin, BMW N o. 11 1 990 , w ith gripper, B M W N o .0 055 0 0 , into locating hole under the third camshaft bearing. • Insert gasket into cylinder head cover. L Not e: Begin installation at the c rescents (1). [...]

00.23 Checking steering bearing play and adjusting if necessary Inspection III • Place a piece of adhesive tape (arrow) on the fork bridge above the setting ring (1). • Mark current position o f setting ring (1) on the adhesive tape and on the setting ri ng (2). • Slide thru st rin g (3), BMW No. 31 4 890 , over the locking tube (4 ). • Loc[...]

00.24 Lubricating guide pins, adjustab le screen Inspections III, IV • Release retaining screw (1) on both sides. • Slightly r aise plate (2). • Spra y guid e pi ns (3 ) wi th silico ne s pray. LT000260 2 1 3 3[...]

00.25 Checking idle speed, synchronising and CO value and adjusting if nec- essary Inspections I, II, III, I V L Note: The basic settings (ignition, valve cl earance) must be correct. Adjusting idle speed • Rem ove kn ee pa d. • Remove left side section of fairing. • Remove caps (1) at the vacuum c onnections. • Connect hoses of the synchro[...]

00.26 Adju sting CO va lue witho ut cata lyt ic conv erter L Not e: Engine must be at operating temperature (85 °C). The basic se ttings (ignition, valve clearance) must be correct. • Insert test probe (arrow) appr ox. 30 cm into the silencer. e Caution: Do not take this measurement in an enclosed space; risk of asphyxi ation. L Not e: If unsuit[...]

11.1 Contents Page 11 Techn ical data .......... ....... ..... ..... ..... ..... ....... ..... ..... ..... ....... ..... ..... ..... ....... ..... ..... ..... ..... ........ .... ..... .. .5 Removing engine ...... ..... ..... ..... ....... ..... ..... ..... ..... ....... ..... ..... ..... ........ .... ..... ..... ........ ..... ..... .... ..... . [...]

11.2 Contents Page Removi ng pi stons wi th c onrods, st ripp ing down and re -assem bling ........... ..... ...26 Removi ng pi ston with c onro d ....... ..... .... ........ ..... ..... ..... ....... ..... ..... ..... ....... ..... ..... ..... ..... ....... .... ... ..... . 26 Disman tling p iston ......... ..... ..... ..... ....... ..... ..... ..[...]

11.3 Contents Page Insta lling timi ng chain ............. ..... .... ..... ..... ........ ..... .... ..... ........ ..... ..... .... ........ ..... ..... ..... ..... ....... ...44 Checking valve cle arances ....... ....... ..... ..... ..... ....... ..... ..... ..... ....... ..... ..... ..... ..... ....... ..... ..... ..... ...45 Installi ng interm[...]

11.4[...]

11.5 11 Technical data K 1100 LT K 1100 RS Engine, general Engine design Inline four-stroke engine installed longi tudinally, with double overhead ca mshafts, liq uid cooling and electronic fuel injection. Location of engine number At lower rear right of engine block Cylind er bo re mm (in) 7 0.5 ( 2.7 7) Strok e mm (in ) 70 (2.7 5) Number of cylin[...]

11.6 Valves Valve clearances with engine cold (max. 35 °C) Inlet valve mm (in) 0.15…0.2 0 (0.005 9…0.0079) Exhaust valve mm (in) 0.25…0.3 0 (0.0098…0. 0118) Valve timing at 5/ 100 mm (0.002 in) preload and 3 mm (0 .118 in) l ift Inlet opens 14° after TDC Inlet closes 18° after BDC Exhaust opens 18° before B DC Exhaust closes 14° before[...]

11.7 Valves Valve guide dia. Extl. dia. mm (in) 11.533 …11.544 ( 0.4541…0 .4545) Intl. dia. mm (in) 6.0…6.012 ( 0.2362…0.23 67) Wear limit mm (in) 6.1 (0.240 2) Bore in cylinder head mm (in) 11.5…11 .518 (0.4528…0. 4535) Repair stag e mm (in) 11.7…11 .718 (0. 4606…0.4613 ) Valve stem clearance Inlet mm (in) 0.025…0 .052 (0.001…0[...]

11.8 Crankshaft Main bearing and crankpin m arkings no colour spot Grinding stage 0 with colour spot G rinding stage 1 Wid th of gu ide beari ng mm (in) 23.020…23 .053 (0. 9063…0.9076 ) Axial play mm (in) 0 .080…0.183 ( 0.0031…0 .0072) Wear limit mm (i n) 0.250 (0.010 ) Main bearing dia. Grin ding stage 0 mm (in) 44.976…45 .000 (1. 7707?[...]

11.9 Piston rings 1st groove Rectangular -section Height mm (in) 1.175…1.19 0 (0.0462…0. 0469) Wear limit mm (in) 1.100 (0.0 433) Ring gap mm (in) 0.20…0.40 (0.0 079…0.0157) Wear limit mm (in) 1.50 (0.059) Side clearance mm (in) 0.040…0.075 (0. 0016…0.0030 ) Wear limit mm (in) 0. 30 (0.0118) 2nd gr oov e Mic ro- cha mfe r Height mm (in)[...]

11.10[...]

11.11 Removing engine • Remove fuel tank. • Rem ove kn ee pa ds. • Remove fuel tank. • Remove lower section of fair ing at left and r ight. • Remove r adiator surr ound. • Drain coolant. • Remove radiator . • Attach hoist, BMW N o. 00 1 510 , to o il sump . • Remove rear shield plate with coolant level equalising tank. • Remove [...]

11.12 Dismantling engine • Remo ve a ir c lean er bo x. • Remove fuel inject ion rail. • Remove throt tle rail . • Attach engine mount, BMW N o. 11 0 610 , to the eng ine bl oc k. • Lower the hoist and support the engine on as- sem bly st an d, BMW No. 00 1 490 . • Remove the hoist. • Drain the oil. LT110050 LT110060 11 0 610[...]

11.13 Removing in termediate flange • Remove alternator. • Remove coils with holder. Removing driv er • To remove the screw, support the driver (ar row). • Pull the driver off by hand. LT110070 LT110080[...]

11.14 Removing clutch h ousing • Install the retaining device ( arrow), B M WN o .1 128 0 0 , in the position illustrated. • Unscrew hex n ut (1) and take off thrust rin g (2). • Push O-ring (3) forwards with the clutch housi ng an d remo ve wit h a hook . • Pull out clutch housi ng (4), noting the presence of th rus t wash er (5). 12 3 45 [...]

11.15 Strippi ng down and re-asse mbling interm ediate flange Removing the driver bea ring • Bearing pl ate (1) • Cup spri ng (2) • Pull ou t ba ll be aring (3) with co unte r-su pport, BMW No. 00 8 572 , and internal puller 21/2, BMW No. 00 8 571 . • Seeger circlip (4) Installing driver bearing • Heat the intermediate flange at the beari[...]

11.16 Removing and ins talling s haft sea ling ring for driv er • If the interm ediate flange has b een removed, le- ver out the sealing ring. • If the intermediate flange is ins talled, pull out the sealing ring with an internal puller, B M WN o .0 050 1 0 , and press ure head. • Pre-shape the sealing ring, which must be dry, with the thumb [...]

11.17 Dismantling and assembling freew heel Stripping down freewheel • Pull freewheel gear (1) off layshaft (5). • Clamp the layshaft into a vice with soft jaws (smooth side down ). • Remove c over pl ate (2) . • Pull off freew heel cage (3). • Take o ut cup spring (4). • Pull needle roller bearing (6) out of the freewheel gear with cou[...]

11.18 • Place the cup spring in position. • Insert the freewheel ( oiled with engine oil) into the outer race. • Install the outer rac e (with cl amp block fac ing cover plate); the cup spring must snap into the outer race. • Place the cover pl ate in position. X Tightening tor que: Retaining screw s ...... ........ .... ..... ..... .......[...]

11.19 Remo ving timi ng chain cover Removing th e Hall-effect sig nal tra nsmitter • Rem ove co ver (1). • Take off ga sket (2 ). • Remove Hall-effect signal transmitter (3), noting the semi-circular shim washers. L Note: Mark the corr ect installed position of the adjusting washer on the engine block, or remove it in the TDC positi on. • R[...]

11.20 Removing the t iming chain • Set cyl inder 1 (timi ng end) to T DC, no ting d irec- tion of ro tation (arrow) . Pin (1) on the crankshaft must be aligned with t he marki ng on t he hous ing. Rem ov ing cha in te ns ion er • Secure chain tensioner (1) with clamp, B M WN o .1 155 0 0 , (arro w) and remove i t. 3 2 1 4 LT110230 11 5 500 1 LT[...]

11.21 Removing ca mshaft chain sprockets • When taking out t he retaining screws, hold the hexagon on the camshaft to prevent it fr om turn- ing. • Rem ove ch ain guide (1) . 4 2 3 LT110260 1 LT110250 Removing chai n guide • Remove keeper s (2) and washers (3) at the pivot pins. • Raise chain gui de (4) slightly at the cylinde r head and pr[...]

11.22 Removing , strippi ng down and assem- bling cylinder head Removing camshafts • Remo ve t he bear ing cap s (1 ) fo r th e th rust bea r- ings first, to prevent tilting. • Release tension uniformly at radial bearin g caps (2) and remo ve them. • Take out the camshafts. Removing cylinder hea d • Unscrew the cylinder head bolts ( 3) with[...]

11.23 Removing val ves • Screw suppo rt plate, BM W No . 11 1 74 9 , for the valve spring clamping tool on to the rear of the cylinder head . • Attach valv e spring clamp ing tool, BMW No. 11 1 740 . • Use pressur e cage ( 1), BMW No. 11 1 748 . • Place the cylinder head flat on a wooden board and clamp the valve spring. • Pull valve coll[...]

11.24 Installing v alve and valve st em seal L Not e: If a valve was remov ed, the valve stem seal must be renew ed. • Oil the stem when installing the valve. • Insert the lower spring plate. • Push assembly sleeve (arrow), B M WN o .1 119 6 0 , on to the valve stem. • Drive in se aling ring (1) with dri ft, B M WN o .1 156 0 1 , until the [...]

11.25 Removing crankshaft Removing big end bearing s • Move the piston in cylinders 1 and 4 to the bot- tom dead centr e (BDC) position. • Remove the big end bearing caps. L Note: Push p rotect ive tube (1) ( app. 5 0 mm (2 in) lon g) o n to big end bolts. • Repeat the work s equence at cylin ders 2 and 3. Removing main bearings • Take out [...]

11.26 Removing pistons with conrods, strip- ping down an d re-assem bling Removing piston with conr od • Press the piston with conrod out from the crank- shaf t sid e. Dism antli ng pist on • Remove the circlip (1) at one side. • Press out pis ton pi n (2) with d rift, B M WN o .1 129 3 0 . • Care full y remo ve p iston r ings (3). • Clea[...]

11.27 Assembling pi stons • Install piston ri ngs, using piston- ring pliers . 1st groove: rec tangular-section ri ng 2nd groove: mi cro-chamfe r ring (note pin for ri ng g ap and TO P mar ki ng). 3rd groove: equal-chamf er ring with tu bular spring , (note TOP m arkin g). L Note: The tubul ar spri ng gap must b e offset by 18 0° from the equal-[...]

11.28 Assem bli ng pi ston s and con rods L Not e: [LT] Modified conrod length and pistons from 1993 model year on • Comply wi th conrod we ight toleran ces. Weigh t toleranc e . ..... ........ .... ..... ..... ..... ........ .... ± 4 g • Assemble piston and conrod . L Not e: The oil bore in the conrod eye is on top in the in- stalled po sitio[...]

11.29 Removing, dismantling a nd assem- bling c ombined oi l-water p ump Removing pump • Pull off the wires for the oil pressure and water temperature display at the switch. • Pull the wires ou t of the housing. • Remove housing cover (2) and loosen the gasket with lig ht blows of a plastic- faced ham mer. • Remove the housing and loosen th[...]

11.30 Removing slipri ng seal an d shaft sea ling ri ng • Pres s out s lipri ng seal (6 ) with a drift. • Using a 5 mm (0.2 in) w ide screwd rive r, carefu lly press out sealin g ring (5). Removing pressure relief valve • Loosen threa ded union ( 12) and p ull out sprin g (13). • Pull valve piston (1 4) out with a magnet and ex- amine it fo[...]

11.31 Removing output shaft Removing oil sump • After removing the screws, loosen the seal with light blows of a plastic-faced hammer. Removing oil filter • Unscrew oil filter (1) with the oil filter wrench, BMW No. 11 4 650 . Remov ing l ower se ct ion of crank case • Take out retain ing scr ews and screws (3) holding the output shaft. • W[...]

11.32 Stripping and assemb ling output shaft Stripping down output shaft • Take off needle rol ler race (1) and circlip (2) . • Pull output shaft (3) out of damper housing (4). • Drive the output shaft out of the inner section of the damper ( 5) with a p lastic-faced hammer. Stripping down tensioning gear • Clamp the damper housing into a v[...]

11.33 Assembling tensioni ng gear • Insert the tensioning spri ng. • Install tensioning gear with counter-holder, BMW No. 12 4 600 . • Clamp the tensioning gear with damper housing together into a vice with soft jaws. • Measure distance “a” from ball bearing seat to ten sio nin g gea r. • Place a suitable spacing wash er (arrow ) on t[...]

11.34 Assembling engine Installing output shaft • Push circlip (1) and needle ro ller sleeve (2) on to the bearing point. • Place the output shaft in the crankcase. L Not e: Gap of ci rclip (1) in crankcas e (arrow ). 1 2 LT110510 1 KR110521[...]

11.35 Assemblin g the crankc ase • Install O -rings (6,7) for the water and oil passag- es. • Coat the sealing faces (which must be free fr om oil and grease) lightly with 3-B ond-1209 . • Place the two halves of the housing together. • Screw in bearing bolts (4, 5) for the shouldered and needle roller bear ings, and tighten alternate- ly. [...]

11.36 Measur ing cran ksha ft b eari ng pla y Meas ur ing ra di al pla y • Crankshaft beari ng points must be clean and lightly oiled. • Place the crankshaft in the crankcase and install the bearing caps so that the joint lines are aligned. L Not e: Bearing caps 1…3 are marked; bearings 4 (thrust bearing) and 5 are not marked. • Tighten the[...]

11.37 Measuring endplay • Install the crankshaft and measure as for radial play. • Screw measuring fixture, BMW N o. 00 2 5 00 , with di al gauge into the tapped hole for the timing case cover. • Move the crankshaft from one limit to the other and take the dial gauge reading. Axial play ..... 0 .080…0. 183 mm (0.0031…0. 0072 in) Wear limi[...]

11.38 Installing crankshaft • Oil the bearings lightly before inserting the cran k- shaf t. • Install th e corresp onding bear ing caps with the grooves ali gned. L Not e: Bearing caps 1…3 are marked for identification; bearing caps 4 (thrust bearing) and 5 ar e not marked . • Tighten the bearings in the order shown, starting fro m the cen [...]

11.39 Instal ling p ist on with conr od • Turn the corresponding crankp in to bottom dead centre. • The piston ri ng gaps must be offset by app. 120° in e ach ca se. L Note: The gap of the m icro-chamfer ring in groove 2 is de- termined by the pin. • Oil the piston rin gs, piston skir t and cylin der wall thoroughly. LT110590 • Using tensi[...]

11.40 Measuring big end bearing play • Turn the crankpin 30° away from bottom dead centre. • Wipe oil off cran kpin and bearing c ap. • Place Pl astig age str ip (arr ow), Type PG-1, B M W N o .0 025 9 0 , ov er the entir e width of the bearing, 6…8 mm (0.2 4…0.32 in) aw ay from the centre of the crankpin. • Attach the bearing caps wit[...]

11.41 Installi ng combined oil- water pu mp • Apply a thin coat of 3-Bon d 1209 to the sealing faces, which must be free of o il and grease. • Place O-ring on water passage. • Insert the input pinion into the output shaft with an oiled O-ring. • Attach the pump housing and insert the sc rews loosely at first. L Note: Turn the c rankshaft s [...]

11.42 Installing cyli nder head • Move the piston in cylinder 1 to top dead centre (cylinde r 1 = timing end) . • Place the cylinder head gasket in position; no holes or passages must be o bstructed. L Not e: Use only cylinder head bolts with long thread [from 12/9 4] . • Place the cylin der head in position and insert bolts (1) with wash ers[...]

11.43 Installing camshafts L Note: Note correct identification of camshafts. Inlet side : three grooves after thrust bearing Exhaust side: two gr ooves after thrust beari ng • The camshaft bearing caps are also marked. Inlet side: o dd n umber s Exhaust side: even numbers • The numbers increase from the front ( timing end) to the rear. • Oil [...]

11.44 Installi ng timing ch ain • Turn the camshaft so that the grooves on the ends are vertical in relation to the cylinder head at the rear. • The grooves at the front end must point towards the crankshaft. • Insert adj usting tool, BMW No. 11 3 70 0 , and at- tach it to the camshaft b earings. • Place the timing chain in guide rail (1) a[...]

11.45 • Press serrated washer (8) with eccentric shoul- der into the chain gu ide rail spacing b ushing by a small amount. • Turn the serrated washer until the guide rail is touching the outer edge of the cylinder head. • Press the serrated washer in fully and allow it to engage at the two pins. • Secure the serrated washer with the small w[...]

11.46 Installing intermedia te flange Installing f reewheel • Insert the freewheel into the crankcase with the helical-cut gearwh eel leading. • Oil the needle roller bear ing well. Installing c ountershaft • Insert countershaft (1) into the crankcase with the small gearwhee l f acing d ownwa rds. • Insert sprin g (2) with the larg er exter[...]

11.47 Installing ti ming case cov er • Apply a thin coat of 3-Bon d 1209 to the sealing faces, which must b e free from oil and grease. • Pass the wires for the telltale lights (oil pressure, coolant temperature) through the cabl e duct (ar- row) . • Place the timing case cover in position and tight- en it. X Tightening to rque: Timing case c[...]

11.48 Installing cover for Hall-effect transmit - ter • Install the wire for the Ha ll-effect transmitter with rubber grommet ( arrow) in the timing case cover. • Secure the wire for the oil pressure telltale and coolant temperat ure with cli p (1). • Install cov er wi th cork gas ket. X Tight ening torq ue: Cover ........ ..... ..... ..... .[...]

11.49 Installing cy linder head cover • Inser t reamed bolt (a rrow), BMW No. 11 1 980 , into inner front hole. • Press centering pin, BMW No . 00 5 50 0 , into mount under the third camshaft bearing. • Install the cylinder head cover gasket with the half-moon cutouts first. The marks at the front and rear of the gasket and the cylinder head [...]

11.50 Installing engine • Attach hoist, BMW No. 00 1 5 10 , to the oil sump. • Set the engine down on the hoist platform. • Release the engine mounting at the engine block. • Install the throttle rail. • Install the inner bulkhead at the cylinder (3). • Install the lower section of the air c leaner hous- ing. • Install the fuel return[...]

11.51 • Connect the engine wiring harness (coolant stub pipe, throttle position sensor, CO detector, injec- tors, air cleaner housing). • Attach cable st raps (thr ee) at fuel injecti on rail. • Attach wire cables fo r increased idle speed and throttle opera tion. Throt tle cable p lay ............ ..... ..... . 0.75 m m (0.0 3 in ) • Insta[...]

11.52 Checking/adjusting valve cle ar- ances e Caution: Never un screw the spark plu gs before mea suring valve clearances. Particles of oily s oot cou ld be- come lodged behind an exhaust valve head and fal- sify the measurement. • Remove left side section of fairing. • Remove the cylinder head cover. • Remove cover for Ha ll-effect tr ansmi[...]

12.1 Contents Page 12 Techn ical data ...... ..... ..... ..... ....... ..... ..... ..... ..... ....... ..... ..... ..... ....... ..... ..... ..... ....... ..... ..... ..... ..... ....... . . 3 Removing and installing Hall gene rator ........ ..... ..... ..... ........ .... ..... ..... ........ ..... ..... .... ..... ... 5 Adjusting ignition timing [...]

12.2[...]

12.3 12 Technical data K 1100 LT K 1100 RS Start er Type Permanent magnet motor Gear ratio 27 : 1 Output k W 0,7 Altern ator Type Three-phase alternator with integr ated fully elec- tronic regulator Drive direct, gear ratio 1 : 1.5 Maximum output W/V 460 /14 / – 700/14 from Mod.93 Max. curr ent A 33/ – 50 Mod.93 Charge cut- in rpm 950 ± 50 Max[...]

12.4[...]

12.5 Removing and installing Hall gene r- ator • Disconnect ground lead o f battery and insulate. • Remo ve rad iato r cowlin g. • Remove fuel tank. • Disconnect Hall generator (1) plug connection. • Remove cover (2) t ogether with gasket ( 3). • Rem ove ba se pl ate (4 ). • Remove rotor (5) and setting plate (6). L Note: Mark install[...]

12.6 Adjusting ignition timing • Remove radiat or cowling. • Remove bottom left fairing. • Remove fuel tank. • Disconnect plug connection on Hall generator lead under the fuel tank. • Connect adapter lead (2), B M W N o .1 236 5 1 , to Hall generator lead. • Connect ignition setting device (3), B M WN o .1 236 5 0 ,to adapter line. • [...]

12.7 • Loosen base plate (1 ) and turn to the left or rig ht until diode (2) on ignition setting device goes out. L Note: Ignition timing adjustme nt Turn to left Retard ignit ion Turn to righ t Ad vance ig nition • Firmly tighten base plate. • Check ignition timing: Cran k en gine in normal di recti on. The d iod e on the ignition setting de[...]

12.8 Removing and installing ig nition coils • Disconnect earth (ground ) lead of batte ry and in- sulate. • Remove top (1 ) and bottom (2) ig nition coil cover. • Disconnect plug connecto r (3) at the ignition coil s. • Disconnect plug connector (4) for terminal “1” and “15”. • Release earth (ground) connection (5) on starter. ?[...]

12.9 Removing and installing ignition output stage • Remove left battery bracket. • Disconnect earth (ground) lead of battery. • Remove ignition coils. • Remove ignition output stage (1). • Press retaining clip (2) and detach ignition output stage. • Install in the reverse order of removal. L Note: Before installing the ignition output [...]

12.10 Removing and installing a lternator • Remove right batte ry panel. • Remove Motronic control uni t. • [ABS I ] Remove ABS control unit. • Remove battery. • Remove cover (1). • Disconnect pl ug (2). • Remove alternator. • Install in the reverse order of removal. X Tight ening torque: Alternato r .. ............. ...............[...]

12.11 Disassemb ling and assembling alternator Alterna tor [only LT up to 1992 model year] • Remove damper elements (1) • Remove coupling housing (2) with holding tool (3), BMW No. 12 4 600 . • Pull off fan w heel (4). • Remove key (5 ). • Release retaining screw ( 6) for bearing end p late. • Clamp alternat or in vice wi th jaw guards.[...]

12.12 • Remove regul ato r (8) with carb on brus hes . • Carefully lift out armature (9) together wit h bear- ing (10). • Remove bear ing (10) fr om armatur e shaft. • Unsolder stator (11) on diode plate (12 ); mark the wires. • Remove diode plate. • Remove O-rin g (14). • Install in the reverse order of removal. L Not e: During assem[...]

12.13 Checkin g armature f or shor t to earth • Measure resistance b etween slip rings and ar- mature. L Note: The resistance must be infinitely large. Measurement r esult: ..... ............. .... OL = ope n line Checking resistance between phase outputs • Check res istance between each pair of o utputs. 1 – 2 1 – 3 2 – 3 Nomina l resist[...]

12.14 Altern ator [LT from 1992 model year on, RS] • Remove fastening screws (1) from cover. • Release clips (2 ) and take off co ver. • Remove volta ge regul ator (3) . • Remove coupl ing housing (4), using counter - hold er, B M WN o .1 246 0 0 . • Assembl e in the r evers e order of wo rk. X Tightening t orque: Coupl ing h ousing .....[...]

12.15 Checking alternator L Note: Before measuring the resistance with the BM W di- agnostic tester, this must be zeroed: Connect the positive (yellow) and negative (green) leads. Press the Ω key until the d igital display s hows 0.00 Ω. • Using BMW diagnostic tester, BMW No. 61 1 510 , measure the resistance be- tween the sliprings. Measured[...]

12.16 Removing and installing starter • Remove control unit. • [ABS I ] Remov e con tr ol uni t. • [ABS II] Drain fro nt and rea r brake system s. • [ABS II] Remove press ure mod ula t or. • Remove battery. • [ABS II] Take off batte ry carrier. • Release earth (grou nd) co nnection (1 ) at starter. • Release positive lead at starter[...]

12.17 Disassembling and assemb ling starter • Clamp starter at retaining lugs in vice wi th jaw guar ds. • Release retaining bolts (1). • Detach bearing cap (2). • Check se al (3) an d O-ring (4 ). • Pull out armature (5). • Note space r washer (6) • Check O-ri ng (10). LT120160 2 3 4 5 6 1[...]

12.18 Removing and inst alling brush holder 1. Hexagon nu t 2. Outer in sula tor 3. Carbon brus h hold er 4. Brush reta ining plate 5. O-ring 6. Inne r in s ul ato r LT120170 5 1 4 3 6 2[...]

12.19 Renewing carbo n brushes • With the aid of a small screwdriver, lift spring (1) and pull ou t carbon brus h. L Note: Fit carb on brush so th at the cham fered side (ar row) faces t owa rds the s pring. LT120180 1[...]

12.20 Checking starter • Connect voltmeter between positive and nega- tive pole of b attery. • Operate starter for 2...3 seconds. • Read off value. L Not e: If the read-of f valu e is be low 8 V olt, this indic ates t he battery does no t have its full capacity . Note do wn value if me asured v alue is ab ove 8 Vol t. • Connect voltmeter be[...]

12.21 Checki ng starte r relay • Connect terminal 86 to positive batte ry terminal, terminal 85 to earth (ground ). L Note: The relay is defe ctive if no swit ching n oise can be heard. Check r esistan ce if clear s witch ing no ise c an be heard. Checkin g starter r elay wi th ohmmeter • Connect p ositive lead f rom meas uring i nstru- ment to[...]

12.22 Troubleshooting Troubleshooting on alternator Altern ator mak es noises . Do carbon br ushes whistl e? yes Rework slip ring s/rep lace c arbon b rush es. Battery produces excessive gas (vapour) no Check contact between r egulator/alternator and between alter nator/diode carrier. Is contact poor? yes Repair cable connections. no Chec k reg ula[...]

12.23 Indicator lamp lights at only ha lf brig htness intensity when eng ine running . no Check contacts of cable connections. Do cable con nections have poo r contact. yes Repair cable connections/pl ug contacts. no Check reg ulator. Is regulato r defective? yes Renew regulator . no Check carbon brushes . Are carbon brushes defective? yes Renew ca[...]

12.24 Indica tor lamp ligh ts at half or full bright ness with engine running. no Chec k reg ulat or. Is reg ulator de fecti ve? yes Renew regu lator. no Check supply line. Does supply line have break /short circuit? yes Rep air bre ak; renew cable/connection elements. no Chec k ca rbon bru shes. Are carbon brus hes defecti ve? yes Renew carbon bru[...]

12.25 Indicator lamp does not light when engine is stat ionar y and ign ition switched on . no Check indicator lamp. Is lamp d efective? yes Replace in dicator lamp. no Check battery. Is battery di scharged/def ective? yes Charge/renew batte ry. no Check alternator. Has generator short at pos itive diod e? yes Immediately disconnect charg e line (d[...]

12.26 Troubleshooting on starter Starter do es not turn when sta rt switc h is operated. no Switch on li ght. Does light operate? no Check battery. Is battery d ischarged, defective? yes Charge or renew bat tery. no Chec k pow er cir cuit . Does power circui t have a break? yes Rep air bre ak.[...]

12.27 Starter does no t turn whe n star t switch is operated. no Switch on lig ht. Does li ght operate? yes Connect jumper at connection betwee n termi- nal 50 and 30. Does starter turn? yes Check ignition s witch and supply line. Is ignitio n switch de fective? yes no R eplace ignition switch. yes Is there a b reak in supply line? yes Repair break[...]

12.28 Star ter turn s too slo wly, does n ot cran k en- gine. no Check battery vo ltage. Is battery v oltage too low? yes Charge battery, replace if necessary. no Check battery terminals. Are terminals loose or oxidised? yes Clean poles and terminals, firmly tighten. no Check connections. Are connections loose? yes Secure connecti ons. no Check col[...]

12.29 Troubleshooting on battery Battery produces excessive gas. no Check battery. Is battery defective? yes Renew battery. no Check contact between regulator/alternator and between alt ernator/di ode car rier. Is contact poor? yes Repair cable connections. no Check reg ulator. Is regulato r defective? yes Renew regulator . Acid level too low. no C[...]

12.30 Acid den sity too l ow. nein Check charge status of battery. Is battery discharged? yes Charge battery. no Check acid concentration. Is acid concentration to o low? yes Adjust acid concentration . no Check line network. Is there short-circuit in line network? yes Check electrical system. no Check alternator. Alternator does not charge correct[...]

12.31 Insufficient po wer output no Check connection terminals. Are terminals loose/oxidated ? yes Clean/tighten terminals. no Chec k a cid leve l. Is level below top edge of plates? yes Top up with dis tilled wat er. no Check charge status. Is cha rge too low? yes Charge battery/replace defective battery. Battery co nstantly o vercharged. no Check[...]

12.32[...]

13.1 Contents Page 13 Techn ical data ...... ..... ..... ..... ....... ..... ..... ..... ..... ....... ..... ..... ..... ....... ..... ..... ..... ....... ..... ..... ..... ..... ....... . . 3 Adjusting idle speed ......... ..... ..... ..... ....... ..... ..... ..... ....... ..... ..... ..... ..... ....... ..... ..... ..... ........ .... ..... ...5[...]

13.2[...]

13.3 13 Technical data K 1100 LS K 11 00 R S Inside ø of throttl e stub pip e mm (in) 35 (1 .37795 ) CO value % b y vol. 1,5 ± 0,5 Idle speed rpm 950 ± 50[...]

13.4[...]

13.5 Adjusting idle speed L Note: The basic setting (ignition, valve clearance) must be correct. • Rem ove kn ee pa d. • Remove left side fairing. • Remove protective caps (1) at the vacuum con- nections. • Connect connection hoses of the Synchrotester, BMW No. 13 0 800 , one after the other (note hose markings 1-4 on tester housing). • C[...]

13.6 Checking start speed increase (choke), adjusting if necessary Checking star t sp eed increase • Remove left battery cover. • Set speed increase to limit stop (stage 2). e Caution: Scre w (2) i s seal ed with lacq uer an d mus t not b e turn ed . L Not e: Stop fa ce (1) must be in contac t with screw (2 ) and the cable must have no play; if[...]

13.7 Adjusting CO value L Note: Engine must b e at op erating temp erature ( 85 °C). Basic settings (ignition timing, valve clearances) must be correct. • Insert the measuri ng probe (ar row) app. 30 cm (12 in) into the silencer (muffler). e Caution: Do not perform this measuring work in an enclosed space: risk of asphyxi ation. L Note: If the a[...]

13.8 Removing/installing and checking/ adjusting throttle position sen sor Removing and instal ling throttle posi - tion sen sor • Unscrew the throttle p osition sensor and pull it off the throttle shaft. • Loos en wi re k eeper (1 ) and pull off m ulti- pin pl ug (2). • Install in the rev erse order of work. e Caution: If the throttle po sit[...]

13.9 Removing and installing air cleane r insert • Remove both kn ee pads. • Remove fuel tank. • Remove left and right heat-insulating bulk head. • Release fron t clip (1) an d both rear clips (2). • Slightly raise top section of air cleaner housing and remove air cleaner element. L Note: Note installed position of air cleaner element: le[...]

13.10 Removing and installing a ir cleaner housing • Remove bot h knee pads. • Remove fuel tank. • Remove left and right sid e fairings. • Remove intake air guide. • Remove fairing retaini ng bracket on right. • Remove air cleaner. • Loosen wi re retainer (1), disconne ct multi plug (2) at air temperatur e sensor. • Release hose cli[...]

13.11 • Loose n an d pull of f oil r eturn pi pe (5 ). • Loosen and pull off air return pipe (6 ). • Pull top secti on of air cleaner hous ing (7) out to the right. • Remove bottom section o f air cleaner housing. • Install in the reverse order of removal. X Tightening torques: Bottom s ection of air c leaner housing ......... . 21 Nm Int[...]

13.12 Removing and installing throttle rail • Remove fuel tank. • Remove left fairing side s ection. • Remove left-hand heat-insulati ng bulkhead. • Release fuel hose (1) at injection rai l. • Release injection rail (2) at cylinder head and pull out together with injectors. • Disconnect multiplug at throttle sens or. L Not e: Only rem o[...]

13.13 Removing an d installi ng injectors • Release wire retainer (1) and detach plug (2). • Release clip (3) at the injector and pull it out. • Install in the reverse order of removal. L Note: Ensure that the O-ring on the injector is in good con- dition! Removing and i nstalling intake stub pipe X T ig htening torque: Intake s tub pipe ....[...]

13.14 Removing and installing M otronic control unit e Caution: Disconnect earth (ground) lead at battery! • Release multiplug (1) and disconnect. • Detach Motronic contro l unit (2). L Not e: Take particular care when connecting the multiplug to ensure the lock engages. X Tightening torque: Control unit ....... ..... ....... ..... ..... ..... [...]

16.1 Contents Page 16 Techn ical data ...... ..... ..... ..... ....... ..... ..... ..... ..... ....... ..... ..... ..... ....... ..... ..... ..... ....... ..... ..... ..... ..... ....... . . 3 Removing and installing fuel tank ........... ..... .... ..... ........ ..... ..... .... ........ ..... ..... ..... ..... ....... .....5 Removing and install[...]

16.2[...]

16.3 16 Technical data K 1100 LT K 1100 RS Fuel tank Tank cap acit y l (Im p.ga l) 22 (4 .84) incl. res erve cap acity l (Imp.g al) 5 (1.1) Fuel pump Type Roller-cell pum p Make Bosch Operating voltage V 12 Fuel pres sur e bar (psi) 2.5 (36. 26) Delive ry rate l /h (gal/ h) 45 (9 .9)[...]

16.4[...]

16.5 Removing and installing fuel tank • Open seat. • Remove left/right k nee pads. • Rem ove re tain in g cli ps (1) . • Release fuel line (2) at fuel tank. • Release fuel line ( 3) at injec tor rail. • Disconnect plug (4). • Lift out fuel tank. • Install in the reverse order of removal. L Note: To facilitate installation, coat rub[...]

16.6 Removing and installing fuel filter • If necessary reduce fuel level with pump until fil- ter is ac cess ib le. • Loosen hose clip (1 ) and slide tow ards fi lter. • Disconnect line and pull filter with line out of the fuel tank. • Change fuel filter. L Not e: Note direction of fuel flow on fi lter. • Reconnect line to pump. • Inst[...]

16.7 Removing and installing fuel leve l sensor • Removing and instal ling fuel level sensor • Remove and emp ty fuel tank. • Remove filler neck. • Release electrical connections (1/2) at the fuel pump. • Pull back insul ation a little and remove fuel level pickup (3) from the outside. • Install in the reverse order of removal. L Note: [...]

16.8 Removing and installing fuel pump • Remove and empty fuel tank. • Remove filler neck. • Release electric al connections ( 1/2) at the fuel pump. • Release hose clips (3/ 4) and detach lines. • Comp ress clips (arr ows) o n ret aini ng ri ng an d pull out pump. • Pull filter (5) off pu mp. • Pull off rubber-metal connection (6) to[...]

16.9 Checking fuel pump pressure • Connect test pressure gauge, BMW No. 16 1 500 , on the delivery side. • Run engine at idle speed. Fuel pressure: Nomi nal value ...... ..... ..... ..... ..... .. 2.5 ba r ( 36.26 psi ) • If the fu el pressu re is lo wer, che ck pu mp, fue l fil- ter and line. LT160050 16 1 500[...]

16.10[...]

17.1 Contents Page 17 Techn ical data ...... ..... ..... ..... ....... ..... ..... ..... ..... ....... ..... ..... ..... ....... ..... ..... ..... ....... ..... ..... ..... ..... ....... . . 3 Changing coolant .......... ........ ..... .... ..... ........ ..... ..... .... ..... ........ ..... ..... .... ........ ..... ..... ..... ....... ..... ....[...]

17.2[...]

17.3 17 Technical data K 1100 LT K 1100 RS Cooling sys tem ca pacit y l(Imp.g al) 3.0 (0. 66) + 0.4 (0.088) in e xpansio n tank Coolant An tifreeze Water % % Conc ent rat ion ( dow n to - 28 °C) 40 60 Only u se nitri de-free lo ng-term frost an d corro - sion pr otection agents Thermos tat ope ns at °C 85 Cut-in temperatu re for fan °C 105 Cut-i[...]

17.4[...]

17.5 Changing coolant Draining coolan t • Remove fuel tank. • Release cap (1 ) on fi ller neck. • [RS] Remove l ower sec tion of fairin g • Release screw pl ug (2) on wate r pump [RS] , or water tem peratur e sensor [LT ] . • Note gasket. X Tightening torque: Drain plug, temper ature s ensor .......... ..... ....... 9 Nm Filling w ith coo[...]

17.6 Removing and installing the rmostat • Remove fuel tank. • Remove right side section of fairing . • Remove radiat or cowling. • Remove cover (1). • Pull out thermostat (2) . Checking thermost at • Heat up thermostat in water bath. • Check start of opening and fully open setting. Opening tempera ture: Start o f openi ng ...... ....[...]

17.7 Removing and installing radiator • Remove fuel tank. • [RS] Remove bot tom se ction of fairin g • Remove left/right side fairing. • Remo ve rad iato r cowlin g. • Remove ai r li ne (1). • Release connections (2,3,4) of the coolant hos- es. • Disconnect plug connection (5) for fan moto r. • Release hose connection (6) and mounti[...]

17.8 Removing and installing fan • Remove radiator. • Remove rubb er ring (1) an d spacer bu sh (2). • Release retaining bolts (3, 4). • Install in the reverse order of removal. LT170070 4 1 3 2[...]

17.9 Removing and installing coolant hoses • Remove fu el tank. • [RS] Remove bot tom se ction of fairin g . • Remove left/right side fairings. • Remove corresponding coolant hose. • Remo ve radia tor in orde r to releas e conne ctions on coolant filler neck (1 ). L Note: Before s crewin g back i n, clean the thr ead of m icro- encapsu la[...]

17.10 Checking cooling system Checki ng cap for fi ller neck • Remove fuel tank. • Connect adapter (1), B M WN o .1 700 0 3 , to pump, B M WN o .1 705 0 0 . • Scre w c ap on to s cre w c oupli ng (2 ), B M WN o .1 700 0 4 , and connect to pump. • Pressure test cap. Pres sure r elief val ve op ens at .. 1.5 bar (2 1.756 psi ) Checking coolan[...]

17.11 Troubleshooting Coolant temper ature warning lamp lig hts up. no Check coolant in expansion tank. Is coolant level too low? yes Top up c oolant. no Check thermostat. Is thermostat defective? yes Replace thermostat. no Check water p ump. Is water pump def ective? yes Repair/renew water pump. Fan motor does not swit ch on. no Check fuse F7. Is [...]

17.12 Übermäßiger Kühlmittelv erlust. no Check coolant circui t. Has coolant circuit a break? yes Rep air bre ak.[...]

18.1 Contents Page 18 Removing and installing exhaust system ..... ..... ..... ........ ..... .... ..... ..... ........ ..... ..... .... ........3 Removing and installing oxygen sensor ... .... ..... ..... ........ ..... .... ..... ..... ........ ..... ..... .... ........4 18 Exhaust system[...]

18.2[...]

18.3 18 Removing and installing exhaust system • Release mounting (1) on c ylinder head. • Release mounting (2) on transmission. • Relea se moun tin g (3) on fo otrest pla te. • [CAT] - Det ach plug conne cti on f or ox ygen sensor. L Note: Use new s ealing r ings (4) dur ing ins tallat ion. X Tightening torques : Exhaus t system to cy lind[...]

18.4 Removing and installing ox ygen sensor • Separate plug connection for oxygen sens or. • Remove left footrest plate. • Unscrew oxygen senso r at hexagon. L Not e: Before installi ng, coat thread of oxygen sensor with Optimoly TA . e Caution: Read out Motr onic defect cod e memory after test run! X Tightening torque: Oxygen se ns or . ....[...]

21.1 Contents Page 21 Techn ical Data ............ ..... ..... ..... ....... ..... ..... ..... ..... ....... ..... ..... ..... ........ .... ..... ..... ........ ..... ..... .... ..... .. 3 Removing clutch ..... ....... ..... ..... ..... ....... ..... ..... ..... ..... ....... ..... ..... ..... ....... ..... ..... ..... ........ ..... .... ..... ..[...]

21.2[...]

21.3 21 Technical Data K 1100 LT K 11 00 R S Type of c lutch Single dry p late clut ch wit h diaph ragm sp ring Outside -ø of diaphr agm spr ing mm (in) 180 (7.0866 ) ± 1 (0.0393 79) Total thicknes s of d riving disc (disc a nd lining ) mm (in) 5.3 (0. 20866) ± 0.25 (0.00984 ) Minimu m thic knes s of dri ving disc mm (in) 4.5 (0.177165) Clutch c[...]

21.4[...]

21.5 Removing clutch • Secure lifting gear, BMW No. 0 0 1 510 , to the oil sump. • Remove main stand. • Remove rear mudguard. • Remo ve righ t-h and fo otrest plate . • Remove Motronic control unit. • Remove battery . • [ABS I] Remove ABS c ontro l unit . • [ABS I] Secu re pres sure mo dulato rs to re ar sectio n of frame . • [ABS[...]

21.6 • Release housing cover (2). • Remove clutc h disc (3), pressure pl ate (4), diap hr agm ring (5) and wire ri ng (6 ). LT210060 6 5 4 2 3 1[...]

21.7 Removing clutch housing • Secure ret ainin g fixtur e?(1), BMW No. 11 2 800 , as shown. • Release hexagon nut (2). • Remo ve thru st ri ng (3) wit h pli ers. • Move clutch housing to and fro until O-ring (4) is visible. • Cut through O-ring. • Pull off clutch housing. L Note: Do not lose thrust was her (5). e Caution: If clutch hou[...]

21.8 Installing clutch housing • Coat tapers in clutch housi ng with Optimoly MP 3 or similar. • Fit thrust washer (1) on the clutch housing. • Using retaining device, fit clutch housing in the correct po siti on. • Install th rust ring (4) with new O-r ing (3). • Screw on hexagon nut (5). e Caution: The hexagon nut must be renewed ev ery[...]

21.9 Installing clutch • Grease all lubricati on points with Optimoly MP 3 . Lubrication point s: Contact surfaces of pressure plate/diaphr agm spring, wire r ing, cone/tip of control rod. L Note: Install diaphragm spring (2) with the convex curve facing towards the pressure plat e (3). • Fit wire ring (1 ), and diaph ragm spring?(2 ) in clutch[...]

21.10 • Release low er retaining b olt (1) of the ignition co il mounting. • Secure centring fixture (2), BMW No. 21 2 670 , to intermediate flange. • Centre drivi ng disc with corres ponding centrin g pin (3). • Evenly tighten retaining bolts (4) crosswise. • Remove centring fixture. X Tight ening torque: Housin g cov er ... ..... ..... [...]

21.11 Adjusting clutch c learance • Detach clutch cable at the clutch release lever ( 1). • Slig htly pull back ru bber g aite r (2). • With the aid of setting gauge, BMW No. 21 3 500 , s et di mension “B ” wi th ad- justing screw at clutch hand l ever. Dimensi on “B” ... 75 ± 1 mm (2.95 275 ± 0.039 37 in) • Re-attach clutch cable[...]

21.12 Removing and installing clutch thrust bearing • Remove rear wheel. • Remove exhaust system. • Detach cl utch cable at clutc h release lever (1). • Loosen r etaining cl ip (2) at s ealing gaiter . • Remove gaiter (3) wi th spring (4) . • Remove thrust bearing (5) with pointed-nose plie rs. • Install in the reverse order of remova[...]

21.13 Removing and installing clutch con- trol rod • Remove rear wheel. • Remove exhaust system. • Remove clutch thrust bearing. • Remove clutch control rod (1) by pulling to the rear. • Install in the reverse order of removal. LT210110 1[...]

21.14 Removing and installing clutch release lever • Remove exhaust system. • Detach cl utch cable at clutc h release lever . • Remo ve r eta ining r ing ( 4) and wash er (3 ) on right-hand side. • Remove mounting pin ( 1) by pulling out to left. • Remove clutch release lev er (2). • Install in the reverse order of removal. L Not e: Che[...]

21.15 Troubleshooting Clutch slips. no Check clutch c learance. Is clutch clearance incorrect? ja Adjust clutch c learance. Replace clutch di sc if necessary. no Check clutch l ining. Is clutch lining oil ed? yes Replace thrust ring on transmission input shaft. no Renew clutch di sc. Is clutch li ning worn? yes Renew clutch di sc. Clutch slips. no [...]

21.16 Clutch operat ion diff icult. Clutch too harsh? no Check output shaft lubrication. Is output shaft not lubricated? yes Lubricate with Optimoly MP 3.[...]

23.1 Contents Page 23 Techn ical Data ............ ..... ..... ..... ....... ..... ..... ..... ..... ....... ..... ..... ..... ........ .... ..... ..... ........ ..... ..... .... ..... .. 3 Removing transmission (gearbox) ............ ..... ..... ..... ..... ....... ..... ..... ..... ....... ..... ..... ..... ....... ...5 Preparator y work .... ...[...]

23.2 Contents Page Disassembling a nd assembling output shaft ..... ....... ..... ..... ..... ....... ..... ..... ..... ........ ..... .... .. 17 Remo ving b all be aring ....... ....... ..... ..... ..... ..... ....... ..... ..... ..... ....... ..... ..... ..... ....... ..... ..... ..... ..... .......... ....17 Remo ving s pur g ears ........ .....[...]

23.3 23 Technical Data K 1100 LT K 11 00 R S Type of gearshif t 5-speed transmis sion w ith dog-cl utch en gage- ment and i ntegr ated damper for all gears Type of gearshif t With ad justa ble g ears hift p edal and gear sel ector drum with overs hoot prote ction Transmission ratio 1st gea r 2nd ge ar 3rd gear 4th g ear 5th g ear 4.50 2.96 2.30 1.8[...]

23.4[...]

23.5 Removing transmission (gearbox) Preparator y work • [RS] Remove le ft fairin g side sect ion . • Remove exhaust system. • Disconnect CAT plug connection for oxygen sensor. • Remove left and right footres t plate. • Remove rear mudguard. • Remove re ar brake cali per. • Remove rear wheel. • Remove suspension strut. • Remove re[...]

23.6 Removin g s tarter • Release positive and negative lead at starter. • Release mounting. • Pull out starter. LT230410[...]

23.7 Removing b earing moun t wi th main stand • Secure lifting gear, BMW No. 0 0 1 510 , to the oil sump and sl ightly raise engine. • Release mounting for ma in stand. e Caution: The retaini ng bolts are micro-en capsulated an d can therefore not be reused. • Cut through cab le clip on main stand. LT230440 00 1 510 LT230500[...]

23.8 Removing transmission (gear box) • Release retaining b olts. • Screw gui de pins, BMW No. 23 1 820 , in hol es with fitted sleeve, long p in on right-hand side. • Slo wly pul l off gea rbox. e Caution: Hold gearbo x at installa tion height u ntil the contro l rod can be seen completely, other wise it can easily bend. 23 1 820 LT230450[...]

23.9 Disassemb ling transmission (gear- box) Removing transmissi on cover. • Secure gearbox with ho lder (arrow “A”) , BMW No. 23 1 600 , to assembly stand. • Eng ag e ne ut ra l. • Release idle lock (1). • Remo ve coil (2 ) and b all (4). • Release screws (3). • Heat bearing seat in transmission cover to 100 °C • Evenly press of[...]

23.10 Disassembling/as sembling tr ansmis- sion cover Removing and inst alling bearing shell • Heat bearing cover t o 100 °C. • Remove bearing shell with Kukko support, B M WN o .0 085 6 0 , and int ernal extractor 21/5, B M WN o .0 085 6 3 . • Fit bear ing shell in transmiss ion cover while sti ll hot . • Drive bearing shell onto the bott[...]

23.11 Removing gear selector drum • Remo ve shaft s (1) of ge arshif t forks. • Press pawl (2) towards the outside and secure with clampi ng fixture (arro w), BMW No. 11 5 500 . • Tilt back i nput shaft b y ap prox . 45° • Turn gearshift for ks towards the outside until guide pins are free. • Remove gear selec tor dru m?(3). L Note: Note[...]

23.12 Rem oving tran smis sio n shaf ts • Heat bearing seat of input shaft (1) and t he inter- mediate shaft (2) to 100 °C. • Pull out both shafts to gether. • Remove input shaft (3). Removing p awl • Using drift, drive out vent (arrow) from the inside. • Remove r etaining ring (1 ) on g uid e rod. • Pull out guide rod . • Remove paw[...]

23.13 Removing selector shaft • Release setscrew (arrow) (secured with Loctite). • Pull out selector shaft together with ge arshift le- ver. Removing segment • Remove retain ing r ing (a rro w). • Remove segment (1) together w ith coil spring (2 ) and limit stop ( 3). • Install in the reverse order of removal. e Caution: Secure setscrew w[...]

23.14 Rem ovi ng and in st all ing shaf t se alin g ring for gear selector drum • Switc h for g ear indi cato r remo ved. • Gear selector dr um removed. • Lever out shaft sealing ring with screwdriver. • Fit shaft s ealing ring us ing drift, B M WN o .2 317 9 0 and handle, B M WN o .0 055 0 0 . Removing and i nstalling beari ng shell for ta[...]

23.15 Disassembling and assemb ling input shaft Disass embling in put shaft • Clamp spline end of input shaft in vice with jaw guard. • Rem ove re tain in g rin g (1). • Using universal pul ler, BMW No. 00 7 5 00 , and pressure tool (arrow) , remove spur gear (3) to- gether with tap er roller bearing (2) . • Also r emov e sec ond ta per rol[...]

23.16 • Fit univers al pulle r under the sp ur gear and pull down tape r roll er bear ing a s far as it will go on th e retaining rin g. L Not e: There must b e no clearance between the bear ing and retaining ring in order to pr ecisely determine the thickness of the spacer ! 00 7 500 LT230200[...]

23.17 Disassembling and assemb ling output shaft • Before dis assembl ing, measure axi al clearance of spur gear for 1st, 2nd and 5th gears. 1st gear .... 0. 10... 0.30 mm (0.00 3937.. .0.0 1181in) 2nd gear ... 0.20. ..0. 60 mm (0.00 7874...0 .02362 in) 5th gear .... 0.20. ..0.40 mm (0 .007874 ...0 .01575 in) • Set axial clearance wi th spacer [...]

23.18 Removing spur gea rs • Remove spur gear for 1st (1 ) and 5th gear (2) with spac er shi m rin gs. • Heat bearin g bush (4) to 8 0 °C. • Care full y rem ove spur ge ar for 3r d gear ( 5) to - gether with sp acer shim ri ng (3) and bear ing bush (4 ). • Heat bearin g bush (6) to 8 0 °C. • Carefully remove spur gear for 4th gear (8), [...]

23.19 Install ing spu r gears • Slide serra ted wash er (1 0) ove r smooth end (ar - row) onto output shaft up to the b earing seat. • Slide on retaining ring (1 1) and fit in groove ahead of serrated washer. • Fit split needle cag e (9) well oiled. • Slide spur gear for 2nd gear (8) from the spl ine side over the needle cage with the windo[...]

23.20 Installing transmis sion shafts • Heat bearing points for intermediate shaft and output shaft in the housing t o 80°C. • Fi t in pu t sha f t. • Install intermediate shaft and output shaft to- gether. • With the aid of light blows (plastic-headed ham- mer), check that bearing is fitted in the base of the seat. Installing gearshift fo[...]

23.21 Measuring dista nces between trans- mission shafts Measuri ng bearin g dist ance of shafts • Place transmission measuring plate, BMW No. 23 3 660 (arrow), on the transmission housing. • Measur ing proced ure for intermediate shaft and output sh aft: Using de pth gau ge, BMW No. 0 0 2 550 , meas- ure dis tance between b all be aring ou ter[...]

23.22 Meas uring tra nsmissio n cover • Measure from the parting surface of the trans- mission cover to the base of the bearing seat. • Only applies to intermediate shaft and output shaf t • The dimension for the input shaft is measured with the taper roll er bearing installed . • Measure from bearing inner face to parting sur- face o f tra[...]

23.23 Measuring distances between tr ansmission shafts Exampl e : • Rem ove meas uring pl at e fr om tr ans mis sio n housing. • Fit calculated spacer shim rings on the input shaft. • Heat taper r oller bearing to 80°C and fit on input shaft. • Lightly grease spacer shims for intermediate shaft and output shaft and fit flush on ball bear- [...]

23.24 Installing transmis sion cover • Knock out cap ( arrow) fr om the inside using a drift. • Heat up transmission cover to 100°C. • Parting surface at housing and cover must be clean and free of grease. • Thinly coat one of the two parting surfaces with Loctit e 574 or with Thre e-Bond 1209 . • With the aid of a drift o r screw driver[...]

23.25 Installing transmission (gearbox) • Clutch th rust bear ing must be remo ved. • Check cent re posi tion o f dri ving disk . • Coat spline of input shaft, f or example with Optimoly MP 3 . • Scre w guid e pin s, BMW No. 23 1 820 , in the holes with centring sleeve in the i ntermediate flange. • Screw in long pin on right-hand side. ?[...]

23.26 Installi ng beari ng mount with main stand L Not e: Clean threaded holes in transmission an d retaining bolts (recut thre ad). • Place switch (1) for electric side support on bear- ing mount, secure lead wi th cabl e clip (2). • Note spacer sleeves (3). • Coat bo lts wi th Loct ite 24 3 , screw in and firmly tighten. X Tightening t orqu[...]

23.27 Installing sta rter • Connect positive and negative leads. X Tightening torque: Positi ve lea d ...... ..... ....... ..... ..... ..... ....... ..... ..... 5 Nm Starter to trans missio n ........ ..... ....... ..... ..... ..... 9 Nm • [ABS I] Install suppor t brack et for pressu re mod- ulator s. L Note: Note arrangement of wiring loom. LT[...]

23.28 Re-assemb ling motorc ycle • Install batte ry. • Intall Motronic control unit. • [ABS II] Install A BS unit. • Install batte ry. • Intall Motronic control unit. • [ABS I ] Install control unit. • Install swinging arm. • Install footrest plates. • [ABS I ] Instal l press ure modul ators. • Install rear wheel d rive. • Ins[...]

31.1 Inhalt Seite 31 Techn ical Data ............ ..... ..... ..... ....... ..... ..... ..... ..... ....... ..... ..... ..... ........ .... ..... ..... ........ ..... ..... .... ..... .. 3 Removing telescopic fork ... ..... ....... ..... ..... ..... ..... ....... ..... ..... ..... ....... ..... ..... ..... ........ ..... .... ..... ...5 Removing fo[...]

31.2[...]

31.3 31 Technical Data K 1100 LT K 11 00 R S Front wheel castor mm (in) 95 (3.74) Steering angle °3 4 Spring travel (nor mal position, 75 kg load) mm (in) 135 (5.3 15) Test i nstallation length o f fixed tubes mm (in) ca. 210 (appr ox. 8. 268) Fixed tube su rface hart ver chromt Fixed tube outside ø mm 41.7 f 8 Slider tube inside ø mm 41.86 H 8 [...]

31.4[...]

31.5 Removing telescopic fork • Secure lifting g ear, B MW No. 00 1 510 , to oi l sump. • Remove fuel tank. • Remove front m udguard. • Remove brake caliper. Removing fork stabilis or • Relea se bra ke dist ribut or (1) . • Disconnect ABS plug connection of sensor line (2) under fuel tank. • Remove fork stabiliser. • Remove front wh[...]

31.6 Removing and i nstallin g lowe r ta per roller beari ng Removing taper roller bearing • Press down steer ing tube ( 1) by approx. 5 mm and press back again. • Press off tap er rol ler be aring (2 ) and dus t ring ( 3) using two larg e screwdrive rs. Installing t aper roll er bearing • Heat taper roller b earing to 80 ° C and slide onto [...]

31.7 Removing and installi ng bearing outer race in st eering head Removing bear ing outer race • Remove bearing outer race (1 ) using extractor BMW No. 00 5 560 ( 2), and su pport ring BMW No. 31 4 800 (3). e Caution: Bearing and b earing outer r ace belong to gether, always fit together! Installing bearing out er race • With the aid of the sp[...]

31.8 Measuring telescop ic fork L Not e: After a collision, the telescopic fork must be exam- ined for cra cks an d damage . Checking lower fork bridge • Cla mp fo rk b ridge at steer ing tube in v ice wi th jaw g uards . • Install two new fixed tubes with test length “A” in low er f ork b ridg e (1). Test inst allat ion leng th ”A” ...[...]

31.9 Checking parallel alignment of fi xed tubes • Clamp fork bridge at steering tube in vice with jaw guards. • Install upper fork bridge. L Note: Fork bridge must slide smoothly on to fixed tubes. • Check parallel alignment of fixed tubes using slide gauge. • Check flush alignment of steering tube with re- spect to fixed tube. LT310090[...]

31.10 Checking runout of fixed tube • Place both ends of stanchion in V-blocks. • Slowly tur n fixed tube while ch ecking dial gaug e. e Caution: Distorted fixed tubes must not be straightened out! Permiss ible runout .. ....... ........ . 0.15 mm (0. 0059 in ) LT310100[...]

31.11 Disassemb ling telescopic fork Removing fixed tube • Loose n clam ping screws at l ower fork b ridg e. • Remove fix ed tube with sl ider t ube from fork bridge. • Drain oil. • Clamp slider tube a t mou nting f or br ake cali per in vice wi th jaw guar ds. • Release bottom screw fitting and pull out fixed tube. Disassembling slid er [...]

31.12 Disassembling fix ed tube • Loosen screw pl ug (1) in fixed tu be. • Screw base sc rew fittin g (arro w) loosely in to damper cart ridge. • Lightly pre ss damper c artrid ge into fix ed tube using clamping fi xture, B M W N o . 3 155 5 0 , and clamp ing ins ert, BMW No . 31 5 55 3 . • With the aid of a screwdriver, push apart retain- [...]

31.13 • Press apart plai n bush (8) on the fixed tube (arro ws) and remo ve. • Slight ly pre form ne w plain bush in order to achieve an optimum fit on the fixed tube. LT310160 LT310170[...]

31.14 Assembling telescopic fork Assemb ling fi xed tu be • Fit for k sup port sp ring (6) o n damper cart ridge (5), small winding spacing at top. • Fit guide sleeve (7). • Care full y clamp fixed t ube (8) in vice with jaw guards. • Slide complete damper cartridge into the fixed tube. • Loosely screw base screw fitting (arrow) into damp[...]

31.15 • Fit spacer sleeve (4). • Fit perforated di sc (3), smo oth side facing down - ward. • Fit retainers (2 ) and relie ve clamping fixture. • Screw in screw plu g, renew seal if necessary. X Tightening torque: Base sc rew fittin g ...... ..... ....... ..... ..... ..... ....... . 20 Nm LT310150 4 3 2[...]

31.16 Assemb ling slid er tu be • Install damper cartridge with hole pattern “Z” (tension stage) in the right-hand slider tube. • Install pl ain bush (1 ) lubri cated with fo rk oil. • Slide fixed tube into slider tube. • Screw together fixed tube and slider tube, if nec- essary use new seali ng ring. X Ti ghtening tor ques: Base scr ew[...]

31.17 Installing telescopic fork • Grease taper roller b earing with Shell “Retinax A” or similar. • Fit telescopic fork from below into steering head. • Install setting ring (1), heat bearing 80 ° C • Install upper fork br idge (2) . • Screw in loc king tube (3). L Note: Do not firmly tighten clamping screws of the upper fork bri dg[...]

31.18 Adjusting st eering bearing play • Fit a piece o f adhesive tape ( arrow) o n the fork bridge above the setting ring. • Mark current position of the setting ring (1) on the adhesive tape and on the setting ring (2). • Fit thrust ri ng (3), BMW N o. 31 4 890 , over the lock ing tub e ( 4). • Lock thrust ri ng with he xagon nut (5 ) whi[...]

31.19 Installi ng fork stabil isor • Install fork stabilisor, handtighten screws . • Insta ll brake di stri butor (1). • Lay ABS sens or line (2) and connect. • Install fuel tank. • Install front wheel. • Install brake caliper . L Note: Compress telescopic fork several times then firmly tighten fork stabiliser crosswise. X Tightening to[...]

31.20[...]

32.1 Contents Page 32 Techn ical Data ............ ..... ..... ..... ....... ..... ..... ..... ..... ....... ..... ..... ..... ........ .... ..... ..... ........ ..... ..... .... ..... .. 3 Removing and installing left and righ t handlebar fittings ... ..... ........ ..... ..... .... ..... ...5 Removing an d installi ng left hand lebar fi tting ...[...]

32.2[...]

32.3 32 Technical Data K 1100 LT K 11 00 R S Stee ring ang le l °2 x 3 4 Steeri ng tube -ø mm (in) 22 (0 .86614 ) Handleba r wid th with weig hts mm (in) 765 (30.118 05) 700 (27. 559)[...]

32.4[...]

32.5 Removing and installing left and right handlebar fittings Removing an d installin g left handleba r fitti ng • Remove fuel tank. • [LT] Cut t hr oug h ca bl e c lip ( 1) • Disconnect plug connection for c lutch switch (2). • Detach cold start operating cable at lever (3). • Detach clutch cable (4) at clutch release lever, then at han[...]

32.6 • Cut open rubber gri p (1) and remov e. • Release multifunction s witch (2). • Loosen cl amping sc rew (3) of handle bar fitt ing . • Remove fitting from handlebar . • Install in the reverse order of removal. L Not e: Bond rubber grip with Loctite 454 on hand lebar. X Tighten ing torque: Clampi ng scre w, handl ebar fitt ing .......[...]

32.7 Removing and i nstalling r ight hand le- bar f itti ng • Remove fuel tank. • [LT] Cut through cab le clip (1 ). • Disconnect plug connection (2) for brake light switch. • Release brake line (3) and close off. • Release multifunction switch (4). • Loosen co ver (5) for ac celer ator cable. • Detach accelerator cable (6). • Remov[...]

32.8 Removing and installing h andlebar • Remove fuel tank. • Remove handlebar cover (1). • Disconnect plug connections for switches. • Remove left and r ight handlebar fittings. • Release top secti ons of clamping bl ock (2). • Install in the reverse order of removal. X Tight ening torque: Clampi ng scre ws ......... ..... .... .......[...]

32.9 Removing an d installi ng handleb ar clamping blocks • Remo ve sto p plate (3 ). • Remove cl amping bloc ks (4). • Drive out handlebar mounting with drift. • Install in the reverse order of removal. X Tightening torque: Clamping block ....... ..... ....... ..... ..... ..... ....... ... 16 Nm LT320070 4 3[...]

32.10 Removing and installing a ccelera- tor cable • Remove fuel tank. • Remove cabl e cover (1) on handleb ar fitting . • Det ach cab le . • Turn in cam disc on th rottle stu b pipe (2) and de- tach cable. • Install in the reverse order of removal. L Not e: When installing, first attach cable at cam disc. Fit ca- ble without k inks. • [...]

32.11 Removing and installing clutch cable • Remove fuel tank. • Detach clutch cable (1) at clutch release lever. • Pull clutch hand lever and press out nipple (2). • Unscrew set scr ew (3) from fitting housin g. • Cut through cable clip and pull out operating cable. • Install in the reverse order of removal. L Note: Ensure the oper ati[...]

32.12 Removing and installing op erating cable for increasing starting speed • Remove fuel tank. • Remove operati ng lever (1). • Detach c able (2) . • On throttle rail, release locknut (3) from adjusting screw (4) and u nscrew a djustin g screw . • Detach n ipple (5) . • Remove cab le by p ulling fr om below. • Install in the reverse[...]

32.13 Adjusting steering bearing play • Fit a piece of adhesive tape (arrow) on the fork bridge above the setting ring. • Mark current position of setting ring (1) on adhe- sive tape and on setting ring (2). • Slide thru st rin g (3), BMW No. 31 4 890 , over the locking tube (4 ). • Lock th rust rin g with hexa gon n ut (5 ) wh ile ho ld- i[...]

32.14[...]

33.1 Contents Page 33 Techn ical data ...... ..... ..... ..... ....... ..... ..... ..... ..... ....... ..... ..... ..... ....... ..... ..... ..... ....... ..... ..... ..... ..... ....... . . 3 Removing, disassembling, assembling and installing rear w heel drive ........5 Removi ng rear whee l drive .. ..... .... ..... ........ ..... ..... .... ....[...]

33.2[...]

33.3 33 Technical data K 1100 LT K 1100 RS Rear wheel drive Type of gearing Klingel nberg Pall oid spir al be vel Number of teeth 32 : 11 Gear ratio 2.91 : 1 Tooth backlas h mm (in) 0.07 ...0.1 6 (0.002 76...0. 006299) Taper ro ller bearing pr eload mm (i n) 0.05...0. 1 (0.01969. ..0.003 937) Oil grades Brand- name h ypoid gear oil , API class GL 5[...]

33.4[...]

33.5 Removing, disassembling, assem- bling and installing rear wheel drive • Remove licence plate bracket. • Remove rear wheel. • Remo ve bra ke disc, m ark po sition with ABS . Removi ng rear whee l drive • Remove s peedome ter drive . • Heat free bearin g journal (1) to max. 120 °C and loosen it; heat fixed bearing jour nal (2) to max.[...]

33.6 • Screw the rear wheel drive centrally with holder, B M WN o .3 315 1 0 , and bearing journal (1). • Scre w on locki ng arm (3). • Move threaded bushings (5) into contact with the rear wheel dr ive. • Secure with wheel bol ts (2). • Screw the grub screws (4) up until they make cont ac t. • Heat hexagon nut (6) on drive b evel gear [...]

33.7 Disassembling drive bevel gear • Remove oute r bear ing ra ce (2 ). • Remo ve spa cer rin g (3) from hou sing. • Clamp drive beve l gear (1) in vice with jaw guard s (splin es faci ng upwa rd). • Usin g p ull er, BMW No. 00 7 500 , remove both bearings at the same time. • Remove thrust bear ing (4), inner race (5), beari ng cage (6) [...]

33.8 Removing needle bearing for drive bevel gear • Destroy needle cage of needle beari ng. • Heat housing to 130 °C. • Remove outer race of needle bearing with the aid of inner extractor, BMW N o. 00 8 5 73 , an d sup - port, BMW No. 00 8 570 . Installing needle bearing for drive bevel ge ar • Heat bearing seat of needle bearing to 100 °[...]

33.9 Assembling drive bevel gear • Heat inner race (4) to 100 °C and sli de onto drive bevel gear (1) as far as it will go. • Slide outer bearing race (2) together with cylin- der rol ler cage (3) ont o inn er ra ce (4 ). • Heat ball bearing (5) to 100 °C and fit on drive bevel gear (1) as far as it will go. • Allow dr ive bev el gear t o[...]

33.10 Installing drive b evel gear • Drive sealing ri ng (2) into thread ed rim (3) with the aid of drift, BMW No. 33 1 760 , and retainer, B M WN o .0 055 5 0 . • Heat housing to 120 °C. • Fit drive bevel gear comple te with spacer (1). • Fit oute r race ( 6). • Coat threa ded rin g (3) with Hylomar SQ 32 M , thread turns must b e free [...]

33.11 Removing an d installi ng taper needle bear ing in r ear whe el dr ive • Remove needle bearing using inner extractor 21/4, B MW N o. 00 8 5 73 , and s upport 22/1 , BMW No. 00 8 572 . • Heat housing neck to 120 °C. • Press in needle bearing with inner race on dri ft, BMW No. 36 3 700 . RT33090 00 8 572 00 8 573[...]

33.12 Removing cr own wheel • Re move hous ing cov er (1 ) wi th crown whe el (2) and be arin g (3). • Heat housing cover (1) to 100 °C and remove. • Drive shaft sealing ring (4) out of housin g cover usi ng dr if t. • Clamp ri ng gear in vice wi th jaw guards . • Fit pressure piec e (arrow), BMW N o. 33 1 3 07 . • Using pu ller, B M W[...]

33.13 • Remove taper ro ller beari ng from ring gear with pulle r, B M W N o .0 075 0 0 . • Remove out er bearing ra ce with internal extrac- tor, BMW No. 00 8 560 . Inst all ing cr ow n whee l • Heat housing to 80 °C. • Press outer race into bearing seat with drift, B M W N o .2 346 7 0 , an d hand l e, B M W N o .0 055 0 0 . L Note: Chec[...]

33.14 Checking/ adjusting toot h backlash • Lock dr ive bevel gear i n posi tion with 36 mm (1.4173 i n) ins ert, BMW No. 33 1 720 . • Fit measuring ring, BMW No. 33 2 600 , wi th di al gauge on crown wheel and secure to housing with k nurled scr ew (1) . • Secu re mea su rin g arm, B M WN o .3 326 0 4 ,centrally on crown wheel. • With the [...]

33.15 Checki ng conta ct patt ern • The contact pattern must be checked when the set of gears, the housing or the bearing of t he drive bevel gear has been replaced. L Note: The contact pattern is set with the spacer ring?(1) on the drive bevel gear. • Remove grease from the tooth profiles of the crown wheel and bevel gear and coat w ith engi- [...]

33.16 Shim ming hous ing co ver • The housing co ver must b e shimmed in order to achieve the corresponding preload of the taper roller bear ing. • Measure distan ce “a” wi th dept h gauge, B M WN o .0 025 0 0 . • Fit measur ing ring (ar row), B M WN o .3 326 0 1 • Measure from the outer race of the ball bearing to the parting surface o[...]

33.17 Installing rear wheel drive • Coat sp line o n slid ing pi ece (arro w), fo r examp le with Opti moly MP 3 . • Fit in ner race (5) of rig ht-ha nd n eedle be arin g with a little grease, e.g. Optimoly TA . • Fit rear wheel drive with gaiter in posi tion, ins ert sliding piece in drive shaft. • Loosely secure spr ing strut to r ear whe[...]

33.18 • Apply a load of ap prox. 85 Kg ( 1887.43 l b)to the motorcycle and tighten loose strut (4) with the nut on the wheel side. X Tight ening torques: Strut t o rear whe el dr ive ....... ..... ..... ..... ........ . 43 Nm Suspensio n strut to re ar wh eel dri ve ...... ..... . 51 Nm • Tighten the strap ho lding the flexible gaiter. • Add [...]

33.19 Removing, disassembling and assembling rear swinging arm • Remove left and right footres t plate. • Heat to max. 1 20 °C at loo se bearing of s winging arm (1), lo osen lockn ut and remo ve bearing pin. • Release the centre and two other bolts on the fixed bear ing (2). • Screw in and lock special tool, BMW No. 26 1 660 , • Release[...]

33.20 Removing and i nstalling ga iter • Remove in ner retaining ring, pull ga iter out of swing ing ar m. • Install in the reverse order of removal. • Coat insi de and outsid e (arr ows) of seal ing l ip with, for example, Optimoly MP3 . Removing d rive shaft • Press off dr ive shaft with screwdr iver. e Caution: Avoid scrat ching pain ted[...]

33.21 Installing swi nging arm • Slide swinging arm over drive shaft. • Lift drive shaft over the support surface in the swinging fork and press forward swinging arm as far as possible until gaiter snaps in po sition at the gearbox neck . • Coat bear ing pi n of fixe d bear ing with Optimoly TA a nd instal l and f irmly tigh ten with specia l[...]

33.22[...]

34.1 Contents Page 34 Techn ical Data ............ ..... ..... ..... ....... ..... ..... ..... ..... ....... ..... ..... ..... ........ .... ..... ..... ........ ..... ..... .... ..... .. 3 Removing and installing front brake caliper ........... ..... ..... .... ........ ..... ..... ..... ....... ..... .....5 Dismantling and assembling fron t brake[...]

34.2 Contents Page [ABS II] Installing ABS unit ....... ..... .... ..... ........ ..... ..... .... ........ ..... ..... ..... ....... ..... ..... ..... ..... ....... ....19 [ABS II] Removing and installing relay an d relay base .... .... ..... ........ ..... ..... ..... .... .. 20 [ABS II] Removin g relay ........ ..... ....... ..... ..... ..... ..[...]

34.3 34 Technical Data K 1100 LT K 11 00 R S Brake fluid D OT 4 Minimum brake pad thickness mm (in) 1.5 (0.059) Front wh eel Brake disc Ø mm (in) 305 ( 12.01) Brake disc thickness mm ( in) 5 ± 0.1 (0.197 ± 0.0039 ) Minimum thickness mm (in) 4.5 (0. 177) Brake pad su rface cm 2 (in 2 ) 100 (15.5) Piston Ø of brake c aliper mm (in) 32/34 (1.26 /1[...]

34.4[...]

34.5 Removing and installing front brake caliper • Mask off brake caliper at top of wheel si de with tape (r im guar d). • Release brake caliper mounting (1) and alterna tely press brake caliper against the brake disc and pull ba ck (arrow) in order to pr ess back the pistons. • Carefully rem ove brake caliper fro m brake dis c. e Caution: Br[...]

34.6 Dismantling and assembling front brake caliper e Caution: The brake caliper halves must not be unscr ewed ! Dismantling front brake caliper • Remove the brake caliper. • Remove keeper from retaining pin (1). • Drive out the retaining pin (1) from the wheel side. • Pull the brake pads ou t downwards . • Seal the bleed screw. X Ti ghte[...]

34.7 Assembling front brake caliper • Coat new s ealing ri ngs (3,4) with br ake fluid and install. • Coat brake ca liper pi stons (2) wi th brake flu id and inse rt. e Caution: Do not tilt the brake pistons when in stalling. • Using piston resett ing tool (5 ), BMW No. 34 1 500 , press the pistons fu lly back. • Insert brake pads and secur[...]

34.8 Rem oving an d inst alli ng bra ke pads • Remove brake ca lipe r. L Not e: If only th e brake pads are t o be rep laced, do not re lease the brake line a t the br ake caliper. • Drive out retaining pin (1). • Remove brake pa ds by pulling down wards. e Caution: Do not allo w brake pads to wear down below the minimum thickness (arrow). Re[...]

34.9 Removing and installing front brake disc • Remove front wheel. • Release retaining screws (1 ) for brake disc car ri- er. • Detach bra ke di sc carr ier (2 ) w ith br ake disc. Removing and installing ABS pu lse wheel • Release pu lse whe el on brake di sc carrier . X Tightening torque: Pulse w heel ....... ........ .... ..... ..... ..[...]

34.10 Removing and installing fron t ABS sensor • Remove fuel tank. • Disconnect plug connection (1) of sensor line. • Remo ve cov er for br ake di stri buto r. • Remove rear section of mudguard. • Detach cab le clips. • Release sensor (2) wi th Torx socket, BMW N o. 34 2 500 . • Install in the reverse order of removal. L Not e: Caref[...]

34.11 Adjusting front ABS sensor gap • Raise front wh eel with front whee l stand, BMW N o. 36 3 9 50 . • Secure dial g auge hol der (1), BM W No. 34 2 5 20 with di al ga uge to f ork slid ing tub e. • Secure meas uring sho e (2), BMW No. 34 2 510 to feeler of dial gauge. • Set dial gauge at marking (arro w) on pulse wh eel to zero. • Mea[...]

34.12 Removing and installing fron t brake line Removing upper brake line • Drain brake system. • Remove fuel tank. • Release brake li ne (1) at han dbrake cy linder . • Remo ve cov er for br ake di stri buto r on mud - guard. • Release brake line at the distributor. • Install in the reverse order of removal. L Not e: Secure brake line [...]

34.13 Removing and installing ABS brake line from front pre ssure modulator • Rem ove kn ee pa ds. • Remove fuel tank. • Release screw connections (1 ,2). • Release c onnection s at p ressure modulato r (3) . • Remove both lines t ogether. • Relea se spac er (4 ) and rep lace de fecti ve line . • Install the re verse order of remo val[...]

34.14 Removing and installing h andbrake cylinder • Drain brake system. e Caution: Ensure brake fluid d oes not come in contact with painted parts of the vehicle; brake fluid destroys the paintw ork. • Remove cover (1). • Remove mounting pin (2) for handbrake lever. L Not e: The mounting pin is secured with Tuflok - blue. This screw fitting c[...]

34.15 Bleeding brake e Caution: Escarpin g brake flui d can dam age painted surf aces. Bleeding front brake Bleeding brake caliper • Remove front b rake pads. e Caution: Do not tilt the brake caliper when removing or install- ing. The brake dis c could be damaged. • Detach the cover fr om the brak e fluid reservoir and remove it together with t[...]

34.16 [ABS II] Bleeding pressure modulator • Remove the left battery cover. • Connect a vessel to the brake caliper bleed screws to trap escaping brake fluid, then open the bleed screw by half a turn. • Maintain pressue at the handbrake lever and open the bleed screw, at the same time pulling the hand brake lever in fir mly. e Caution: Do not[...]

34.17 Removing and installing pressure modulator e Caution: Work on the ABS unit is only to be carried out by an authorised BMW wo rkshop . [ABS I] Rem oving and in stall ing f ront or rea r pres sure modul ator • Remove the fuel tank . • Separate plug connector (1) (blue) for the pres sure modulato r. • Clean the hydraulic pump assembly and [...]

34.18 [ABS II] Remo ving ABS uni t • Remove the dualseat. • Remove the left and right battery trim panels. • Remove the Motronic contr ol unit. • Remove the battery. • Remove the coolan t level equalising tank. • Take off the lower section of the front mudguard. • Drain the front and rear brake circuits. e Caution: Escap ing brake flu[...]

34.19 [ABS II] I nstalli ng ABS unit • Install ABS u nit (6). • Reconnect central plug (5). e Caution: Do not tilt the cables or the insulation may be dam- aged. • Push 2-pi n plug (4) on correvtl y and as far as it will do, then press the two wires i nto the centre (smal ler) c able entries . • Attach both plugs of the connecting cable/wir[...]

34.20 [ABS II] Removing and installing relay and relay base [ABS II] Removin g relay e Caution: Switch off the ignition and disconnect and insulate the e arth (grou nd) lead . • Remove cover (1) from ABS c ontrol unit, pr ess the catch in with a screwdriver and p ull the cover off upwards. • Cover (1) mus t be scrapped . • Disconnect wi res ([...]

34.21 • Install a new cover (1) . e Caution: When pushing on, make sur that all cables are cor- rectly located in their guides. Scrap the old co ver. [ABS II] Rem oving relay base e Caution: Switch off the i gnition and d isconnect and insulate the earth (ground) lead. • Remove cover (1) from ABS control unit, press in the catch with a screwdri[...]

34.22 Removing and installing re ar brake caliper • Drain brake System. • Release bo ttom of suspensio n strut (1). • Detach sus pensions strut fr om stud bolt . • Release brake line at brake caliper. • Disconnect ABS plug connection for sensor line. • Release brake cal iper and carefully lif t out. • Install in the reverse order of r[...]

34.23 Dismantling and assembling rear brake caliper Dismantling rear brake cal iper • Remove keeper s (1). • Drive out sprin g (2) and retain ing pin (3). • Take out br ak e pads . • Seal the bleed screw . X Tightening torque: Blee d scre w at b rake ca liper rea r .. ..... ..... .... . 11 Nm • Remove sealing rings (4) from left/right cyl[...]

34.24 Removing and installing re ar brake disc • Remove brake ca lipe r. • Remove rear wheel. • Remove brake dis c. L Not e: Mark installation position of the brake disc so that the vertical runout of the pulse wheel is not changed. • Install in the reverse order of removal. L Not e: Scre w in retaini ng scr ews with Loct it e 270 . Check A[...]

34.25 Removing and installing rear ABS sensor • Remove brake caliper but do not loosen brake line. • Release sensor with socket wrench, BMW No. 00 2 640 . • Disconnect plug connection (1) for sensor line. • Install in the reverse order of removal. e Caution: Check sensor spacing where the g ap is greatest; if necessary, adjust with spacer p[...]

34.26 Measuring vertical runout at re ar pulse wheel • Remove brake ca lipe r. • Remove rear wheel. • Secure dial gauge with retaining fixture to bottom of spring strut mounting . • Posit ion dia l gaug e wit h measu ring shoe (1), BMW N o. 34 2 510 , on pulse wheel. • Set dial gauge to zero. • Measure vertical runout ov er the entire c[...]

34.27 Removing and installing rear master brake cylinder • Drain brak e sy stem. e Caution: Ensure brake fluid does not come in contact with painted parts of the v ehicle; brake fluid destroys t he paintwork . • Release brake line (1) at master brake cylinder ( 2). • Rem ove f ootr est plat e. • Release master brake cylinder ( 2). • Note [...]

34.28 Disassembling r ear master b rake cyl- inder e Caution: Piston is under spr ing loading . • Usin g th rust pi ece (1 ), push p isto n (2) a lit tle wa y inwa rds. • Press o ut stop screw ( 3). • Pull out pis ton with spri ng (4). • Loosen spring from ring g roove. • Check piston and se aling rings (5) for damag e. • Install in the[...]

34.29 Removing and installing brake pedal • Rem ove f ootr est plat e. • Detach sealing gaiter (1) at master b rake cylin- der. • Release mo unting (2) for brake pedal . e Caution: Spring is und er tension. • Remo ve bear ing bu sh (3) . • Install in the reverse order of removal. L Note: Grease bearing bush with „ Shell Retinax A “ o [...]

34.30 Adjusting foot brake pedal • Loosen locknut ( 1). • Perform basic setting with adjusting screw (2). • Adjust distance „A“ with feeler gau ge. Basi c setti ng: Distance „A“ ......... ...... ......... .... 0 .2 mm (0.00787 in) • Turn adjust ing s crew (3) on maste r brake cyli nder until slig ht resistance is felt when the foot [...]

34.31 Troubleshooting: Fron t wheel/rear wheel brake Brak e ru bs/ vibr ate s. no Check brake pad s. Are brake pads wor n/damaged? yes Renew brake p ads. Brake pedal soft/spongy. no Check brake f luid. Is brake fluid too low? yes Top up brake fluid to MAX level. no Check brake system. Is there air in brake system? yes Bleed brake system. no Check b[...]

34.32 Reduced brake effect when applied hard? no Ch eck br ake f luid . Has brake fluid aged? yes Renew brake fluid. Only mederate brake effect? no Ch eck br ake pa ds. Are br ak e pad s wor n/da mag ed? yes Renew brake pads . no Check brake system. Is there air in brake sy st em? yes Bleed brake system . Brake s squea k. no Ch eck br ake pa ds. Ar[...]

34.33 Brakes rubbing. no Check hy drauli c syste m. Is there a defect in hydraulic system operation? yes Rectify defect. no Check brake pi ston. Are brake pistons jammed? yes Change break piston/ master brake cylinder. no Check brake discs/wheels. Is lateral runout too large? yes Replace brake discs/w heels.[...]

34.34[...]

36.1 Contents Page 36 Techn ical Data ............ ..... ..... ..... ....... ..... ..... ..... ..... ....... ..... ..... ..... ........ .... ..... ..... ........ ..... ..... .... ..... .. 3 Removing and installing front w heel ....... ..... ..... ....... ..... ..... ..... ....... ..... ..... ..... ..... ....... ..... ...5 Removing and instaling whe[...]

36.2[...]

36.3 36 Technical Data K 1100 LT K 11 00 R S Rim size front 2.50 x 18 MT H 2 3.50 x 17 MT H 2 rear 3.00 x 17 MT H 2 4.50 x 18 MT H 2 Vertical runout mm (in) 0.3 (0.012) Lateral runout mm (in) 0.3 (0.012) Tyre size front 110/80 VB 18 Tubeless 120/70 VB 17 Tubeless rear 140/80 V B 17 Tubeless 160/60 VB 18 Tubel ess Tyre press ures (col d) Solo, fron [...]

36.4[...]

36.5 Removing and installing front w heel • [RS] Raise the front wheel with the front wheel stand, BMW No. 36 3 95 0 . • [LT] Raise the front wheel with the front wheel stand and adapter, B M WN o .3 639 5 4 . • [LT] Remove the rear mudguar d. • Apply adhesive tape to the top of the brake cali- per on the wheel side, to protect the wheel. ?[...]

36.6 Rem oving and in sta ling wh eel bearin gs • Place the wheel on two wooden blocks so that the brake disc is free. Rem ovi ng le ft bear ing • Take out circli p (1) with Seeger circ lip pli ers. • Place the protective ring (2), B MW N o. 31 3 6 10 , in position with the open side upwards. • Pull out wheel bearing (3) with internal pu ll[...]

36.7 Removing and installing rear wheel Removing r ear wh eel • Remove n umber plate brack et. • Remove the br ake calip er. • Pull off cap (1) with an angled screw driver. • Unscr ew wheel st uds (2). • Take out the rear wheel. • Note the presence of spacing washer (3). Installing rear wheel • The contact faces o n the spacing washer[...]

36.8 Static balancing of front and rear wheels Static balancing of front wheel • Remove the wheel. • Insert the balancing shaft, BMW No. 36 3 61 4 , through the front wheel. • Secure the balancing axle with knurled nut (3), but do not over-tighten. • Raise the wheel on the balancing device, B M WN o .3 636 0 0 , and allow it to find its own[...]

36.9 Checking wheel for ru nout Checking front wheel for runout • Install the wheel without tyre on the balanci ng shaft, BMW No. 36 3 614 , and bal ancing stand, BMW No. 36 3 600 . • When checking the front wheel, use a pin in the balancing shaft to prevent it from turning in the balancing stand. • To check the rear wheel, clamp retaining di[...]

36.10[...]

46.1 Contents Page 46 Techn ical Data ............ ..... ..... ..... ....... ..... ..... ..... ..... ....... ..... ..... ..... ........ .... ..... ..... ........ ..... ..... .... ..... .. 3 Removing and installing front m udguard ........ ..... ....... ..... ..... ..... ....... ..... ..... ..... ..... ....... ...5 Removing and installing rear secti[...]

46.2 Contents Page Checki ng frame with gau ge ....... ....... ..... ..... ..... ..... ....... ..... ..... ..... ........ .... ..... ..... ........ ..... ..... .... .. 18 Removing and installing frame ........... ..... ..... ..... .... ........ ..... ..... ..... ....... ..... ..... ..... ....... ..... ....20 Removi ng frame ...... ....... ..... ...[...]

46.3 46 Technical Data K 1100 LT K 11 00 R S Location of type identification plate Rear right frame tube Location of chassis number Rear right frame tube Maximum width (over mirrors) mm ( in) 915 (36. 02) 802 (31. 57) Seat height, without load mm (in) 810 (31.89) 800 (31.5) Wheelbase, wi thout load mm (in) 1565 (61.6) Unladen weight kg (lb ) 290 (6[...]

46.4[...]

46.5 Removing and installing front mudguard • Loosen clampi ng screws (1,2). • Detach cover (3). • Remove rear sect ion of mudg uard (4 ). • [LT] Detach Velcro connections (5) . • Remove front section of mudguard (6). • Install in the reverse order of removal. L Note: [LT] Pos ition of Velcro connection (6 ). LT460010 4 6 3 1 2 5 LT4600[...]

46.6 Removing and installing re ar sec- tion • Remove dualseat. • Remove com bined tail lig ht unit. • Rele ase securin g screw (1 ). • Install in the reverse order of removal. LT460030 1[...]

46.7 Removing and installing rear mudguard 1. Rubb er sleeves on gearbox 2. Bracket 3. Sheet-metal nuts 4. Licence plate support bracket LT490040 3 4 2 1[...]

46.8 Removing and installing fairing [LT] Removing side secti ons of fai ring • Remove knee pad (1). • Remo ve sto rage box (2). • Remove cover (3). • Remove si de sectio n (4). • Install in the reverse order of removal. Removing radiator co wling • Remove radiat or cowling (5) . • Remove cover (6). 1. Frame 2. Grille 3. Cowling 4. Co[...]

46.9 Removing an d installi ng wind shield • Release securi ng screws (1) on left and righ t and detach screen. Removing an d installi ng wind shield compl ete w ith m otor • Remove inner cover. • Release securing sc rews (2). • Detach water ducts (3) at the top nipple. • Disconnect electrical p lug connection. • Remove wi ndshield with[...]

46.10 Disassembling and assembl ing adjust- able wind shield Removing and ins talling a ctuator motor • Release securing elements (1) for actuator motor an d remo ve mot or . Removing plate • Remove actuator motor • Release mounting element ( 1) for pla te (2). • Install in the reverse order of removal. L Note: The retaining screws ar e mic[...]

46.11 Removing lever • Remove actuator motor. • Remove plate. • Detach spring. • Release securing element (3) of guide rod (4) , while hold ing wit h pin (5) . • Pull guide rod out of sliding bush ing, note O-rings (6). • Remove retainer (7) and press o ut shaft (8). • Install in the reverse order of removal. L Note: The retaining scr[...]

46.12 Rem oving and in sta llin g upper section of fairing • Remove side s ections o f fairing and radiat or cowl ing . • Remove cover (1). • Remove complete windshield (2). • Disconnect plug connections for headlight and turn indicators. • Remove uppe r secti on of fair ing (3). • Install in the reverse order of removal. LT460130 3 2 1[...]

46.13 Removing and installing fairing [RS] Removing an d installi ng lower sec tion of fairing – Lower section of fairing (1) • Release securing element on side secti on (2). • Release securing sc rew at oil sump. • Install in the reverse order of removal. Removing and installi ng side section of fairing – Sid e sectio n of fairing (2) ?[...]

46.14 Rem oving and in sta llin g upper section of fairing • Remove lo wer section of fair ing, side sections and ra diat or cowli ng. • Remove cover (1). • Remo ve su ppor t b racke t (2 ). • Remove cover at right/ left (3) an d centre (4) . • Disconnect plug connection for turn signal in di- cator and headl amp. • Release securing scr[...]

46.15 Removing an d installi ng fair ing support b racket • Remove fairing. • [LT] Remove instrument cl uster. • Remo ve horn s (1). • Discon nect c able cli ps for wiri ng loom. • Release sec uring s crew (2). • Install in the reverse order of removal. Arrang ement of c able clips [L T] Arrangement o f cable cl ips [RS] X Tightening to[...]

46.16 Checking running ge ar Measuring track offset • Mount motorcycle on c entre stand on even bas e. • Position track offset gauge (1), B M WN o .3 639 2 0 , on left or right s ide of motor- cycl e. L Not e: In order to measure with the track offset gauge from the left or right side, the supports need o nly be screwed in from the other side. [...]

46.17 • Calculate track offset ”S” : EXAMPLE : • The track offset ”S” represents the amount by which the longitudinal axis of the front wheel is offset to the left or right wi th respect to the rear wheel. Permissible track offset: S ........ ........ ..... ..... ..... ....... ..... ..... ..... ....... ..... . 12 mm L Note: Significance[...]

46.18 Checki ng frame with gau ge • Remove fairing. • Support motor cycle wi th lifting gear, B M WN o .0 015 1 0 . • Remove telescopic fork. • Outer bearing race at top and bottom remain in steering head. • [RS] Remov e left and right footrest plat e. • Release frame securing screw at gearbox. L Not e: After releasing the fram e securi[...]

46.19 • Fit measuring pins (1 ), BMW No. 46 5 602 , lightly greased, in the outer holes. • Slightly loosen nut on steering head and align gauge so that the same d istance is obtained on the left and right with respect to the measuring discs. L Note: The frame is in order when the tips of the measuring pins on the left and right are located in a[...]

46.20 Removing and installing frame Removi ng frame • Set motorcyc le on centr e stand. • Support with lifting gear, B M W N o .0 015 1 0 , un- der oil sump. • Remove seat. • Remove r ear sectio n. • Remove rear mudgua rd. • Remove fuel tank. • Remove fairing complete. • Remove fairing suppor t bracket. • Remove radiator. • Drai[...]

46.21 Removing and installi ng seat lock 1. Saucer-head screw 2. Phillips-h ead screw 3. Stop nut Removing and installing handle • Lever out spri ng using screwdri ver, remove spring seat. • Detach handle. • Remove spring with second spri ng seat. • Install in the reverse order of removal. L Note: Grease the pivot point a li ttle before ins[...]

46.22 Install ing fram e • Installation basically takes place in the reverse order of remov al. • Place frame on drive train and firmly tighten screws and bolts in th e specified order. 1. Scr ew in a ll 5 s crews loo sel y, i.e . not as fa r as they will go. Fit a 1 mm thick spacer ring, inner support ring at the front right between the cylin-[...]

46.23 Removing and installing main centre stand • [RS] Remove lo wer sec tion of fairing . • Raise motorcycle with lifting gear, BMW No. 00 1 510 , un der the oil sump unti l stand is free to move. • Disconnect cable clips for si de stand line. • Release retaining scr ews (1) and detach main stand together with side stand. • Install in th[...]

46.24 Disassembling a nd assembling side stand D isa sse mbl in g sid e sta nd • Detac h switch (1 ). • Detach tension sp rings (2). • Re move brac ket (3) with spring. • Remove operati ng hook (4). • Remove leg spri ng (5). • Rele ase sec uring scr ew (6) of side stan d. LT460340 1 2 6 4 5 3[...]

46.25 Assemblin g side stan d L Note: The securing screw of the side support is micro-en- capsulated and cannot be reused. Clean thread and holes. Coat sc rews with Loctite 243 before insert - ing. • Fit securing screw (6) with Loctite 243 . • Fit leg spring ( 1) as illustrated. • Install op erating ho ok (2) and brac ket (3), note in- stalla[...]

46.26 Disassembling a nd assembling main centre stand • Detach tension sp rings (1). • Release screws ( 2) on left/right. • Release retaining ring (3). • Press out sleeve (4) on left/right. • Re move be ari ng bl oc k (5). • Loosen grease nipple (6). • Assemble in the r everse order of disassembly. L Not e: Screws (2) are micro -encap[...]

46.27 Checking switching function of side stand • Set vehicle on centre stand on even base or lift- ing platform . • Spray swi tchin g kin ema tics o f side st and wi th quick- actio n cleaner and fo ld out and in se veral times. • Complet ely f old out si de st and and m ark po siti on on the base. • Make a second marking at the distance ?[...]

46.28[...]

51.1 Contents Page 51 Removing and installing ignition switch/steering lock ...... ..... ..... ....... ..... ..... ..... .....3 Removing and installing lock cylinder for fuel tank ........ ..... ....... ..... ..... ..... ..... ....... ...4 Removing lock cylind er . ........ ..... .... ..... ........ ..... ..... .... ........ ..... ..... ..... .... [...]

51.2[...]

51.3 51 Removing and installing ignition switch/steering lock • Remove fuel tank. • Disconnect plug connection (1) for ignition switch/steering lock. • Detach crash pad on upper fork b ridge. • Loosen hand lebar c lamping bl ocks and pl ace handlebar on frame. • Remove screw plug s (2 ). • Fit drilli ng bushing (1), BMW No. 51 0 500 , i[...]

51.4 Removing and installing lock cylin- der for fuel tank Removing lock cylinder • Open cov er and release scr ews (1) . • Remove housing (2) for lock cylinder. • Fit key in lock cylinder, press catch (3). • Pull out lock cylinder together with key. • Note positi on of O-rin g (4). Installing locking cylinder • Grease lock c ylinder wi[...]

51.5 Removing and installing dualseat lock 5. Saucer-head screw 6. Phillip-head scr ew 7. Stop nut LT510040 2 1 1 3[...]

51.6[...]

61.1 Contents Page 61 Techn ical Data ............ ..... ..... ..... ....... ..... ..... ..... ..... ....... ..... ..... ..... ........ .... ..... ..... ........ ..... ..... .... ..... .. 3 Removing and installing Motron ic control unit .......... ..... ....... ..... ..... ..... ....... ..... ..... .....5 [ABS I] Removing and installing control uni[...]

61.2[...]

61.3 61 Technical Data K 1100 LT K 11 00 R S Battery Ah 19[...]

61.4[...]

61.5 Removing and installing Motron ic control unit e Caution: Switch off ignition, disconnect and insul ate earth (ground ) lead! • Open dualseat. • Press catch (1) for mu lti-pin plug and detac h plug. • Loosen scre ws (2) and rem ove contro l unit . X Tig htening torque: Motroni c contr ol uni t ........ ........ ..... ....... ..... ..... [...]

61.6 [ABS I] Removing and installing control unit e Caution: Switch off ignition, disconnect and insulate earth (groun d) le ad! • Switch off ignition, d isconnect and in sulate ground lead! • Open dualseat. • Press ca tch (1) for mu lti-pi n plug and detac h plug. • Loosen screws (2 ) at left and right an d remove housing (3) together with[...]

61.7 Removing and installing battery e Caution: Switch off ignition, disconnect and insulate ground lead! • Remove Motronic control unit. • [ABS I] Remove ABS control unit. • Disconnect po sitive lead. • Detach vent hose (1). • Install in the reverse order of removal. L Note: First connec t positi ve pole, followe d by nega tive pole. Coa[...]

61.8 Relay locations (central elect rical unit) • First remove the fuel tank in o rder to remove a relay. 1. Lamp contr ol unit 2. St art re lay 3. Turn indic ator rela y 4. [ABS I ] ABS relay L Not e: With ABS I I the relay is on the ABS uni t. See Group 34 “Rem oving and instal ling ABS relay bas e”. 5. Motronic relay 6. ABS warn in g rel a[...]

61.9 Locations and connections, ABS wiring loom L Note: All ABS plug connecti ons are blue. 1. [ABS I] Multi-pin p lug, ABS control unit 2. [ ABS I] Plug connection, front pressure modulator 3. [ABS I] Plug connection, rear pressur e modulator 4. Plug connection, front sensor 5. Plug connection, rear sensor L Note: [ABS II] See Group 34. LT610050 5[...]

61.10 Locations, frame wirin g loom View fr om left L Not e: When removing the wiring loo m, also remove the central electrical box together with the wiring loom. 1. Central earth (ground) at frame 2. Plug connection for tail light 3. Equalisation loop 4. Headlight connection 5. Parking light connection 6. Left multfunction switch connection 7. Alt[...]

61.11 View from right 1. Right multi-function switch connection 2. Ignition lock connection 3. Handbrake l ight switch plug connectio n 4. Hall generato r pl ug connecti on 5. Hall generator line 6. Oil pr es sure swit ch l ine 7. Brake light switch plug connection 8. Plug connection for fuel pump/fuel war ning lamp 9. Transmission switch plug conn[...]

61.12[...]

62.1 Contents Page 62 Techn ical Data ............ ..... ..... ..... ....... ..... ..... ..... ..... ....... ..... ..... ..... ........ .... ..... ..... ........ ..... ..... .... ..... .. 3 Removing and installing instrument cluster ......... ..... ........ .... ..... ..... ........ ..... ..... .... ..... ...5 [LT] ........ ..... ..... ..... ..... [...]

62.2[...]

62.3 62 Technical Data K 1100 LT K 11 00 R S Instrument clus ter Turn si gnal indi cator la mps 12 V/4 W T 8/4 Other indic ator lamp s, instrum ent lights 12 V/3 W 10/3[...]

62.4[...]

62.5 Removing and installing instrument cluster [LT] • Remove upper section of fairing. • Release screw (1) and disconnect central plug connector. • Release screws (2), remove instrument cluster and coun terwe ight (3 ). • Rubber buffers (4) remain in instrument sup port bracket. • Install in the reverse order of removal. LT620010 4 3 2 1[...]

62.6 [RS ] • Remove uppe r secti on of fair ing . • Release scre w (1) and di sconnec t central plug connector. • Rele ase sc rews ( 2) and re mov e instr ument clus- ter. • Housing ba se (3) and c able cover (4 ) remain on the frame. • Install in the reverse order of removal. LT620020 1 4 3 2[...]

62.7 Disassembling and assemb ling instrumen t cluster • Release inst rument suppo rt bracket (1) . • Release housing cover (2) and remove together with gasket (3 ). • Instrument housing (4). • Assemble in the revers e order of di sassem bly. L Note: Ensure gasket is fitted in corre ct position. Removing and i nstallin g indicato r lamp •[...]

62.8 Removing and inst alling p.c. boa rd • Release sec uring screws and car efully lift out p.c. b oard (1). L Not e: Do not damage p .c. b oard wh en remov ing and installing. Ensure plug contacts are fitted correctly. Removing and inst alling quartz clock • Carefull y remove frame (1) by pulling upwa rds. • Carefully press retaining hooks [...]

62.9 Removing and installi ng revolut ion coun ter • Release screws (1). • Lift out revolution counter (2). Removing and installing speedometer • Release screws (3). • Completely pull out reset button (4 ) to the right. • Lift out speedometer (5). LT620090 1 2 LT620100 5 4 3[...]

62.10 Removing and installing p.c. board for gear indi- cator • Remove tachometer. • Careful ly pull poi nter (1) off the spindl e. • Release screws (2) . • Remove dial face (3) . • Release screws (4) . • Lift out p. c. boar d (5) . L Not e: Note position of spacer (6). LT620110 2 4 1 3 5 6[...]

63.1 Contents Page 63 Techn ical Data ............ ..... ..... ..... ....... ..... ..... ..... ..... ....... ..... ..... ..... ........ .... ..... ..... ........ ..... ..... .... ..... .. 3 Disassembling and assembling headlights ......... ..... ..... ..... .... ........ ..... ..... ..... ....... ..... .....5 Adjusting headlights ......... ..... ..[...]

63.2[...]

63.3 63 Technical Data K 1100 LT K 11 00 R S Lights Headlight Halogen rectangular headlight with two- stage manual range adjustment Bulbs High beam /low beam H 4 halog en bulb 55/60 W, asymmetric Parking light 12 V/4 W Rear light 12 V/10 W Brake light 12 V/21 W Turn signal light 12 V/21 W[...]

63.4[...]

63.5 Disassemb ling and assembling headlights • Remove upper section of fairing. • Remove headlight. • Release retaining spring (5). L Note: Do not touch the inside of the reflector or bulbs with bare hands. Individual par ts: 1. Glass 2. Gasket 3. Reflector 4. Reflector 5. Retaining spring 6. Bulb 7. Bulb socket 8. Retaining spring 9. Cover [...]

63.6 Adjusting headlights • Engage swivel lever (1 ) in top positi on. • Corr ect h eadlig ht range wit h adju stin g sc rew ( 2). • Turning co unterc lockwi se: shor ter • Turning clockwise : further • Adjust si de angle with knurled s crew (3). LT630020 2 3 1[...]