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BMW K1100LT K1100RS AG Motorcycle Service Manual – PDF DOWNLOAD
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BMW K1100LT K1100RS AG Motorcycle Service Manual
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Description
BMW K1100LT K1100RS AG Motorcycle Service Manual
FILE DETAILS:
BMW K1100LT K1100RS AG Motorcycle Service Manual
Language : English
Pages : 364
Downloadable : Yes
File Type : PDF
Size: 8.19 MB
DESCRIPTION:
BMW K1100LT K1100RS AG Motorcycle Service Manual
INTRODUCTION:
This repair manual will help you to perform all the main maintenance and repair work correctly and efficiently. If it is consulted regularly by workshop personnel it will form a useful addition to the theoretical and practical knowledge acquired at the BMW Training Centre. It is a contribution towards achieving even higher Service quality. All information in both text and illustrations refers to motorcycles in standard condition or with genuine BMW accessories installed, and not to motorcycles which have been modified in any way to depart from the manufacturer’s specification.
• The repair manual is structured in the logical sequence of the work to be performed: Removal, Disassembly, Repair, Assembly, Installation.
• The entire contents are divided into individual chapters, corresponding to the Construction Groups.
TABLE OF CONTENTS:
BMW K1100LT K1100RS AG Motorcycle Service Manual
Repair Manual........................................................ 1 Introduction......................................................... 3 U sage........................................................... 4 Key to symbols................................................... 4 Contents..................................................... 4 Maintenance Schedule K 75 RT/K1100RS/LT............................ 5 Pre-delivery Check K 75 RT/K1100RS/LT.............................. 6 Contents............................................................. 7 00 Maintenance and general instructions.............................. 9 Tightening torque................................................ 11 Table of operating fluids........................................ 18 Key to maintenance intervals..................................... 19 Changing engine oil.............................................. 19 Inspections I, II, III, IV................................... 19 Changing oil in transmission (gearbox).......................... 19 Inspections I, III, IV....................................... 19 Changing oil in rear wheel drive................................. 20 Inspections I, III, IV....................................... 20 Changing oil in telescopic fork.................................. 20 Inspection I, III, IV........................................ 20 Renewing intake air cleaner...................................... 20 Inspection III............................................... 20 Renewing fuel filter............................................. 21 Inspection III............................................... 21 Cleaning inductive pulse generator at rear wheel d............... 21 Inspections I, III, IV....................................... 21 Checking brake pads, brake discs for wear and rene............... 22 Inspection II, III........................................... 22 Front wheel brake............................................ 22 Rear wheel brake............................................. 22 Checking brake fluid level and correcting if neces............... 23 Inspections I, II, III....................................... 23 Checking brake fluid level................................... 23 Adding brake fluid........................................... 23 Checking brake system............................................ 23 Inspection III............................................... 23 Checking ABSsensor spacing and adjusting if neces............... 23 Inspections I, II, III....................................... 23 Front sensor................................................. 23 Rear sensor.................................................. 23 Renewing brake fluid............................................. 24 Renewing front brake fluid................................... 24 Renewing rear brake fluid.................................... 24 Checking function of electric switch on side stand............... 25 Inspections I, II, III....................................... 25 Checking clutch clearance and adjusting if necessa............... 26 Inspections I, III........................................... 26 Reading out Motronic defect code memory.......................... 26 Inspections II, III.......................................... 26 Checking increased starting speed (choke) and adju............... 27 Inspections I, III........................................... 27 Checking increased starting speed............................ 27 Checking valve clearance and adjusting if necessar............... 28 Inspections I, III........................................... 28 Adjusting valve clearance........................................ 28 Removing sprockets........................................... 28 Removing camshafts........................................... 28 Installing camshafts......................................... 29 Installing sprockets......................................... 29 Installing cylinder head cover............................... 30 Checking steering bearing play and adjusting if ne............... 31 Inspection III............................................... 31 Lubricating guide pins, adjustable screen........................ 32 Inspections III, IV.......................................... 32 Checking idle speed, synchronising and CO value an............... 33 Inspections I, II, III, IV................................... 33 Adjusting idle speed......................................... 33 Adjusting CO value without catalytic converter............... 34 11 Motor............................................................. 35 Removing engine.................................................. 45 Dismantling engine............................................... 46 Removing intermediate flange................................. 47 Removing driver.......................................... 47 Removing clutch housing.................................. 48 Stripping down and re-assembling intermediate flan........... 49 Removing the driver bearing.............................. 49 Installing driver bearing................................ 49 Removing and installing shaft sealing ring for dri....... 50 Removing countershaft and layshaft with freewheel............ 50 Dismantling and assembling freewheel......................... 51 Stripping down freewheel................................. 51 Assembling freewheel..................................... 51 Removing and installing layshaft needle roller bea........... 52 Removing bearing......................................... 52 Installing bearing....................................... 52 Removing timing chain cover.................................. 53 Removing the Hall-effect signal transmitter.............. 53 Remove the crankshaft cover.............................. 53 Removing cylinder head cover............................. 53 Removing and installing sealing ring in timing cas....... 53 Removing the timing chain.................................... 54 Removing chain tensioner................................. 54 Removing chain tensioner rail............................ 54 Renewing chain tensioner rail facing..................... 54 Removing camshaft chain sprockets........................ 55 Removing chain guide..................................... 55 Removing, stripping down and assembling cylinder h........... 56 Removing camshafts....................................... 56 Removing cylinder head................................... 56 Removing bucket-type tappets............................. 56 Removing valves.......................................... 57 Remachining valve seat................................... 57 Installing valve and valve stem seal..................... 58 Removing crankshaft.......................................... 59 Removing big end bearings................................ 59 Removing main bearings................................... 59 Removing pistons with conrods, stripping down and ........... 60 Removing piston with conrod.............................. 60 Dismantling piston....................................... 60 Checking piston dimensions............................... 60 Assembling pistons....................................... 61 Checking cylinder dimensions............................. 61 Removing and installing small-end bushing................ 61 Assembling pistons and conrods........................... 62 Removing and installing crankshaft pinion and roto........... 62 Removing, dismantling and assembling combined oil-........... 63 Removing pump............................................ 63 Dismantling pump......................................... 63 Removing slipring seal and shaft sealing ring............ 64 Removing pressure relief valve........................... 64 Installing pressure relief valve......................... 64 Install the shaft sealing ring and slipring seal......... 64 Installing pump shaft and impeller....................... 64 Removing output shaft........................................ 65 Removing oil sump........................................ 65 Removing oil filter...................................... 65 Removing lower section of crankcase...................... 65 Removing and installing oil level sight glass............ 65 Stripping and assembling output shaft........................ 66 Stripping down output shaft.............................. 66 Stripping down tensioning gear........................... 66 Assembling tensioning gear............................... 67 Installing damper........................................ 67 Assembling engine................................................ 68 Installing output shaft...................................... 68 Assembling the crankcase................................. 69 Installing oil mesh strainer............................. 69 Installing oil filter.................................... 69 Installing oil sump...................................... 69 Measuring crankshaft bearing play............................ 70 Measuring radial play.................................... 70 Measuring endplay........................................ 71 Checking dimensions of crankshaft............................ 71 Installing crankshaft........................................ 72 Installing piston with conrod................................ 73 Measuring big end bearing play............................... 74 Installing big end bearing................................... 74 Installing combined oil-water pump........................... 75 Installing cylinder head..................................... 76 Installing camshafts......................................... 77 Installing timing chain...................................... 78 Checking valve clearances.................................... 79 Installing intermediate flange............................... 80 Installing freewheel..................................... 80 Installing countershaft.................................. 80 Installing intermediate flange........................... 80 Installing driver............................................ 80 Installing alternator........................................ 80 Installing timing case cover................................. 81 Installing hall-effect transmitter........................... 81 Installing cover for Hall-effect transmitter................. 82 Installing cylinder head cover............................... 83 Installing engine................................................ 84 Checking/adjusting valve clearances.............................. 86 Adjusting valve clearances................................... 86 12 Engine electrics.................................................. 87 Removing and installing Hall generator........................... 91 Adjusting ignition timing........................................ 92 Removing and installing ignition coils........................... 94 Removing and installing ignition output stage.................... 95 Removing and installing alternator............................... 96 Disassembling and assembling alternator.......................... 97 Alternator [only LT up to 1992 model year]................... 97 Checking exciter winding................................. 98 Checking armature for short to earth..................... 99 Checking resistance between phase outputs................ 99 Checking stator winding for short to earth............... 99 Alternator [LT from 1992 model year on, RS]..................100 Checking alternator......................................101 Checking armature for short to earth.....................101 Removing and installing starter..................................102 Disassembling and assembling starter.........................103 Removing and installing brush holder.....................104 Renewing carbon brushes..................................105 Checking starter.................................................106 Checking starter relay.......................................107 Checking starter relay with ohmmeter.....................107 Troubleshooting..................................................108 Troubleshooting on alternator................................108 Troubleshooting on starter...................................112 Troubleshooting on battery...................................115 13 Fuel preparation and control......................................119 Adjusting idle speed.............................................123 Checking start speed increase (choke), adjusting i...............124 Checking start speed increase................................124 Adjusting start speed increase...............................124 Adjusting CO value...............................................125 Removing/installing and checking/ adjusting thrott...............126 Removing and installing throttle position sensor.............126 Checking trottle position sensor.............................126 Adjusting throttle position sensor...........................126 Removing and installing air cleaner insert.......................127 Removing and installing air cleaner housing......................128 Removing and installing throttle rail............................130 Removing and installing injectors............................131 Removing and installing intake stub pipe.....................131 Removing and installing Motronic control unit....................132 16 Fuel tank and lines...............................................133 Removing and installing fuel tank................................137 Removing and installing fuel filter..............................138 Removing and installing fuel level sensor........................139 Removing and installing fuel pump................................140 Checking fuel pump pressure......................................141 17 Radiator..........................................................143 Changing coolant.................................................147 Draining coolant.............................................147 Filling with coolant.........................................147 Removing and installing thermostat...............................148 Checking thermostat..........................................148 Removing and installing radiator.................................149 Removing and installing fan......................................150 Removing and installing coolant hoses............................151 Checking cooling system..........................................152 Checking cap for filler neck.................................152 Checking coolant system for leaks............................152 Troubleshooting..................................................153 18 Exhaust system....................................................155 Removing and installing exhaust system...........................157 Removing and installing oxygen sensor............................158 21 Clutch............................................................159 Removing clutch..................................................163 Removing clutch housing..........................................165 Installing clutch housing........................................166 Installing clutch................................................167 Adjusting clutch clearance.......................................169 Removing and installing clutch thrust bearing....................170 Removing and installing clutch control rod.......................171 Removing and installing clutch release lever.....................172 Troubleshooting..................................................173 23 Gearbox...........................................................175 Removing transmission (gearbox)..................................179 Preparatory work.............................................179 Removing starter.............................................180 Removing bearing mount with main stand.......................181 Removing transmission (gearbox)..............................182 Disassembling transmission (gearbox).............................183 Removing transmission cover..................................183 Disassembling/assembling transmission cover..................184 Removing and installing bearing shell....................184 Removing and installing shaft sealing ring on inpu.......184 Removing and installing locking lever....................184 Removing gear selector drum..................................185 Removing gearshift forks.....................................185 Removing transmission shafts.................................186 Removing pawl................................................186 Removing selector shaft......................................187 Removing segment.............................................187 Removing and installing shaft sealing ring on inpu...........187 Removing and installing shaft sealing ring for gea...........188 Removing and installing bearing shell for taper ro...........188 Removing and installing ball bearing on intermedia...........188 Disassembling and assembling input shaft.....................189 Disassembling input shaft................................189 Assembling input shaft...................................189 Disassembling and assembling output shaft....................191 Removing ball bearing....................................191 Removing spur gears......................................192 Installing spur gears....................................193 Installing transmission shafts...............................194 Installing gearshift forks...................................194 Measuring distances between transmission shafts..............195 Measuring bearing distance of shafts.....................195 Measuring transmission cover.............................196 Installing transmission cover................................198 Installing transmission (gearbox)................................199 Installing bearing mount with main stand.....................200 Installing starter...........................................201 Re-assembling motorcycle.................................202 31 Front fork........................................................203 Removing telescopic fork.........................................207 Removing fork stabilisor.....................................207 Removing telescopic fork without fork bridge.................207 Removing telescopic fork with fork bridge....................207 Removing upper fork bridge...............................207 Removing and installing lower taper roller bearing...........208 Removing taper roller bearing............................208 Installing taper roller bearing..........................208 Removing and installing upper taper roller bearing...........208 Removing taper roller bearing............................208 Installing taper roller bearing..........................208 Removing and installing bearing outer race in stee...........209 Removing bearing outer race..............................209 Installing bearing outer race............................209 Measuring telescopic fork....................................210 Checking lower fork bridge...............................210 Checking parallel alignment of fixed tubes...............211 Checking runout of fixed tube............................212 Disassembling telescopic fork....................................213 Removing fixed tube..........................................213 Disassembling slider tube....................................213 Disassembling fixed tube.....................................214 Assembling telescopic fork.......................................216 Assembling fixed tube........................................216 Assembling slider tube.......................................218 Installing telescopic fork.......................................219 Adjusting steering bearing play..............................220 Installing fork stabilisor...................................221 32 Steering..........................................................223 Removing and installing left and right handlebar f...............227 Removing and installing left handlebar fitting...............227 Removing and installing handlebar weight.................227 Removing and installing right handlebar fitting..............229 Removing and installing handlebar................................230 Removing and installing handlebar clamping blocks............231 Removing and installing accelerator cable........................232 Removing and installing clutch cable.............................233 Removing and installing operating cable for increa...............234 Adjusting steering bearing play..................................235 33 Rear wheel drive..................................................237 Removing, disassembling, assembling and installing...............241 Removing rear wheel drive....................................241 Removing, disassembling and assembling drive bevel...........241 Removing retaining ring..................................241 Disassembling drive bevel gear...........................243 Removing needle bearing for drive bevel gear.............244 Installing needle bearing for drive bevel gear...........244 Assembling drive bevel gear..............................245 Installing drive bevel gear..................................246 Removing and installing taper needle bearing in re...........247 Removing crown wheel.........................................248 Installing crown wheel.......................................249 Checking/adjusting tooth backlash............................250 Checking contact pattern.....................................251 Shimming housing cover.......................................252 Installing housing cover.....................................252 Installing slider............................................252 Installing rear wheel drive..................................253 Removing, disassembling and assembling rear swingi...............255 Removing and installing taper roller bearing.................255 Removing and installing gaiter...............................256 Removing drive shaft.........................................256 Checking universal joint for wear........................256 Removing retaining ring..................................256 Installing drive shaft.......................................256 Installing swinging arm......................................257 Installing footrest plates...............................257 34 Brakes............................................................259 Removing and installing front brake caliper......................263 Dismantling and assembling front brake caliper...................264 Dismantling front brake caliper..............................264 Assembling front brake caliper...............................265 Removing and installing brake pads...........................266 Removing and installing front brake disc.........................267 Removing and installing ABS pulse wheel......................267 Removing and installing front ABS sensor.........................268 Adjusting front ABS sensor gap...................................269 Removing and installing front brake line.........................270 Removing upper brake line....................................270 Removing lower brake line....................................270 Removing and installing ABS brake line from front ...............271 Removing and installing handbrake cylinder.......................272 Bleeding brake...................................................273 Bleeding front brake.........................................273 Bleeding brake caliper...................................273 [ABS II] Bleeding pressure modulator.....................274 Bleeding the handlebar fitting...........................274 Bleeding rear brake..........................................274 Bleeding brake caliper...................................274 [ABS II] Bleeding pressure modulator.....................274 Removing and installing pressure modulator.......................275 [ABS I] Removing and installing front or rear pres...........275 [ABS II] Removing ABS unit...................................276 [ABS II] Installing ABS unit.................................277 [ABS II] Removing and installing relay and relay b...............278 [ABS II] Removing relay......................................278 [ABS II] Installing relay....................................278 [ABS II] Removing relay base.................................279 [ABS II] Installing relay base...............................279 Removing and installing rear brake caliper.......................280 Removing and installing rear brake pads..........................280 Dismantling and assembling rear brake caliper....................281 Dismantling rear brake caliper...............................281 Assembling rear brake caliper................................281 Removing and installing rear brake disc..........................282 Removing and installing rear ABS sensor..........................283 Measuring vertical runout at rear pulse wheel....................284 Removing and installing rear master brake cylinder...............285 Disassembling rear master brake cylinder.....................286 Removing and installing brake pedal..............................287 Adjusting foot brake pedal.......................................288 Troubleshooting: Front wheel/rear wheel brake....................289 36 Wheels and tyres..................................................293 Removing and installing front wheel..............................297 Removing and instaling wheel bearings.......................298 Removing left bearing....................................298 Removing right bearing...................................298 Installing left and right bearings.......................298 Removing and installing rear wheel...............................299 Removing rear wheel..........................................299 Installing rear wheel........................................299 Static balancing of front and rear wheels........................300 Static balancing of front wheel..............................300 Static balancing of rear wheel...............................300 Checking wheel for runout........................................301 Checking front wheel for runout..............................301 Checking rear wheel for runout...............................301 46 Frame.............................................................303 Removing and installing front mudguard..........................307 Removing and installing rear section.............................308 Removing and installing rear mudguard...........................309 Removing and installing fairing [LT].............................310 Removing side sections of fairing............................310 Removing radiator cowling....................................310 Removing and installing windshield...........................311 Removing and installing windshield complete with m...........311 Disassembling and assembling adjustable windshield...........312 Removing and installing actuator motor...................312 Removing plate...........................................312 Removing lever...........................................313 Removing guide bush in lever.............................313 Removing sliding piece...................................313 Removing and installing upper section of fairing............314 Removing and installing fairing [RS].............................315 Removing and installing lower section of fairing.............315 Removing and installing side section of fairing..............315 Removing and installing radiator cowling....................315 Removing and installing upper section of fairing............316 Removing and installing windshield, spoiler and he...........316 Removing and installing fairing support bracket.............317 Arrangement of cable clips [LT]..........................317 Arrangement of cable clips [RS]..........................317 Checking running gear............................................318 Measuring track offset.......................................318 Checking frame with gauge....................................320 Removing and installing frame....................................322 Removing frame...............................................322 Disassembling and assembling frame...........................322 Removing outer bearing race in steering head.............322 Installing outer bearing race in steering head...........322 Removing and installing seat lock........................323 Removing and installing handle...........................323 Installing frame.............................................324 Removing and installing main centre stand........................325 Line arrangement for side stand..............................325 Disassembling and assembling side stand......................326 Disassembling side stand.................................326 Assembling side stand....................................327 Disassembling and assembling main centre stand...............328 Checking switching function of side stand........................329 51 Equipment.........................................................331 Removing and installing ignition switch/steering l...............333 Removing and installing lock cylinder for fuel tan...............334 Removing lock cylinder.......................................334 Installing locking cylinder..................................334 Removing lock cylinder with broken key.......................334 Removing and installing dualseat lock............................335 61 General electrical equipment......................................337 Removing and installing Motronic control unit....................341 [ABS I] Removing and installing control unit.....................342 [ABS II] Removing and installing control unit....................342 Removing and installing battery..................................343 Relay locations (central electrical unit)........................344 Locations and connections, ABS wiring loom.......................345 Locations, frame wiring loom.....................................346 View from left...............................................346 Wiring arrangement, fairing bracket, [LT]....................346 View from right..............................................347 Wiring arrangement fairing bracket, [RS].....................347 62 Instruments.......................................................349 Removing and installing instrument cluster.......................353 [LT].........................................................353 [RS].........................................................354 Disassembling and assembling instrument cluster.............355 Removing and installing indicator lamp...................355 Removing and installing p.c. board.......................356 Removing and installing quartz clock.....................356 Removing and installing frame for indicator lamps........356 Removing and installing p.c. board for fuel gauge........356 Removing and installing revolution counter...............357 Removing and installing speedometer......................357 Removing and installing p.c. board for gear indica.......358 63 Lights............................................................359 Disassembling and assembling headlights..........................363 Adjusting headlights.............................................364
BMW K1100LT K1100RS AG MOTORCYCLE SERVICE MANUAL – PDF DOWNLOAD:
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