BMW K 1100 LT, RS - Repair, Service Manual - Reparaturanleitung

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BMW K 1100 LT-RS - SERVICE MANUAL - REPARATURANLEITUNG

- English & Deutsch service manual to motorcycles BMW K 1100 LT-RS.


CONTENTS:
    
REPAIR MANUAL

INTRODUCTION
U sage
Key to symbols
Contents
MAINTENANCE SCHEDULE K 75 RT/K 1100 RS/LT
PRE-DELIVERY CHECK K 75 RT/K 1100 RS/LT
CONTENTS
00 MAINTENANCE AND GENERAL INSTRUCTIONS
Tightening torque
Table of operating fluids
Key to maintenance intervals
Changing engine oil
Inspections I, II, III, IV
Changing oil in transmission (gearbox)
Inspections I, III, IV
Changing oil in rear wheel drive
Inspections I, III, IV
Changing oil in telescopic fork
Inspection I, III, IV
Renewing intake air cleaner
Inspection III
Renewing fuel filter
Inspection III

Inspections I, III, IV
Checking brake pads, brake discs for wear and rene...
Inspection II, III
Front wheel brake
Rear wheel brake
Checking brake fluid level and correcting if neces...
Inspections I, II, III
Checking brake fluid level
Adding brake fluid
Checking brake system
Inspection III
Checking ABS sensor spacing and adjusting if neces...
Inspections I, II, III
Front sensor
Rear sensor
Renewing brake fluid
Renewing front brake fluid
Renewing rear brake fluid
Checking function of electric switch on side stand...
Inspections I, II, III
Checking clutch clearance and adjusting if necessa...
Inspections I, III
Reading out Motronic defect code memory
Inspections II, III
Checking increased starting speed (choke) and adju...
Inspections I, III
Checking increased starting speed
Checking valve clearance and adjusting if necessar...
Inspections I, III
Adjusting valve clearance
Removing sprockets
Removing camshafts
Installing camshafts
Installing sprockets
Installing cylinder head cover
Checking steering bearing play and adjusting if ne...
Inspection III
Lubricating guide pins, adjustable screen
Inspections III, IV
Checking idle speed, synchronising and CO value an...
Inspections I, II, III, IV
Adjusting idle speed
Adjusting CO value without catalytic converter
11 MOTOR
Removing engine
Dismantling engine
Removing intermediate flange
Removing driver
Removing clutch housing
Stripping down and re-assembling intermediate flan...
Removing the driver bearing
Installing driver bearing
Removing and installing shaft sealing ring for dri...
Removing countershaft and layshaft with freewheel
Dismantling and assembling freewheel
Stripping down freewheel
Assembling freewheel
Removing and installing layshaft needle roller bea...
Removing bearing
Installing bearing
Removing timing chain cover
Removing the Hall-effect signal transmitter
Remove the crankshaft cover
Removing cylinder head cover
Removing and installing sealing ring in timing cas...
Removing the timing chain
Removing chain tensioner
Removing chain tensioner rail
Renewing chain tensioner rail facing
Removing camshaft chain sprockets
Removing chain guide
Removing, stripping down and assembling cylinder h...
Removing camshafts
Removing cylinder head
Removing bucket-type tappets
Removing valves
Remachining valve seat
Installing valve and valve stem seal
Removing crankshaft
Removing big end bearings
Removing main bearings
Removing pistons with conrods, stripping down and ...
Removing piston with conrod
Dismantling piston
Checking piston dimensions
Assembling pistons
Checking cylinder dimensions
Removing and installing small-end bushing
Assembling pistons and conrods
Removing and installing crankshaft pinion and roto...
Removing, dismantling and assembling combined oil-...
Removing pump
Dismantling pump
Removing slipring seal and shaft sealing ring
Removing pressure relief valve
Installing pressure relief valve
Install the shaft sealing ring and slipring seal
Installing pump shaft and impeller
Removing output shaft
Removing oil sump
Removing oil filter
Removing lower section of crankcase
Removing and installing oil level sight glass
Stripping and assembling output shaft
Stripping down output shaft
Stripping down tensioning gear
Assembling tensioning gear
Installing damper
Assembling engine
Installing output shaft
Assembling the crankcase
Installing oil mesh strainer
Installing oil filter
Installing oil sump
Measuring crankshaft bearing play
Measuring radial play
Measuring endplay
Checking dimensions of crankshaft
Installing crankshaft
Installing piston with conrod
Measuring big end bearing play
Installing big end bearing
Installing combined oil-water pump
Installing cylinder head
Installing camshafts
Installing timing chain
Checking valve clearances
Installing intermediate flange
Installing freewheel
Installing countershaft
Installing intermediate flange
Installing driver
Installing alternator
Installing timing case cover
Installing hall-effect transmitter
Installing cover for Hall-effect transmitter
Installing cylinder head cover
Installing engine
Checking/adjusting valve clearances
Adjusting valve clearances
12 ENGINE ELECTRICS
Removing and installing Hall generator
Adjusting ignition timing
Removing and installing ignition coils
Removing and installing ignition output stage
Removing and installing alternator
Disassembling and assembling alternator
Alternator [only LT up to 1992 model year]
Checking exciter winding
Checking armature for short to earth
Checking resistance between phase outputs
Checking stator winding for short to earth
Alternator [LT from 1992 model year on, RS]
Checking alternator
Checking armature for short to earth
Removing and installing starter
Disassembling and assembling starter
Removing and installing brush holder
Renewing carbon brushes
Checking starter
Checking starter relay
Checking starter relay with ohmmeter
Troubleshooting
Troubleshooting on alternator
Troubleshooting on starter
Troubleshooting on battery
13 FUEL PREPARATION AND CONTROL
Adjusting idle speed
Checking start speed increase (choke), adjusting i...
Checking start speed increase
Adjusting start speed increase
Adjusting CO value
Removing/installing and checking/ adjusting thrott...
Removing and installing throttle position sensor
Checking trottle position sensor
Adjusting throttle position sensor
Removing and installing air cleaner insert
Removing and installing air cleaner housing
Removing and installing throttle rail
Removing and installing injectors
Removing and installing intake stub pipe
Removing and installing Motronic control unit
16 FUEL TANK AND LINES
Removing and installing fuel tank
Removing and installing fuel filter
Removing and installing fuel level sensor
Removing and installing fuel pump
Checking fuel pump pressure
17 RADIATOR
Changing coolant
Draining coolant
Filling with coolant
Removing and installing thermostat
Checking thermostat
Removing and installing radiator
Removing and installing fan
Removing and installing coolant hoses
Checking cooling system
Checking cap for filler neck
Checking coolant system for leaks
Troubleshooting
18 EXHAUST SYSTEM
Removing and installing exhaust system
Removing and installing oxygen sensor
21 CLUTCH
Removing clutch
Removing clutch housing
Installing clutch housing
Installing clutch
Adjusting clutch clearance
Removing and installing clutch thrust bearing
Removing and installing clutch control rod
Removing and installing clutch release lever
Troubleshooting
23 GEARBOX
Removing transmission (gearbox)
Preparatory work
Removing starter
Removing bearing mount with main stand
Removing transmission (gearbox)
Disassembling transmission (gearbox)
Removing transmission cover.
Disassembling/assembling transmission cover
Removing and installing bearing shell
Removing and installing shaft sealing ring on inpu...
Removing and installing locking lever
Removing gear selector drum
Removing gearshift forks
Removing transmission shafts
Removing pawl
Removing selector shaft
Removing segment
Removing and installing shaft sealing ring on inpu...
Removing and installing shaft sealing ring for gea...
Removing and installing bearing shell for taper ro...
Removing and installing ball bearing on intermedia...
Disassembling and assembling input shaft
Disassembling input shaft
Assembling input shaft
Disassembling and assembling output shaft
Removing ball bearing
Removing spur gears
Installing spur gears

Installing transmission shafts
Installing gearshift forks
Measuring distances between transmission shafts
Measuring bearing distance of shafts
Measuring transmission cover
Installing transmission cover
Installing transmission (gearbox)
Installing bearing mount with main stand
Installing starter
Re-assembling motorcycle
31 FRONT FORK
Removing telescopic fork
Removing fork stabilisor
Removing telescopic fork without fork bridge
Removing telescopic fork with fork bridge
Removing upper fork bridge
Removing and installing lower taper roller bearing...
Removing taper roller bearing
Installing taper roller bearing
Removing and installing upper taper roller bearing...
Removing taper roller bearing
Installing taper roller bearing
Removing and installing bearing outer race in stee...
Removing bearing outer race
Installing bearing outer race
Measuring telescopic fork
Checking lower fork bridge
Checking parallel alignment of fixed tubes
Checking runout of fixed tube
Disassembling telescopic fork
Removing fixed tube
Disassembling slider tube
Disassembling fixed tube
Assembling telescopic fork
Assembling fixed tube
Assembling slider tube
Installing telescopic fork
Adjusting steering bearing play
Installing fork stabilisor
32 STEERING
Removing and installing left and right handlebar f...
Removing and installing left handlebar fitting
Removing and installing handlebar weight
Removing and installing right handlebar fitting
Removing and installing handlebar
Removing and installing handlebar clamping blocks
Removing and installing accelerator cable
Removing and installing clutch cable
Removing and installing operating cable for increa...
Adjusting steering bearing play
33 REAR WHEEL DRIVE
Removing, disassembling, assembling and installing...
Removing rear wheel drive
Removing, disassembling and assembling drive bevel...
Removing retaining ring
Disassembling drive bevel gear
Removing needle bearing for drive bevel gear
Installing needle bearing for drive bevel gear
Assembling drive bevel gear
Installing drive bevel gear
Removing and installing taper needle bearing in re...
Removing crown wheel
Installing crown wheel
Checking/adjusting tooth backlash
Checking contact pattern
Shimming housing cover
Installing housing cover
Installing slider
Installing rear wheel drive
Removing, disassembling and assembling rear swingi...
Removing and installing taper roller bearing
Removing and installing gaiter
Removing drive shaft
Checking universal joint for wear
Removing retaining ring
Installing drive shaft
Installing swinging arm
Installing footrest plates
34 BRAKES
Removing and installing front brake caliper
Dismantling and assembling front brake caliper
Dismantling front brake caliper
Assembling front brake caliper
Removing and installing brake pads
Removing and installing front brake disc
Removing and installing ABS pulse wheel
Removing and installing front ABS sensor
Adjusting front ABS sensor gap
Removing and installing front brake line
Removing upper brake line
Removing lower brake line
Removing and installing ABS brake line from front ...
Removing and installing handbrake cylinder
Bleeding brake
Bleeding front brake
Bleeding brake caliper
[ABS II] Bleeding pressure modulator
Bleeding the handlebar fitting
Bleeding rear brake
Bleeding brake caliper
[ABS II] Bleeding pressure modulator
Removing and installing pressure modulator
[ABS I] Removing and installing front or rear pres...
[ABS II] Removing ABS unit
[ABS II] Installing ABS unit
[ABS II] Removing and installing relay and relay b...
[ABS II] Removing relay
[ABS II] Installing relay
[ABS II] Removing relay base
[ABS II] Installing relay base
Removing and installing rear brake caliper
Removing and installing rear brake pads
Dismantling and assembling rear brake caliper
Dismantling rear brake caliper
Assembling rear brake caliper
Removing and installing rear brake disc
Removing and installing rear ABS sensor
Measuring vertical runout at rear pulse wheel
Removing and installing rear master brake cylinder...
Disassembling rear master brake cylinder
Removing and installing brake pedal
Adjusting foot brake pedal
Troubleshooting: Front wheel/rear wheel brake
36 WHEELS AND TYRES
Removing and installing front wheel
Removing and instaling wheel bearings
Removing left bearing
Removing right bearing
Installing left and right bearings
Removing and installing rear wheel
Removing rear wheel
Installing rear wheel
Static balancing of front and rear wheels
Static balancing of front wheel
Static balancing of rear wheel
Checking wheel for runout
Checking front wheel for runout
Checking rear wheel for runout
46 FRAME
Removing and installing front mudguard
Removing and installing rear section
Removing and installing rear mudguard
Removing and installing fairing [LT]
Removing side sections of fairing
Removing radiator cowling
Removing and installing windshield
Removing and installing windshield complete with m...
Disassembling and assembling adjustable windshield...
Removing and installing actuator motor
Removing plate
Removing lever
Removing guide bush in lever
Removing sliding piece
Removing and installing upper section of fairing
Removing and installing fairing [RS]
Removing and installing lower section of fairing
Removing and installing side section of fairing
Removing and installing radiator cowling
Removing and installing upper section of fairing
Removing and installing windshield, spoiler and he...
Removing and installing fairing support bracket
Arrangement of cable clips [LT]
Arrangement of cable clips [RS]
Checking running gear
Measuring track offset
Checking frame with gauge
Removing and installing frame
Removing frame
Disassembling and assembling frame
Removing outer bearing race in steering head
Installing outer bearing race in steering head
Removing and installing seat lock
Removing and installing handle
Installing frame
Removing and installing main centre stand
Line arrangement for side stand
Disassembling and assembling side stand
Disassembling side stand
Assembling side stand
Disassembling and assembling main centre stand
Checking switching function of side stand
51 EQUIPMENT
Removing and installing ignition switch/steering l...
Removing and installing lock cylinder for fuel tan...
Removing lock cylinder
Installing locking cylinder
Removing lock cylinder with broken key
Removing and installing dualseat lock
61 GENERAL ELECTRICAL EQUIPMENT
Removing and installing Motronic control unit
[ABS I] Removing and installing control unit
[ABS II] Removing and installing control unit
Removing and installing battery
Relay locations (central electrical unit)
Locations and connections, ABS wiring loom
Locations, frame wiring loom
View from left
Wiring arrangement, fairing bracket, [LT]
View from right
Wiring arrangement fairing bracket, [RS]
62 INSTRUMENTS
Removing and installing instrument cluster
[LT]
[RS]
Disassembling and assembling instrument cluster
Removing and installing indicator lamp
Removing and installing p.c. board
Removing and installing quartz clock
Removing and installing frame for indicator lamps
Removing and installing p.c. board for fuel gauge
Removing and installing revolution counter
Removing and installing speedometer
Removing and installing p.c. board for gear indica...
63 LIGHTS
Disassembling and assembling headlights
Adjusting headlights


REPARATURANLEITUNG

REPARATURANLEITUNG
VORWORT
H and habung
Zeichenerklärung
Inhalt
WARTUNGSPLAN K 75 RT/K 1100 RS/K 1100 LT
ÜBERGABEDURCHSICHT K 75 RT/K 1100 RS/LT
GESAMTINHALTSVERZEICHNIS
00 WARTUNG UND ALLGEMEINE HINWEISE
Anziehdrehmomente
Betriebsmitteltabelle
Verschlüsselung der Wartungsintervalle
Motoröl wechseln
Inspektion I, II, III, IV
Öl im Schaltgetriebe wechseln
Inspektion I, III, IV
Öl im Hinterradantrieb wechseln
Inspektion I, III, IV
Öl in der Teleskopgabel wechseln
Inspektion I, III, IV
Ansaugluftfilter erneuern
Inspektion III
Kraftstoffilter erneuern
Inspektion III
Induktivgeber am Hinterradantrieb reinigen
Inspektion I, III, IV
Bremsbeläge, Bremsscheiben auf Verschleiß prüfen ...
Inspektion II, III
Vorderradbremse
Hinterradbremse
Bremsflüssigkeitsstand prüfen, ggf. ergänzen
Inspektion I, II, III
Bremsflüssigkeitsstand prüfen
Bremsflüssigkeitsstand ergänzen
Bremsanlage prüfen
Inspektion III
ABS Sensorabstand prüfen, ggf. einstellen
Inspektion I, II, III
Sensor vorne
Sensor hinten
Bremsflüssigkeit wechseln
Bremsflüssigkeit vorne wechseln
Bremsflüssigkeit hinten wechseln
Schaltfunktion elektrische Seitenstütze prüfen (W...
Inspektion I, II, III
Kupplungsspiel prüfen, ggf. einstellen
Inspektion I, III
Motronic-Fehlerspeicher auslesen
Inspektion II, III
Startdrehzahlanhebung (Choke) prüfen, ggf. einste...
Inspektion I, III
Startdrehzahlanhebung prüfen
Ventilspiel prüfen, ggf. einstellen
Inspektion III
Ventilspiel einstellen
Kettenräder ausbauen
Nockenwellen ausbauen
Nockenwellen einbauen
Kettenräder einbauen
Zylinderkopfhaube einbauen
Lenkungslagerspiel prüfen, ggf. einstellen
Inspektion III
Führungsbolzen verstellbares Windschild schmieren...
Inspektion III, IV
Leerlaufdrehzahl, Synchronisation und CO-Wert prüf...
Inspektion I, II, III, IV
Leerlauf einstellen
CO-Wert einstellen, ohne Katalysator
11 MOTOR
Motor ausbauen
Motor zerlegen
Zwischenflansch ausbauen
Mitnehmer ausbauen
Kupplungsgehäuse ausbauen
Zwischenflansch zerlegen und zusammenbauen
Lager für Mitnehmer ausbauen
Lager für Mitnehmer einbauen
Wellendichtring für Mitnehmer aus-/einbauen
Vorgelege- und Nebenwelle mit Freilauf ausbauen
Freilauf zerlegen und zusammenbauen
Freilauf zerlegen
Freilauf zusammenbauen
Nadellager für Nebenwelle aus- und einbauen
Lager ausbauen
Lager einbauen
Kettenkastendeckel ausbauen
Hallgeber ausbauen
Abdeckung für Kurbelwelle ausbauen
Zylinderkopfhaube ausbauen
Dichtring im Kettenkastendeckel aus-/einbauen
Steuerkette ausbauen
Kettenspanner ausbauen
Kettenspannschiene ausbauen
Belag der Kettenspannschiene ersetzen
Kettenräder der Nockenwelle ausbauen
Kettenführung ausbauen
Zylinderkopf ausbauen, zerlegen und zusammenbauen
Nockenwellen ausbauen
Zylinderkopf ausbauen
Tassenstößel ausbauen
Ventile ausbauen
Ventilsitz nacharbeiten
Ventil und Ventilschaftabdichtung einbauen
Kurbelwelle ausbauen
Pleuellager ausbauen
Kurbelwellenlager ausbauen
Kolben mit Pleuel ausbauen, zerlegen und zusammenb...
Kolben mit Pleuel ausbauen
Kolben zerlegen
Kolben vermessen
Kolben zusammenbauen
Zylinder vermessen
Pleuelbüchse aus-/einbauen
Kolben und Pleuel zusammenbauen
Kurbelwellenritzel und Rotorflansch aus-/einbauen
Kombinierte Öl-Wasserpumpe ausbauen, zerlegen und ...
Pumpe ausbauen
Pumpe zerlegen
Gleitringdichtung und Wellendichtring ausbauen

AND MORE....