BMW R1150RT - MAINTENANCE INTEGRAL ABS Technical data

Maintenance BMW Integral ABS
R 1150 RT
BMW Motorrad
After Sales
Published by:
© BMW Motorrad
After Sales
UX-VS-2
All rights reserved. Not to be reprinted, translated or duplicated either wholly or in part without prior written
permission.
Errors and omissions excepted; subject to technical amendment.
Produced in Germany 01/01
Mechanic’s signature
BMW
Annual Service
Order No.
BMW Inspection
every 20,000 km
(12,000 miles)
Registration No.
BMW Service
10,000 km
(6,000 miles)
Customer
BMW Inspection
at 1,000 km
(600 miles)
BMW Motorrad
Maintenance schedule
R 1100 S EVO / R 1150 R / R 1150 RT
Read the fault code memory with the BMW MoDiTeC
[Integral ABS] perform bleed test with BMW MoDiTeC
Change oil while at regular operating temperature and replace the oil filter element
If the motorcycle is ridden only for short distances or outside temperatures are below 0 °C: at the
latest every 3,000 km (1,800 miles)*)
Change oil in gearbox while at operating temperature
every 2 years*) at the latest
every
2 years
Change oil in rear wheel drive while at operating temperature
if necessary, clean inductive sensor on rear wheel
every 40,000 km (24,000 miles) or at the latest every 2 years*)
40,000
Replace fuel filter *)
Normally every 40,000 km (24,000 miles), if fuel is of poor quality every 20,000 km (12,000 miles)
40,000
every
2 years
Check the battery fluid level, if necessary top up with distilled water
Clean and grease battery poles if necessary
Replace intake air filter element
In very dirty and dusty operating conditions, replace every 10,000 km (6,000 miles) or even more
frequently if necessary *)
Replace Poly-V belt *)
Replace the Poly-V belt every 60,000 km (36,000 miles); do not adjust it
60,000
Check brake fluid level at front and rear
Check operation of brake system and freedom from leaks; repair/replace items if necessary*)
Examine brake pads and discs for wear, replace as necessary*)
[Without ABS] change brake fluid every twelve months
[Integral ABS] change bake fluid in wheel circuit every 12 months
[Integral ABS] change brake fluid in control circuit every 2 years*)
every
2 years
[Integral ABS] perform bleed test with BMW MoDiTeC
Check clutch fluid level
Change the clutch fluid*)
every 2 years at the latest
every
2 years
Check tightness of rear wheel studs
Check rear wheel bearing play by tilting wheel
Check swinging arm bearings (freedom from play), adjust if necessary *)
Grease the side stand pivot
Check function of side stand contact switch
Check condition of spark plugs
Replace spark plugs
Tighten cylinder head nuts
Check/adjust valve clearances
Check that the throttle cable moves freely and is free of kinks and chaffing, replace if necessary *)
Check throttle-cable play
check synchronisation, repair leaks if necessary *)
Final inspection with road safety and functional check:
–
Condition of tyres and wheels, tyre pressures
–
Lights and signalling equipment, telltale and warning lights, instruments,
–
clutch, gearshift mechanism, hand brake and foot brake, steering,
–
if necessary, test drive
*)
Charged as an additional item
Order No. 01 71 0 029 614
UX-VS-2, 12.2000
Printed in Germany
BMW Motorrad
Pre-delivery check
R 1100 S EVO / R 1150 R / R 1150 RT
Customer
Registration No.
Order No.
Mechanic’s signature
BMW
Pre-delivery check
Check the shipping crate for damage
Motorcycle:
–
–
–
–
unpack
install remaining items
inspect for damage
check that delivery is complete:
Toolkit
On-board literature
Ignition keys
Scope of optional extras
Fill and charge the battery (mark with charging date)
Check engine oil level when cold and correct if necessary.
Check headlight setting and adjust if necessary.
Check tightness of rear wheel studs
(note correct tightening torque)
Check tyre pressures
Fill up with fuel
[Integral ABS] perform bleed test with BMW MoDiTeC
Final inspection as functional check:
–
–
–
–
–
Clutch, gear shift
Handbrake and foot brake
Lights and signalling equipment, telltale and warning lights, instruments,
Check operation of optional extras
If necessary, test drive
Confirm pre-delivery check in “Service and Technical Booklet”.
Final cleaning
Motorcycle handed over on:
Order No. 01 71 0 029 614
UX-VS-2, 12.2000
Printed in Germany
BMW Motorrad
Service data
R 1150 RT
Item
Desired value
Oil capacities
Engine
(with filter)
(without filter)
3.75 (6.6)
3.50 (6.15)
Unit of measurement/specification
litres (Imp. pints)
litres (Imp. pints)
[SI 11 048 90]
Engine oil grade: brand-name HD oil
for four-stroke spark-ignition engines,
API classes SE, SF, SG; combination
with CC or CD specification
Transmission
Initial filling
Oil changes
Rear wheel drive
approx. 1.0 (1.76)
approx. 0.8 (1.41)
litres (Imp. pints)
litres (Imp. pints)
of oil to bottom edge of
filler neck
Brand-name hypoid gear oil, SAE
class GL 5 SAE 90
approx. 0.25 (0.44)
Initial filling/oil change
Valve clearances
measured cold (max. 35 °C/95 °F)
Ignition timing
static setting
litres (Imp. pints)
of oil to bottom edge of
filler neck
Brand-name hypoid gear oil, SAE
class GL 5 SAE 90
Inlet: 0.15 (0.006)
Exhaust: 0.30 (0.012)
mm (in)
mm (in)
adjust at TDC
Spark plugs
Electrode gap
Wear limit
0.8 (0.0315)
1.0 (0.039)
Idle speed
1,100
Throttle cable setting
for cold-start (increased idle) speed
for throttle (twistgrip) cable
for divider cable
±50
zero play
approx. 0.5 (0.02)
zero play
Brakes
Colour of identification mark on brake calipers/brake pads, front
Minimum front pad thickness
Minimum rear pad thickness
Minimum front disc thickness
Minimum rear disc thickness
Tyre pressures
depending on load
mm (in)
mm (in)
rpm
mm (in) free travel
DOT 4 brake fluid
white
1.0 (0.039)
1.0 (0.039) (wear mark)
4.5 (0.177)
4.5 (0.177)
mm
mm
mm
mm
(in)
(in)
(in)
(in)
front: 2.2 – 2.5
(31.9 – 36.26)
rear: 2.5 – 2.9
(36.26 – 42.06)
bar (psi)
Tightening torques:
Oil filter
Engine oil drain plug
11
32
Nm
Nm
Gearbox oil filler plug
Gearbox oil drain plug
30
30
Nm
Nm
Rear wheel drive oil filler/drain plug
23
Nm
Fuel tank to rear frame
Fuel pump assembly to tank
22
5
Nm
Nm
Poly-V belt preload
Alternator to cover mount
8
20
Nm
Nm
Brake caliper fasteners, front
Brake caliper fasteners, rear
30
40
Nm
Nm
105
Nm
unscrew/20
180
unscrew/40
Nm
° tightening angle
Nm
Locknut, valve adjusting screw
8
Nm
Cylinder head cover
8
Nm
25
Nm
Rear wheel studs
Tightening cylinder heads
Nut
M 10 screw
Spark plugs NGK BKR 7 EKC
Order No. 01 71 0 029 621
UX-VS-2, 11.00
bar (psi)
Printed in Germany
00
00 Tightening torque
Table of operating fluids
Contents
Page
Tightening torque .........................................................................................................................3
11 Engine ...........................................................................................................................................3
12 Engine electrics ........................................................................................................................5
13 Fuel preparation and control ...............................................................................................5
16 Fuel tank and lines ...................................................................................................................5
18 Exhaust system .........................................................................................................................5
21 Clutch ............................................................................................................................................6
23 Transmission ..............................................................................................................................6
31 Front forks ...................................................................................................................................7
32 Steering ........................................................................................................................................7
33 Rear wheel drive .......................................................................................................................8
34 Brakes ...........................................................................................................................................9
36 Wheels and tyres ......................................................................................................................9
46 Frame .......................................................................................................................................... 10
51 Equipment ................................................................................................................................. 11
61 General electrical equipment ............................................................................................ 11
Table of operating fluids
.........................................................................................................12
00.1
00.2
00
Tightening torque
Model
R 1150 RT
Connection
11 Engine
Cylinder head
Tightening sequence:
1 Tighten cylinder head nuts (oiled) in
diagonally opposite sequence
1.1 Tighten all nuts to closing torque
Nm
20
1.2 Tighten all nuts to correct wrench
angle
°
90
1.3 Tighten all nuts to correct wrench
angle
°
90
2 M 10 screw
Nm
40
3 M 6 screw
Nm
9
Nm
20
After 1,000 km (600 miles), tighten cylinder
head nuts in diagonally opposite sequence:
1 Slacken one nut
2 Tighten nut to initial torque
3 Tighten nut to wrench angle
°
180
4 Slacken and retighten M 10 screw
Nm
40
Timing gear carrier to cylinder head
Nm
9
Bearing cap on rocker shaft
Nm
18
Locknut, valve adjusting screw
Nm
8
Cylinder head cover to cylinder head
Nm
8
Camshaft end cover to cylinder head
Nm
9
Air intake connection to cylinder head
Nm
9
Chain sprocket to camshaft
Nm
65
Camshaft bearing cap
Nm
15
M 6 screw
Nm
9
M 8 screw
Nm
20
Chain sprocket to crankshaft
Nm
10
Chainwheel to auxiliary shaft
Nm
70
Chain tensioner housing to engine block
Nm
9
Camshaft
Alternator mount cover
Auxiliary shaft
00.3
Model
R 1150 RT
Connection
11 Engine
Oil filter
Oil filter
Nm
11
Oil drain plug
Nm
32
Mesh filter basket to engine block
Nm
10
Oil pump cover
Nm
9
Pressure relief valve
Nm
42
Oil pressure switch
Nm
30
Cooling oil line to engine block
Nm
10
Cooling oil line banjo screw with oil vent
valve
Nm
25
Oil cooler to bracket
Nm
9
Oil cooler return line to engine block
Nm
35
Oil cooler connection to crankcase
Nm
9
1 M 8 screw
Nm
20
2 M 6 screw
Nm
9
3 Chain guide rail pivot screw
Nm
18
Nm
32
Nm
20
°
80
Nm
25
°
90
Oil pump
Oil cooler
Cylinders
Tightening sequence:
Timing chain
Chain tensioner
Connecting rod
Big end cap
Closing torque
Wrench angle
Crankcase
Tightening sequence:
M 10 screw (oiled) to initial torque
Wrench angle
M 8 screw
Nm
22 (oiled)
M 6 screw
Nm
9
00.4
Model
R 1150 RT
Connection
12 Engine electrics
Starter motor to engine
Nm
20
Positive lead to starter motor
Nm
10
Alternator to generator support cover
Nm
20
Tensioning and retaining link to alternator
Nm
21
Spacer to alternator
Nm
21
Positive lead to alternator
Nm
15
Belt pulley to alternator
Nm
50
Belt pulley to crankshaft
Nm
50
Poly-V belt preload
Nm
8
NGK BKR 7 EKC spark plug
Nm
25
Model
R 1150 RT
Connection
13 Fuel preparation and control
Oil temperature sensor to crankcase
Nm
25
Air temperature sensor to air-filter housing
Nm
10
Model
R 1150 RT
Connection
16 Fuel tank and lines
Fuel tank to rear frame
Nm
22
Fuel pump assembly to tank
Nm
5
Model
R 1150 RT
Connection
18 Exhaust system
Manifold to cylinder head
Nm
21
Clamp for manifold
Nm
45
(apply Optimoly TA to clamp seat)
Silencer to footrest plate
Nm
35
Oxygen sensor to silencer
Nm
45
(apply Optimoly TA to thread)
00.5
Model
R 1150 RT
Connection
21 Clutch
Clutch housing
Initial tightening torque
Nm
40
(oil screw threads lightly)
°
32
Housing cover to housing
Nm
12
Clutch line to handlebar fitting
Nm
14
Slave cylinder to gearbox
Nm
9
Grub screw in filler adapter
Nm
10
+ additional wrench angle
Model
R 1150 RT
Connection
23 Transmission
Oil drain plug
Nm
30
Oil filler plug
Nm
30
Gearbox to engine block
Nm
22
Shift lever to footrest plate
Nm
35
Selector lever to selector shaft
Nm
9
Housing cover to housing
Nm
9
1. to gearbox and left footrest plate
Nm
42
(clean thread + Loctite 243)
2. terminal block, frame tube to transmission
Nm
9
3. to gearbox and right footrest plate
Nm
42
(clean thread + Loctite 243)
Frame tube to gearbox
00.6
Model
R 1150 RT
Connection
31 Front forks
Quick-release axle clamp screws
Nm
22
Sliding tube bridge to slider tube
Nm
25
(clean thread + Loctite 243)
Threaded connection, fork fixed tube to
fork bridge
Nm
45
(free from oil and grease)
Threaded stud to frame
Nm
130
(clean thread + Loctite 243)
Ball joint to sliding tube bridge
Nm
230
(lightly grease threads with Optimoly TA)
Initial tightening
Nm
80
Final tightening
Nm
130
(clean thread + Loctite 2701)
Leading link
Leading link to ball joint
Leading link to engine
Right
73
Left-hand screw cap
42
(lightly grease threads with Optimoly TA
Spring strut
Spring strut to front frame
Nm
43
Spring strut to leading link
Nm
50
Model
R 1150 RT
Connection
32 Steering
Handlebars to fork bridge
Nm
21
Handlebar weight to handlebars
Nm
21
Pivot screw, handlebar lever
Nm
11
(Tuflok-Blau thread-locking compound; screw
can be released and tightened a number of
times)
00.7
Model
R 1150 RT
Connection
33 Rear wheel drive
Rear axle differential
Oil filler plug
Nm
23
Oil drain plug
Nm
23
Threaded ring
Nm
160
(clean thread + Loctite 577)
Hexagon nut, input bevel gear
Nm
200
(clean thread + Loctite 2701)
Cover to rear-wheel drive housing
Nm
35
Reaction link to rear wheel drive / gearbox
Nm
43
(load approx. 85 kg (187 lbs) onto motorcycle
and tighten loose reaction link)
Fixed bearing stud bolt,
Swinging arm to right rear axle housing
Nm
160
(clean thread + Loctite 2701)
Nm
9
Nm
7
(clean thread + Loctite 2701)
Lock nut, floating bearing stud bolt,
Swinging arm to left rear axle housing
Nm
160
Fixed bearing stud bolt,
Swinging arm to right of transmission
Nm
160
(clean thread + Loctite 2701)
Nm
9
Nm
7
(clean thread + Loctite 2701)
Nm
160
Spring strut to rear frame
Nm
50
Spring strut to rear swinging arm
Nm
58
(clean thread + Loctite 243)
Hydraulic spring adjustment on rear frame
Nm
22
Swinging arm
Floating bearing stud bolt,
Swinging arm to left rear axle housing
1. initial torque
2. slacken
3. final torque
Floating bearing stud bolt,
Swinging arm to left of transmission
1. initial torque
2. slacken
3. final torque
Lock nut, floating bearing stud bolt,
Swinging arm to left of transmission
Spring strut
00.8
Model
R 1150 RT
Connection
34 Brakes
Front brake
Brake caliper to EVO brake sliding tube
Nm
30
Front brake caliper bleed screw
Nm
7
Brake disc to front wheel
Nm
21
(clean thread + Loctite 2701)
Pivot screw, handlebar lever
Nm
11
(Tuflok-Blau thread-locking compound; screw
can be released and tightened a number of
times)
Brake caliper to rear wheel drive
Nm
40
Rear brake caliper bleed screw
Nm
5
Brake disc to rear wheel drive
Nm
21
(clean thread + Loctite 2701)
Master cylinder to footrest plate
Nm
9
Brake pedal to footrest plate
Nm
21
(clean thread + Loctite 2701)
Footbrake-lever stop
Nm
9
Brake lines/brake hose to brake components
Nm
18
Brake hose to brake lever fitting
Nm
18
Filler adapter to brake line
Nm
18
Bracket to front frame
Nm
9
Retainer to rear frame
Nm
9
(clean thread + Loctite 2701)
ABS pressure modulator on retainer
Nm
7
ABS pressure modulator on battery carrier
Nm
10
Rear brake
Brake lines
BMW Integral ABS
Model
R 1150 RT
Connection
36 Wheels and tyres
Quick-release axle clamp screws
Nm
22
Quick-release axle threaded fastener
Nm
30
Rear wheel to rear wheel drive
screw wheel bolts finger-tight in a crosswise pattern
Nm
105
00.9
Model
R 1150 RT
Connection
46 Frame
Frame
Frame to engine
Nm
82
Struts to frame
Nm
58
Strut to engine
Nm
58
(clean thread + Loctite 2701)
Rear frame to left/right of engine
Nm
42
(clean thread + Loctite 2701)
Rear frame with footrest plate to left/right
of transmission
Nm
42
(clean thread + Loctite 2701)
Fairing bracket to frame
Nm
20
Nm
72
(clean thread + Loctite 2701)
M 12 screw
Nm
72
(clean thread + Loctite 2701)
M 8 screw
Nm
21
(clean thread + Loctite 2701)
Pivot mount of main (centre) stand (stud
bolt)
Nm
21
(clean thread + Loctite 243)
Pivot mount of main (centre) stand (machine screw)
Nm
21
Side stand to pivot mount
Nm
58
(clean thread + Loctite 2701)
Nm
19
M 10 screw
Nm
36
M 8 screw
Nm
19
M 10 screw
Nm
36
M 8 screw
Nm
19
Nm
35
Side stand
Mounting bracket to right of engine, M 12
screw
Pivot mount to engine, left
Footrest plate
Footrest plate to left/right transmission
Footrest plate to left of rear frame
Footrest plate to right of rear frame
Shift lever to footrest plate
00.10
Model
R 1150 RT
Connection
51 Equipment
Ignition/steering lock to fork bridge
Nm
Model
20
(micro-encapsulated)
R 1150 RT
Connection
61 General electrical equipment
Horn to holder
Nm
8
(clean thread + Loctite 243)
Horn to fairing bracket
Nm
10
Ground (earth) strap to engine block
Nm
9
Battery carrier to rubber-metal element
Nm
8
Strut to battery carrier
Nm
10
00.11
Table of operating fluids
Item
Use
Order number
Quantity
Staburags NBU 30 PTM
High-performance lubricating paste
07 55 9 056 992 75 g tube
Optimoly MP 3
High-performance lubricating paste
07 55 9 062 476 100 g tube
Optimoly TA
High-temperature assembly paste
18 21 9 062 599 100 g tube
Silicone grease 300, heavy
Damping grease
07 58 9 058 193 10 g tube
Retinax EP2
Wheel, steering head and taper roller
83 22 9 407 845 100 g tube
bearing grease
Contact spray
Contact spray
81 22 9 400 208 300 ml spray
Chain spray
Drive chain
72 60 2 316 676 50 ml spray
72 60 2 316 667 300 ml spray
3-Bond 1110 B
Surface sealant
07 58 9 056 998 5 g tube
3-Bond 1209
Surface sealant
07 58 9 062 376 30 g tube
OMNI VISC 1002
Surface sealant
07 58 1 465 170 90 g tube
Loctite 574
Surface sealant
81 22 9 407 301 50 ml tube
Loctite 577
Thread locking compound
07 58 2 328 736 5 g tube
Curil K 2
Heat-conductive sealant
81 22 9 400 243 250 g can
Lubricant
Sealants
Adhesives and retaining agents
Loctite 648
Joint adhesive (narrow gap)
07 58 9 067 732 5 g bottle
Loctite 638
Joint adhesive (wide gap)
07 58 9 056 030 10 ml bottle
Loctite 243
Thread retainer, medium-strength
07 58 9 056 031 10 ml bottle
Loctite 270
Thread retainer, strong
81 22 9 400 086 10 ml bottle
Loctite 2701
Thread retainer, strong
33 17 2 331 095 10 ml bottle
Loctite 454
Cyanacrylate adhesive (gel)
07 58 9 062 157 20 g tube
Brake cleaner
Brake cleaner
83 11 9 407 848 600 ml spray
Metal Polish
Polish for chrome-plated parts
82 14 9 400 890 100 g tube
Penetrant MR 68
Crack testing agent for aluminium
housings
83 19 9 407 855 500 ml spray
Developer MR 70
Crack testing agent for aluminium
housings
81 22 9 407 495 500 ml spray
Cooling spray
83 19 9 407 762 300 ml spray
Cleaners
Testing agents
Installation aids
BMW cooling spray
00.12
00
00 Pre-delivery check
Contents
Page
General view of crated motorcycle
...................................................................................15
Checking the crated motorcycle for damage
In case of damage in Germany
...............................................................................................16
In case of damage in importer markets
Unpacking the motorcycle
.............................................................16
..............................................................................16
....................................................................................................16
Assembling the motorcycle
..................................................................................................17
Installing the front wheel
............................................................................................................17
Installing front mudguard
...........................................................................................................17
Filling and charging the battery ...............................................................................................18
Installing cover for windscreen adjuster and installing windscreen
........................20
Installing mirrors
............................................................................................................................20
Assembling case
...........................................................................................................................20
Inspecting motorcycle for damage
...................................................................................21
Checking that delivery is complete
..................................................................................21
Checking engine oil level when cold, adding oil if necessary
Checking tightness of rear wheel studs
...........................21
........................................................................21
Checking tyre pressures .........................................................................................................21
Checking headlight beam angle, adjusting if necessary
......................................22
[Integral ABS] Performing bleed test with BMW MoDiTeC
Final inspection and function check
..................................23
................................................................................23
Final cleaning ................................................................................................................................23
Handing over the motorcycle
...............................................................................................24
00.13
00.14
00
General view of crated motorcycle
B M
W
BM
W
R22009010
00.15
Checking the crated motorcycle for
damage
•
When the motorcycle arrives, check the crated
motorcycle immediately for damage and, if necessary, examine the contents for consequential
damage.
In case of damage in Germany
•
•
•
Note the damage on the delivery slip.
Read the information sheet on damage in transit.
Notify the supplier without delay (e.g. freight
company or DB) and also
Bavaria Wirtschaftsagentur GmbH
Abteilung ZW - 12
80788 München
Tel. +49 89/14327-632
Fax. +49 89/14327-709
In case of damage in importer markets
•
•
•
Note the damage on the delivery slip.
Comply with specific national market procedures.
In case of doubt, please submit enquiries to:
Bavaria Wirtschaftsagentur GmbH
Abteilung ZW - 12
D-80788 München
Tel. +49 89/14327-632
Fax. +49 89/14327-709
Notify the supplier (e.g. freight company) without
delay.
00.16
Unpacking the motorcycle
•
•
•
–
–
–
–
–
–
–
–
–
–
–
•
•
Lever off the cover.
Remove plastic covers.
Take out the separate pack of items:
Front wheel
Case lid
Aerial
Windscreen
Covers
Engine spoiler
Cover for windscreen adjuster
Front mudguard
Mirrors
Small parts/fasteners
Documentation
Remove the set of keys from the left rear footrest.
Force off cross-struts with a suitable lever.
e
Attention:
Do not knock the cross-struts out or the motorcycle
may be damaged.
•
•
Remove the end-walls.
Remove the side-walls.
e
Attention:
Remove any nails projecting from the base of the
crate or lying on the base or on the floor.
•
Dispose of the packing materials in an environmentally responsible manner as described in Circular 23/91 - Sales.
Assembling the motorcycle
1
Installing the front wheel
3
e Attention:
2
Degrease all brake discs.
•
A
Remove front straps.
B
R22000020
•
Install the front wheel with spacer (1) and speedometer drive (2).
e Attention:
Locate stop on slider tube (A) in recess in speedometer drive (B).
R22000010
•
Using the straps, secure the front of the motorcycle to the assembly crane,
BMW No. 46 5 640.
•
•
•
•
•
Tighten the retaining screw (3).
Install the front brake calipers.
Release the motorcycle from the assembly
crane, BMW No. 46 5 640.
Compress the front fork firmly several times.
Tighten the clamp screws.
e
Attention:
Do not damage the brake lines, Bowden cables and
d Warning:
fairing panels.
•
Raise the front of the motorcycle.
e Attention:
Make sure that the motorcycle cannot topple sideways.
•
•
•
Remove rear straps.
Using the assembly crane, BMW No. 46 5 640,
carefully push the motorcycle forward off the pallet.
Extend the main stand and lower the motorcycle
until it is resting firmly on the main stand and the
rear wheel.
The brakes are not ready for use until the brake
pads have been bedded against the brake discs
with the ignition switched on.
X
Tightening torque:
Bolt of quick-release axle ............................ 30 Nm
Clamping screws of quick-release axle ....... 22 Nm
Brake caliper to fork slider ........................... 30 Nm
Installing front mudguard
d
Warning:
Integral ABS When removing and installing the
brake calipers, carefully force back the pistons only
far enough to ensure that the wheel-circuit reservoir
does not overflow.
If fluid escapes, top up the level in the wheel-circuit
reservoir to “MAX” mark.
•
Remove screws securing the front brake calipers.
L
Note:
Do not apply handbrake lever or footbrake lever with
R22000030
brake calipers removed/front wheel removed.
00.17
4x
2x
4x
3x
4x
R22460020
Filling and charging the battery
•
•
•
•
•
Remove seat.
Remove left side fairing panel.
Remove the air filter cover.
Remove air intake pipe.
Disengage the rubber strap holding the battery.
d Warning:
Battery acid is highly caustic.
It must not contact the eyes, face hands, clothing or
the motorcycle’s paintwork.
•
•
R22000040
•
•
Disconnect the battery breather hose.
Pull the battery to the left to remove.
00.18
Fill all the cells with pure battery acid of
density 1.28 to the upper mark.
Allow the battery to stand for approximately
30 minutes.
•
The battery does not achieve full charge capacity
from being filled, so it has to be charged with a
battery charger.
L Note:
Follow the instructions for use supplied with the battery charger.
Charge current (amps)
.........................10 % of rated battery capacity (Ah)
Charging time
............................................................. 5-10 hours
•
Battery charge can be measured by checking
the density of the battery acid.
Acid density
Battery full charged
............ 1.26-1.30 at a temperature of 20 °C (68 °F)
•
•
•
•
•
Switch on the ignition.
L
Note:
After switching on the ignition, always wait for the
BMW Integral ABS to complete its self-diagnosis.
Do not operate the brake lever until self-diagnosis
has completed.
•
•
With the ignition switched on, bed in the brake
pads against the brake discs.
Without starting the engine, fully open the throttle
once or twice so that the Motronic control unit
can register the throttle-valve positions.
L Note:
Disconnecting the battery means that the entries in
the fault memory of the Motronic MA2.4 control unit
are deleted and the adaptation values are reset.
This can temporarily impair the operating characteristics when the engine is restarted.
Shake the battery slightly to allow the gas bubbles to escape.
Wait until the battery acid has settled, check that
no more bubbles rise and if necessary, top up
the acid to the max. mark.
Reinstall the plugs.
Make a note of the charging date on the battery.
R22000050
e Attention:
Connect the positive battery terminal first, then the
negative terminal.
•
•
•
•
•
•
•
Connect the positive cable, coat with acid-proof
grease and install the protective cap.
Install the battery.
Connect the negative cable and coat with acidproof grease.
Assembly is the reverse of the disassembly procedure.
Install the left side fairing panel.
Install the engine spoiler.
Install the covers.
00.19
Installing cover for windscreen
adjuster and installing windscreen
Assembling case
R22000070
R22000060
•
•
•
Install the cover for the windscreen adjuster.
Install windscreen with washers.
Install the aerial.
Installing mirrors
•
•
–
–
•
•
Position the lid on the case for alignment. Open
the hinges of the lid and guide them into the base
with the guide hook.
From the inside, insert the pop rivets into the
base and the hinges.
2x long rivets in hinge at rear, as viewed in forward direction of travel.
2x short rivets in hinge at front, as viewed in forward direction of travel.
Engage riveting tool on rivets, hold the hinge at
the outside to keep it in position and secure all
four rivets.
Oil the seal in the bottom of the case, using the
sponge provided for the purpose.
e
Attention:
Make sure that the seal is not squeezed out of
shape and that the lid closes without catching.
•
•
RT460280
•
•
•
Connect the turn indicators.
Position the mirror at the 3 attachment points.
Engage by pressing at the front first, then the
rear.
00.20
•
Carefully close the case.
Insert the lock cylinder into the case with the key
in the lock and turn the lock.
Affix the stickers.
Inspecting motorcycle for damage
•
•
•
•
•
–
–
–
Check for defects.
Use the “express handling service” to notify
BMW Motorrad,
UX-VS-1
Fax: + 49 89-382-33220
Rectify the fault.
If parts are needed, order them through the usual
channel.
Costs are to be processed by the warranty claim
system (stage 4). Defect codes:
Parts missing
10 01 00 00 00
Parts damaged
10 02 00 00 00
Incorrect parts delivered
10 03 00 00 00
Checking that delivery is complete
–
–
–
All optional extras
Toolkit
Documentation
Checking tightness of rear wheel
studs
X
Tightening torque:
Securing screws for rear wheel .................. 105 Nm
Checking tyre pressures
•
Check/correct tyre pressures.
Tyre pressures:
one-up ............................... front 2.2 bar (31.90 psi)
........................................... rear 2.5 bar (36.26 psi)
two-up ............................... front 2.5 bar (36.26 psi)
........................................... rear 2.9 bar (42.06 psi)
two-up + luggage ............... front 2.5 bar (36.26 psi)
........................................... rear 2.9 bar (42.06 psi)
Checking engine oil level when
cold, adding oil if necessary
L Note:
The difference between the oil level indicated when
the engine is at operating temperature and the oil
level indicated when the engine is very cold due to
extremely low outdoor temperatures can be as
much as 10 mm (0.3937 in).
R22000080
•
Check oil level with the motorcycle upright.
e Attention:
Never top up the engine-oil level past the “MAX”
mark.
Required level:............................................... MAX
BMW recommends Castrol
00.21
Checking headlight beam angle,
adjusting if necessary
1
2
R22000110
R22000090
•
•
•
•
Motorcycle on level surface.
Rider’s weight on motorcycle
(approx. 85 kg/187.4 lbs).
Turn knob (1) counter-clockwise as far as it will
go.
Check headlight beam throw.
R22000100
Setting for headlight beam angle adjuster
... .-10 cm (-3.937 in) at a distance of 10 m (32.8 ft)
00.22
•
Turn screw (2) to adjust beam throw, if necessary.
Direction of rotation, left .....................further/higher
Direction of rotation, right.................shorter/deeper
Integral ABS Performing bleed test
with BMW MoDiTeC
d
Warning:
Self-diagnosis is not performed unless both brake
levers are in their fully released positions. Prior
to conclusion of the self-diagnosis, only RESIDUAL
BRAKING FUNCTION is available.
Final inspection and function check
•
•
•
•
Perform BMW Integral ABS self-diagnosis:
• Release the brake levers, if necessary.
• Switch on the ignition.
• With the ignition switched on, bed in the brake
pads against the brake discs.
–
–
–
–
–
–
–
–
–
–
ABS warning light.............................flashes at 4 Hz
General warning light ........................................ ON
•
•
•
–
•
Self-diagnosis is in progress
ABS warning light.............................flashes at 1 Hz
General warning light ....................................... OFF
– Self-diagnosis successfully completed.
Perform bleed test with BMW MoDiTeC:
• Remove front and rear seats.
• Connect the BMW MoDiTeC to the diagnosis
connector.
d
Clutch
Check gear shift action.
Handbrake and foot brake
Check lights and signalling equipment:
Front and rear parking lights
Instrument lighting
Low and high headlight beams, headlight flasher
Fog lamps
Brake light (operate brake at front and rear)
Turn signals left/right
Hazard warning lights
Horn
Telltale and warning lights
Instruments
Check operation of optional extras.
If necessary, take the motorcycle for a test ride.
Confirm pre-delivery check in Service and Technical Booklet.
See “Checking motorcycle for damage” if defects
are found.
Final cleaning
•
Clean the motorcycle.
L
Note:
Do not use a steam or high-pressure water jet. The
high steam or water pressure could damage seals,
the hydraulic system or electrical components.
Warning:
When performing maintenance and repair work on
BMW Integral ABS, never pump quickly or vigorously.
•
•
Perform bleed test.
Perform all requisite repair work.
Perform BMW Integral ABS pull-away test:
When a speed of 5 km/h (3 mph) is reached, the
ABS warning light must go out.
•
L Note:
The ABS warning light and the general warning light
must both be OFF after successful self-diagnosis
and the pull-away test.
00.23
Handing over the motorcycle
This is the ideal opportunity to familiarise the customer with the motorcycle in order to ensure the
customer’s satisfaction and safety.
•
–
–
–
–
–
–
–
–
–
–
–
•
–
–
–
–
–
The following points must be demonstrated and
explained to the customer:
documentation and stowage space
toolkit and stowage space
suspension preload adjustment to suit total
weight
checking brake fluid/clutch operating fluid
provision for adjusting handlebars lever positions
procedure for adjusting seat
how to adjust the mirrors
controls
instruments and telltale lights
optional equipment and accessories fitted
features of BMW Integral ABS:
brake servo,
residual braking function,
pump noises,
self-diagnosis with pull-away test.
The user must be given the following information:
running-in recommendations and inspection intervals
safety check
features of BMW Integral ABS:
fully integral brake,
brake-fluid levels in the control circuits remain
constant despite brake-pad wear.
the clutch fluid level rises gradually as the motorcycle is ridden (clutch lining wear)
Always check the oil level when the engine is at
operating temperature, because the difference
between the oil level indicated when the engine
is at operating temperature and the oil level indicated when the engine is very cold due to extremely low outdoor temperatures can be as
much as 10 mm (0.3937 in). After switching off
the engine at operating temperature, wait at least
5 minutes for the oil to drain back into the sump.
Checking the oil level just after the engine has
been run or when it is not properly warm will falsify the reading.
00.24
00
00 Maintenance
Contents
Page
Key to maintenance intervals ...............................................................................................29
Reading the BMW MoDiTeC fault code memory
.......................................................29
(Inspections I, II, III and IV) .................................................................................................................29
Integral ABS: Performing bleed test with BMW MoDiTeC ....................................29
(Inspections I, II, III and IV) .................................................................................................................29
Changing engine oil, replacing oil filter element
......................................................30
(Inspections I, II, III and IV) .................................................................................................................30
Changing oil in gearbox
..........................................................................................................31
(Inspections III and IV) .......................................................................................................................31
or at the latest every 2 years ..............................................................................................................31
Changing the oil in the rear wheel drive
........................................................................31
(Inspections I, III and IV) ....................................................................................................................31
every 40,000 km (24,000 miles) or at the latest every 2 years ............................................................31
Replacing fuel filter
...................................................................................................................32
(Inspection III) ....................................................................................................................................32
In normal operating conditions every 40,000 km (24,000 miles); if fuel quality is poor every
20,000 km (12,000 miles) ..................................................................................................................32
Checking battery fluid level and topping up if necessary; cleaning and
greasing the battery posts......................................................................................................34
(Inspections III and IV) .......................................................................................................................34
Replacing intake air filter element
....................................................................................35
(Inspection III) ....................................................................................................................................35
in very dirty and dusty operating conditions, replace every 10,000 km (6,000 miles) or even more frequently if necessary ..........................................................................................................................35
Replacing Poly-V belt
...............................................................................................................35
(Inspection III) ....................................................................................................................................35
every 60,000 km (36,000 miles) .........................................................................................................35
Checking brake fluid level
.....................................................................................................36
(Inspections II and III) ......................................................................................................................36
Front brake
.......................................................................................................................................36
Rear brake
........................................................................................................................................36
Checking brake system for correct operation and freedom from leaks;
repairing/replacing if necessary ........................................................................................36
(Inspection III) ..................................................................................................................................36
00.25
Contents
Page
Checking brake pads and discs for wear/replacing
...............................................37
(Inspections II and III) .........................................................................................................................37
Checking brake pads for wear
................................................................................................37
Brake pads, front brake .....................................................................................................................37
Brake pads, rear brake ......................................................................................................................37
Checking brake disc wear .........................................................................................................38
Replacing brake pads
.................................................................................................................38
Brake pads, front brake .....................................................................................................................38
Brake pads, rear brake ......................................................................................................................39
Changing/bleeding brake fluid in wheel circuit
.........................................................40
Change brake fluid in wheel circuit once a year .................................................................................40
(Inspection IV) ....................................................................................................................................40
Bleeding/changing brake fluid in front wheel circuit ......................................................40
Instructions for filling front wheel circuit reservoir ..............................................................................42
Bleeding/changing brake fluid in rear wheel circuit
.......................................................44
Instructions for filling rear wheel circuit reservoir ...............................................................................46
Changing/bleeding brake fluid in control circuit
......................................................48
Change brake fluid in control circuit every 2 years .............................................................................48
(Inspection IV) ....................................................................................................................................48
Bleeding/changing brake fluid in front control circuit
Bleeding/changing brake fluid in rear control circuit
...................................................48
.....................................................50
Checking clutch operating fluid level
..............................................................................51
(Inspections II and III) .........................................................................................................................51
Changing the clutch fluid
.......................................................................................................52
(Inspection IV) ....................................................................................................................................52
every 2 years at the latest ..................................................................................................................52
Checking tightness of rear wheel studs
........................................................................53
(Inspection I) ......................................................................................................................................53
Checking rear wheel bearing play by tilting wheel
..................................................53
(Inspection III) ....................................................................................................................................53
Checking swinging arm bearings, adjusting if necessary
...................................53
(Inspections I and III) .........................................................................................................................53
Greasing the side stand pivot
..............................................................................................53
(Inspections I, II and III) ......................................................................................................................53
Checking function of side stand contact switch
......................................................53
(Inspections I, II, III and IV) .................................................................................................................53
Checking/replacing spark plugs
........................................................................................54
(Inspection II) check/(Inspection III) replace .......................................................................................54
Tightening cylinder heads
.....................................................................................................54
(Inspection I) ......................................................................................................................................54
00.26
Contents
Page
Checking/adjusting valve clearances
.............................................................................55
(Inspections I, II and III) ......................................................................................................................55
Checking freedom of throttle cable, checking for chaffing and kinks,
replacing if necessary, Checking throttle-cable play
Checking and adjusting idle speed and throttle-valve synchronisation
......55
(Inspections I, II and III) ......................................................................................................................55
Final inspection with road safety and functional check
.......................................57
(Inspections I, II, III and IV) .................................................................................................................57
Road safety check .............................................................................................................................57
Roadworthiness check ......................................................................................................................57
00.27
00.28
00
Key to maintenance intervals
–
–
–
–
BMW Inspection at 1,000 km
(600 miles)
BMW Service every 10,000 km
(6,000 miles)
BMW Inspection every 20,000 km
(12,000 miles)
BMW Annual Service
Reading the BMW MoDiTeC
fault code memory
00 13 624
I
(Inspections I, II, III and IV)
II
•
•
III
IV
•
•
Remove front and rear seats.
Connect the BMW MoDiTeC to the diagnosis
connector.
Read all fault memories.
Perform all requisite repair work.
Integral ABS: Performing bleed test
with BMW MoDiTeC
(Inspections I, II, III and IV)
•
•
Remove front and rear seats.
Connect the BMW MoDiTeC to the diagnosis
connector.
d Warning:
When performing maintenance and repair work on
BMW Integral ABS, never pump quickly or
vigorously.
•
•
Perform bleed test.
Perform all requisite repair work.
00.29
00 11 209 Changing
engine oil, replacing oil filter element
•
(Inspections I, II, III and IV)
Attention:
Never top up the engine-oil level past the “MAX”
mark.
L
Note:
If the motorcycle is ridden only for short distances or
outside temperatures are below 0°C (32°F) change
the oil and replace the oil filter element every 3
months, or not later than every 3,000 km (1,800
miles).
•
Change the oil at operating temperature.
Insert and tighten the screw plug.
e
X
Tightening torque:
Oil filter......................................................... 11 Nm
Oil drain plug................................................ 32 Nm
Engine oil capacities:
with oil filter renewal
................... 3.75 l (6.60 Imp. pints/3.96 US quarts)
without oil filter renewal
................... 3.50 l (6.16 Imp. pints/3.69 US quarts)
Quantity of oil between MIN and MAX marks
................... 0.50 l (0.88 Imp. pints/0.52 US quarts)
Engine oil grade:
Brand-name HD oil for spark-ignition engines, API
classifications SF, SG, SH; combination with CD or
CE specification.
Brand-name HD oil of CCMC classification G4, G5;
amendment PD2 is permissible.
R22000080
•
•
Remove screw plug.
Remove oil drain plug and drain off oil.
11 4 650
C000030
•
•
•
•
Use oil filter wrench, BMW No. 11 4 650, to remove the oil filter.
Coat sealing ring on new oil filter element with oil
and install filter.
Reinstall the oil drain plug with a new sealing
ring.
Refill with oil to correct level.
BMW recommends Castrol
00.30
00 11 229
Changing oil in gearbox
(Inspections III and IV)
or at the latest every 2 years
•
Change the gearbox oil at operating temperature.
Changing the oil in the rear
wheel drive
00 11 229
(Inspections I, III and IV)
every 40,000 km (24,000 miles) or at the latest
every 2 years
•
Change the gearbox oil at operating temperature.
1
1
2
2
R22000250
•
•
•
•
•
•
Remove oil filler plug (1).
Push in oil drain tube, BMW No. 23 4 680, and
turn it to the right.
Remove oil drain plug (2) and allow the oil to
drain out.
Reinstall the oil drain plug with a new sealing
ring.
Fill with gearbox oil.
Insert oil filler plug with new seal.
R28000100
e Attention:
Do not allow oil to drip onto the rear tyre.
•
•
Remove oil filler plug (1).
Remove oil drain plug (2) and allow the oil to
drain out.
Reinstall the oil drain plug with a new sealing
ring.
Fill with gearbox oil.
Insert oil filler plug with new seal.
X
•
Quantity:
to bottom edge of filler neck
........ approx. 0.8 l (1.41 Imp. pints/0.85 US quarts)
X
Tightening torque:
Oil drain plug................................................ 30 Nm
Oil filler plug ................................................. 30 Nm
Oil grade for gearbox:
Brand-name hypoid gear oil, SAE 90, API class GL 5
•
•
Tightening torque:
Oil drain plug................................................ 23 Nm
Oil filler plug ................................................. 23 Nm
Quantity:
to bottom of thread in oil filler hole
...... approx. 0.25 l (0.44 Imp. pints/0.26 US quarts)
Oil grade for rear wheel drive:
Brand-name hypoid gear oil, SAE 90, API class GL 5
00.31
R22160010
16 12 008 Replacing
fuel filter
(Inspection III)
In normal operating conditions every 40,000 km
(24,000 miles); if fuel quality is poor every 20,000 km
(12,000 miles)
•
•
•
•
Remove front and rear seats.
Remove left and right side sections of fairing.
Disengage stowage compartment and lift it up to
remove.
Use a cable tie to secure the stowage compartment to the motorcycle.
d
Warning:
Fuel is flammable and a hazard to health. Observe
relevant safety regulations.
•
Remove screw securing fuel tank.
00.32
•
•
•
•
Disconnect breather and overflow hoses.
Disconnect quick-connect adapters of the fuel
lines.
Disconnect the plug of the fuel pump.
Drain fuel tank.
L
Note:
To avoid damaging the paintwork of the fuel tank, lay
a cloth between the fork bridge and the fuel tank.
•
•
Pull fuel tank up and to the rear to remove.
Remove fuel pump unit.
R22160021
•
•
Disconnect hoses from fuel filter.
Install new fuel filter.
e
Attention:
Note correct direction of flow through fuel filter.
•
Secure non-reusable hose clips with pliers,
BMW No. 13 1 500.
e
Attention:
Make sure O-ring (arrow) is in perfect condition. Af-
•
Installation is the reverse of the removal procedure.
L
Note:
Make sure that breather lines are correctly routed.
X
Tightening torque:
Fuel pump unit to fuel tank ............................. 5 Nm
Fuel tank to rear frame ................................. 22 Nm
ter installing, check fuel pump unit for leaks.
00.33
R22000120
61 20 029 Checking
battery fluid level
and topping up if necessary; cleaning and greasing the battery posts
(Inspections III and IV)
d
L Note:
Disconnecting the battery means that the entries in
the fault memory of the Motronic MA2.4 control unit
are deleted and the adaptation values are reset.
This can temporarily impair the operating characteristics when the engine is restarted.
Warning:
Battery acid is highly caustic.
It must not contact the eyes, face hands, clothing or
the motorcycle’s paintwork.
•
•
•
•
•
•
•
•
Remove front and rear seats.
Check the battery fluid level.
L Note:
Remove the battery if the acid level is incorrect or
cannot be read correctly.
•
•
•
•
•
•
Remove the left side case.
Remove left cover and side trim panel.
Remove the air filter cover.
Remove air intake pipe.
Disengage the rubber strap holding the battery.
Disconnect the battery breather hose.
e
Attention:
Disconnect the negative battery terminal first, then
the positive terminal.
00.34
•
•
Disconnect the negative terminal of the battery.
Pull the battery to the left to remove.
Disconnect the positive terminal of the battery.
If necessary, top up the acid level to the “MAX”
mark with distilled water.
Clean and grease the battery terminals.
Installation is the reverse of the removal procedure.
Switch on the ignition.
Without starting the engine, fully open the throttle
once or twice so that the Motronic control unit
can register the throttle-valve positions.
e
Attention:
Connect the positive battery terminal first, then the
negative terminal.
Acid proof battery-post grease:
................................................e.g. Bosch Ft 40 V1
Replacing intake air filter
element
13 72 000
(Inspection III)
in very dirty and dusty operating conditions,
replace every 10,000 km (6,000 miles) or even
more frequently if necessary
3
2
4
1
RS110480
•
•
Slacken alternator securing screws (1,3,4).
Remove old Poly-V belt.
L Note:
R22000130
•
•
•
•
Open clips securing air filter cover.
Replace air filter element.
Close air filter cover.
12 31 240
Install new Poly-V belt.
Poly-V belt adjusting procedure:
Replacing Poly-V belt
(Inspection III)
every 60,000 km (36,000 miles)
•
•
•
Loop Poly-V belt over crankshaft belt pulley first,
then over alternator belt pulley.
Remove left side fairing panel.
Remove front intake pipe.
Disengage fairing bracket from end cover on left.
•
Place the Poly-V belt in position, tension it and
turn the engine over once, then relieve belt tension.
Poly-V belt tensioning procedure:
1 Slightly tighten hex nut (1) on adjusting screw (2)
by hand (do not use tools).
2 Tighten adjusting screw (2) with a torque wrench
and keep preload applied.
3 Tighten upper retaining nut (3), then remove
torque wrench from adjusting screw.
4 Tighten all screws and nuts.
X
Tightening torque:
Preload for Poly-V belt ................................... 8 Nm
Belt pulley to alternator ................................ 50 Nm
Belt pulley to crankshaft ............................... 50 Nm
Alternator to alternator support cover........... 20 Nm
R22110010
•
Remove front cover.
00.35
Checking brake fluid level
•
(Inspections II and III)
Brake fluid ...................................................DOT 4
L Note:
Checking brake system for correct
operation and freedom from leaks;
repairing/replacing if necessary
The brake fluid level in the sight glass/brake fluid
reservoirs of control circuits remains constant despite wear of the brake pads.
If the level drops below the MIN mark, this indicates
some other fault.
(Inspection III)
•
Front brake
•
•
•
•
•
Place the motorcycle on its centre stand.
Turn the handlebars fully to the left.
Check brake fluid level at sight glass.
Correct the fluid level if necessary.
Check all brake lines and their holders for damage and correct positioning.
Wipe down all threaded unions on the brake lines
and check them.
Switch on the ignition.
L
Note:
After switching on the ignition, always wait for the
BMW Integral ABS to complete its self-diagnosis.
Do not operate the brake lever until self-diagnosis
has completed.
d
Warning:
When performing maintenance and repair work on
BMW Integral ABS, never pump quickly or
vigorously.
•
R22000140
Required level
not below ......................................................... MIN
(top edge of the marking ring)
•
Correct the fluid level if necessary.
Brake fluid....................................................DOT 4
Rear brake
•
•
•
Place the motorcycle on its centre stand.
Remove case and right trim panel.
Check the brake fluid level.
R22000150
Required level
not below ......................................................... MIN
00.36
•
Apply the brake hard and hold on in this position
for a short time.
After this, inspect the brake lines for leaks.
d
Warning:
Defective lines and threaded unions in the brake
system must always be replaced without delay.
Checking brake pads and discs for
wear/replacing
Brake pads, rear brake
(Inspections II and III)
Checking brake pads for wear
Brake pads, front brake
1
R22000170
2
•
–
•
R22000160
•
–
•
Visually inspect the brake pads.
Wear indicators (1) must be clearly visible.
If necessary, check/measure thickness of brake
pads.
e
Attention:
Do not permit brake pad thickness to fall below the minimum value. Always replace the brake pads as a
complete set.
Visually inspect the brake pads.
Make sure that the brake disc is not visible
through the bore (arrow) in the inner brake pad.
If necessary, check/measure thickness of brake
pads.
e Attention:
Do not permit brake pad thickness to fall below the minimum value. Always replace the brake pads as a complete set.
Minimum pad thickness: ........ 1.0 mm (0.0393 in)
– If the brake disc is visible through the bore in the
wheel-side brake pad, the brake lining is worn to
its minimum permissible thickness.
Minimum pad thickness: ......... 1.0 mm (0.0393 in)
•
Check that colour codes of brake pads and
brake calipers (2) match.
Colour code: ................................................. white
00.37
Checking brake disc wear
•
•
Carefully check the brake discs for cracks, damage, deformation and scoring.
e
Attention:
Integral ABS Press back pistons on only one side
of the brake caliper. Allow the brake pad on the opposite side to remain in the caliper during this process.
Make sure that the fluid level in the wheel-circuit reservoir does not rise above “max”.
Risk of fluid escaping.
If fluid escapes, proceed in accordance with “instructions for filling reservoir”.
•
•
R22000260
•
Measure the thickness of the brake discs at several points with a caliper gauge.
Brake disc wear limit:
front:........................................... 4.5 mm (0.177 in)
rear: ............................................ 4.5 mm (0.177 in)
Replacing brake pads
34 11 008 Brake pads, front brake
•
•
e
After switching on the ignition, always wait for the
BMW Integral ABS to complete its self-diagnosis.
Do not operate the brake lever until self-diagnosis
has completed.
2
3
After replacing the pads of a caliper, always bed
in the new brake pads with the ignition switched
on.
L
Note:
Note position and arrow (4) of spring (3).
•
•
4
Press back piston with inner brake pad only far
enough to allow the new brake pad to be slipped
into position.
Remove remaining old brake pad and insert new
brake pad.
Press back piston with outer brake pad only far
enough to allow the new brake pad to be slipped
into position.
Remove remaining old brake pad and insert
new brake pad.
L Note:
•
Attention:
Integral brakes, the rear brake must be ready for
use.
Remove grub screw (2) and spring (3).
•
Install grub screw (2) and spring (3).
Reinsert the split-pin keeper (1) in the groove in
grub screw (2).
Check operation of the brake system with the ignition switched on.
X
Tightening torque:
Grub screw in front brake caliper ................... 7 Nm
Colour code:
Brake pads/brake calipers ..............................white
1
R22000270
•
Remove the split-pin keeper (1) from grub
screw (2).
00.38
34 21 200 Brake pads, rear brake
•
e
Attention:
Integral brakes, the front brake must be ready for
•
use.
X
Tightening torque:
Brake caliper to rear wheel drive .................. 40 Nm
Installation is the reverse of the removal procedure.
Check operation of the brake system with the ignition switched on.
R22000180
•
•
•
•
Remove keeper (arrow) from retaining pin.
Drive the retaining pin out towards the wheel
side.
Remove brake caliper.
Remove brake pads.
e
Attention:
Integral ABS Press back pistons in brake caliper
brake pad only far enough to allow the brake disc to
the slipped in.
Make sure that the fluid level in the wheel-circuit reservoir does not rise above “max”.
Risk of fluid escaping.
If fluid escapes, proceed in accordance with “instructions for filling reservoir”.
•
Force back the pistons.
R22000280
•
–
Check that spring is correctly positioned and secure.
Engraved arrow (arrow) points in direction of
travel.
00.39
Changing/bleeding brake
fluid in wheel circuit
34 00 090
Change brake fluid in wheel circuit once a year
(Inspection IV)
d
Warning:
All repair and maintenance work on the
BMW Integral ABS must be performed by trained,
qualified specialists.
Comply with all maintenance and repair instructions
and always work through the various steps in the
correct order.
Use only new brake fluid from freshly opened containers.
•
•
Draw off the old brake fluid from the wheel-circuit
reservoir.
Remove front brake pads (left and right).
e
Attention:
Install piston resetting tool, BMW No. 34 1 531,
only when the cap has been removed from the
wheel-circuit reservoir.
L Note:
34 1 531
This description applies for the brake filling and
bleeding unit with extraction of the brake fluid by
partial vacuum.
If other devices are used, comply with their manufacturers’ instructions.
34 1 532
R22000290
34 00 070 Bleeding/changing
brake fluid
in front wheel circuit
e
Attention:
Do not scrape the wheel – mask it off if necessary.
e Attention:
Integral brakes, the rear brake must be ready for
use.
•
•
Remove fuel tank.
•
e Attention:
Do not allow brake fluid to come into contact with
painted parts of the motorcycle as brake fluid destroys paint.
–
•
1
R28340110
•
Open front wheel-circuit reservoir (1).
00.40
Use resetting tool, BMW No. 34 1 531, and
locator, BMW No. 34 1 532, to force the pistons
in the left and right brake calipers all the way
back and hold them in this position.
Wrap cloths around the left and right brake calipers.
[Bleeding only] Bleed the front wheel circuit.
(a 00.43)
Draw off the old brake fluid from the wheel-circuit
reservoir.
34 1 581
e Attention:
The brake fluid must always be visible in the container, because the piston in the base of the wheel-circuit reservoir must always be covered by the fluid.
The procedure must be repeated if the fluid drops
below the “min” level.
•
•
•
R22000340
•
•
•
Screw container, BMW No. 34 1 581,
onto front wheel circuit reservoir.
Slowly fill container, BMW No. 34 1 581, with
new brake fluid until it is approximately 1/2 full.
Connect the brake bleeding device to the bleed
screw of the left brake caliper, but do not switch
on the device.
L Note:
If necessary, use a cable tie to secure the bleed
hose to the bleed screw.
•
L Note:
The higher the brake pressure the faster the fluid is
pumped through the system, which means that the
level in the wheel-circuit reservoir drops all the more
rapidly.
•
•
•
•
•
Switch on the ignition.
L Note:
After switching on the ignition, always wait for the
BMW Integral ABS to complete its self-diagnosis.
Do not operate the brake lever until self-diagnosis
has completed.
Pump off brake fluid until it emerges clear and
free from air bubbles.
Close the bleed screw.
Release the brake.
Disconnect the brake bleeding device from the
bleed screw.
Connect the brake bleeding device to the bleed
screw of the right brake caliper, but do not
switch on the device.
L Note:
If necessary, use a cable tie to secure the bleed
hose to the bleed screw.
•
•
•
•
•
MAX
Very gently pull the handbrake lever until the
pump just starts up.
Open the bleed screw, while topping up the
container with new brake fluid if necessary.
Pump out the brake fluid with virtually no pressure to begin with, then vary the brake pressure.
•
The procedure for changing the brake fluid in the
right brake caliper is the same as that for the
left caliper.
When the brake fluid is clear and free of bubbles,
continue pumping until the fluid in the container
just disappears from view.
Close the bleed screw.
Release the brake and switch off the ignition.
Disconnect the brake bleeding device from the
bleed screw.
Disconnect the container from the wheel-circuit
reservoir.
e
Attention:
After changing and/or bleeding the brakes, always
MIN
R28340090
top up the fluid in the wheel-circuit reservoir to the
correct level in accordance with the instructions.
00.41
Instructions for filling front wheel
circuit reservoir
e
Attention:
Integral brakes, the rear brake must be ready for
use.
MAX
MIN
34 1 533
R28340090
34 1 531
•
34 1 532
•
R22000300
•
•
Top up fluid in front wheel-circuit reservoir to
“MAX” mark if necessary
Install adapters 22, BMW No. 34 1 533, in resetting tool, BMW No. 34 1 531/532, for both front
brake calipers, and tighten the resetting tool until
the adapters are secure.
e
•
•
•
•
•
•
Top up the fluid in the wheel-circuit reservoir until
one of the three protrusions in the filler neck just
touches the surface of the fluid (arrow).
Screw container, BMW No. 34 1 581,
onto front wheel circuit reservoir.
Remove adapter, BMW No. 34 1 533, and force
back pistons far enough to allow the brake pads
to be fitted.
Install front brake pads.
With the ignition switched on, bed in the brake
pads against the brake discs.
Disconnect the container from the wheel-circuit
reservoir.
Hand-tighten cap of front wheel-circuit reservoir.
Check the function of the brake system.
Attention:
The piston in the base of the wheel-circuit reservoir
must always be covered by the fluid, as otherwise air
can be drawn into the brake system.
Bleed the system again if this happens.
Attention:
After all the work on the brake system has been
completed, run a bleed test using the
BMW MoDiTeC and check the fault code memory!
•
•
Switch on the ignition.
L Note:
After switching on the ignition, always wait for the
BMW Integral ABS to complete its self-diagnosis.
Do not operate the brake lever until self-diagnosis
has completed.
•
Pull handbrake lever until the pistons of the front
brake calipers are in contact with resetting
tool, BMW No. 34 1 531.
00.42
e
Install fuel tank.
Brake fluid ...................................................DOT 4
X
Tightening torque:
Bleed screw in front brake caliper .................. 7 Nm
Only bleeding the front wheel circuit
–
–
–
Draw off the old brake fluid from the wheel-circuit
reservoir.
Remove left and right brake pads, force back the
brake pistons and secure the pistons in this position.
Wrap cloths around the left and right brake calipers.
e
Attention:
Integral brakes, the rear brake must be ready for
use.
d Warning:
Check that the brake fluid in the hose does not
foam.
If the fluid foams, proceed as described in the section on bleeding and changing brake fluid in front
wheel circuit.
(a 00.40)
•
•
•
•
34 1 561
•
•
•
•
34 2 541
•
Pump brake fluid through the system until it is
clear and free from air bubbles.
Close the bleed screw.
Release the brake and disconnect silicon
hose, BMW No. 34 1 561.
Fill front wheel-circuit reservoir with brake fluid
up to “MAX” mark and install cap,
BMW No. 34 2 541.
Connect 1.5m (4.9214 ft) silicon hose,
BMW No. 34 1 561, to the bleed screw of the
right brake caliper.
The procedure for bleeding the right brake caliper is the same as that for the left caliper.
Release the brake and switch off the ignition.
Disconnect silicon hose, BMW No. 34 1 561,
from bleed screw and drain the hose.
Remove cap, BMW No. 34 2 541.
e Attention:
R28000220
•
•
Fill front wheel-circuit reservoir with brake fluid
up to “MAX” mark and install cap,
BMW No. 34 2 541.
Connect 1.5 m (4.9214 ft) silicon hose,
BMW No. 34 1 561, to the bleed screw of the left
brake caliper.
L Note:
If necessary, use a cable tie to secure the bleed
hose to the bleed screw.
•
After switching on the ignition, always wait for the
BMW Integral ABS to complete its self-diagnosis.
Do not operate the brake lever until self-diagnosis
has completed.
•
•
•
•
•
Fill front wheel-circuit reservoir with brake fluid in
accordance with instructions. (a 00.42)
•
Check operation of the brake system with the ignition switched on.
e Attention:
After all the work on the brake system has been
completed, run a bleed test using the
BMW MoDiTeC.
Switch on the ignition.
L Note:
•
After changing and/or bleeding the brakes, always
top up the fluid in the wheel-circuit reservoir to the
correct level in accordance with the instructions.
Brake fluid ...................................................DOT 4
X
Tightening torque:
Bleed screw in front brake caliper .................. 7 Nm
Grub screw in front brake caliper ................... 7 Nm
Very gently pull the handbrake lever until the
pump just starts up.
Open the bleed screw.
Pump the brake fluid with virtually no pressure
until the hose is full of brake fluid.
Connect end of hose to cap, BMW No. 34 2 541.
Pump the brake fluid with virtually no pressure to
begin with, then vary the brake pressure.
00.43
34 00 080 Bleeding/changing
brake fluid
in rear wheel circuit
e
Attention:
Integral brakes, the front brake must be ready for
use.
•
34 1 536
Remove fuel tank.
34 1 531
e Attention:
Do not allow brake fluid to come into contact with
painted parts of the motorcycle as brake fluid destroys paint.
R28000170
•
•
•
–
•
1
Install adapter, BMW No. 34 1 536, instead of
the outboard brake pad.
Install resetting tool, BMW No. 34 1 531, with
the handle toward the outside in the rear brake
caliper, press the pistons fully back and secure
them in this position.
Wrap a cloth around the brake caliper.
[Bleeding only] Bleed the rear wheel circuit.
(a 00.47)
Draw off the old brake fluid from the wheel-circuit
reservoir.
R28340110
•
•
•
•
34 1 581
Open rear wheel-circuit reservoir (1).
Draw off the old brake fluid from the wheel-circuit
reservoir.
Remove rear brake pads.
If necessary, manually push back brake piston
far enough to permit installation of resetting
tool, BMW No. 34 1 531.
e
Attention:
Install piston resetting tool, BMW No. 34 1 531 only
when the cap has been removed from the wheel-circuit reservoir.
R22000350
•
•
•
Screw container, BMW No. 34 1 581,
onto rear wheel circuit reservoir.
Slowly fill container, BMW No. 34 1 581, with
new brake fluid until it is approximately 1/3 full.
Connect the brake bleeding device to the bleed
screw, but do not switch on the device.
L Note:
If necessary, use a cable tie to secure the bleed
hose to the bleed screw.
00.44
•
Switch on the ignition
L
Note:
After switching on the ignition, always wait for the
BMW Integral ABS to complete its self-diagnosis.
Do not operate the brake lever until self-diagnosis
has completed.
•
•
•
•
Close the bleed screw.
Release the brake and switch off the ignition.
Disconnect the brake bleeding device from the
bleed screw.
Disconnect the container from the wheel-circuit
reservoir.
e
Attention:
After changing and/or bleeding the brakes, always
top up the fluid in the wheel-circuit reservoir to the
correct level in accordance with the instructions.
MAX
MIN
R28340090
e Attention:
The brake fluid must always be visible in the container, because the piston in the base of the wheel-circuit reservoir must always be covered by the fluid.
The procedure must be repeated if the fluid drops
below the “min” level.
•
•
•
Very gently press the footbrake lever until the
pump just starts up.
Open the bleed screw, while topping up the container with new brake fluid if necessary.
Pump out the brake fluid with virtually no pressure to begin with, then vary the brake pressure.
L
Note:
The higher the brake pressure the faster the fluid is
pumped through the system, which means that the
level in the wheel-circuit reservoir drops all the more
rapidly.
•
When the brake fluid is clear and free of bubbles,
continue pumping until the fluid in the container
just disappears from view.
00.45
Instructions for filling rear wheel
circuit reservoir
e
Attention:
Integral brakes, the front brake must be ready for
use.
MAX
MIN
34 1 536
R28340090
•
34 1 531
•
R28000170
•
•
Top up fluid in rear wheel-circuit reservoir to
“MAX” mark if necessary.
Fully tighten resetting tool, BMW No. 34 1 531,
and adapter, BMW No. 34 1 536.
e
Attention:
The piston in the base of the wheel-circuit reservoir
must always be covered by the fluid, as otherwise air
can be drawn into the brake system.
Bleed the system again if this happens.
•
Switch on the ignition.
L Note:
After switching on the ignition, always wait for the
BMW Integral ABS to complete its self-diagnosis.
Do not operate the brake lever until self-diagnosis
has completed.
Top up the fluid in the wheel-circuit reservoir until
one of the three protrusions in the filler neck just
touches the surface of the fluid (arrow).
Remove resetting tool, BMW No. 34 1 531, and
adapter, BMW No. 34 1 536.
d
Warning:
Make sure that the wheel-circuit reservoir does not
overflow when the brake pads/brake calipers are installed.
•
•
•
•
Install rear brake pads and brake caliper.
Disconnect the container from the wheel-circuit
reservoir.
Hand-tighten cap of rear wheel-circuit reservoir.
Check operation of the brake system with the ignition switched on.
e
Attention:
After all the work on the brake system has been
completed, run a bleed test using the
BMW MoDiTeC.
•
•
Perform bleed test with BMW MoDiTeC.
(a 00.29)
Install fuel tank.
Brake fluid ...................................................DOT 4
•
Operate the footbrake lever until the pistons of
the rear brake caliper are in contact with
resetting tool, BMW No. 34 1 531, and
adapter, BMW No. 34 1 536.
00.46
X
Tightening torque:
Bleed screw in rear brake caliper ................... 5 Nm
Brake caliper to rear wheel drive .................. 40 Nm
Only bleeding the rear wheel circuit
–
–
–
Draw off the old brake fluid from the wheel-circuit
reservoir.
Remove rear brake pads, force back the brake
pistons and secure the pistons in this position.
Wrap a cloth around the rear brake caliper.
d Warning:
Check that the brake fluid in the hose does not
foam.
If the fluid foams, proceed as described in the section on bleeding and changing brake fluid in rear
wheel circuit. (a 00.44)
•
•
•
•
34 1 561
•
34 2 541
Pump brake fluid through the system until it is
clear and free from air bubbles.
Close the bleed screw.
Release the brake and switch off the ignition.
Disconnect silicon hose, BMW No. 34 1 561,
from bleed screw and drain the hose.
Remove cap, BMW No. 34 2 541.
e
Attention:
After changing and/or bleeding the brakes, always
top up the fluid in the wheel-circuit reservoir to the
correct level in accordance with the instructions.
R28000230
•
•
Fill rear wheel-circuit reservoir with brake fluid up
to “MAX” mark and install cap,
BMW No. 34 2 541.
Connect 1.5m (4.9214 ft) silicon
hose, BMW No. 34 1 561, to the bleed screw.
L
Note:
If necessary, use a cable tie to secure the bleed
•
•
Fill rear wheel-circuit reservoir with brake fluid in
accordance with instructions.
(a 00.46)
Check operation of the brake system with the ignition switched on.
e
Attention:
After all the work on the brake system has been
completed, run a bleed test using the
BMW MoDiTeC.
hose to the bleed screw.
•
Switch on the ignition.
L Note:
After switching on the ignition, always wait for the
BMW Integral ABS to complete its self-diagnosis.
Do not operate the brake lever until self-diagnosis
has completed.
•
•
•
•
•
Brake fluid ...................................................DOT 4
X
Tightening torque:
Bleed screw in rear brake caliper ................... 6 Nm
Brake caliper to rear wheel drive .................. 40 Nm
Very gently press the footbrake lever until the
pump just starts up.
Open the bleed screw.
Pump the brake fluid with virtually no pressure
until the hose is full of brake fluid.
Connect end of hose to
cap, BMW No. 34 2 541.
Pump the brake fluid with virtually no pressure to
begin with, then vary the brake pressure.
00.47
34 00 091 Changing/bleeding
brake
fluid in control circuit
Change brake fluid in control circuit every 2
years
(Inspection IV)
d
Warning:
All repair and maintenance work on the
BMW Integral ABS must be performed by trained,
qualified specialists.
Comply with all maintenance and repair instructions
and always work through the various steps in the
correct order.
Use only new brake fluid from freshly opened containers.
R21000020
•
34 00 072 Bleeding/changing
brake fluid
Top up the brake fluid level to the “MAX”
mark (arrow).
in front control circuit
1
3
d Warning:
When performing maintenance and repair work on
BMW Integral ABS, never pump quickly or vigorously.
•
•
•
•
•
Place the motorcycle on its side stand and turn
the handlebars all the way to the left.
Repeatedly and slowly pull front brake lever lightly to expel air from brake master cylinder.
Place the motorcycle on its main stand.
Remove fuel tank.
Turn the front wheel to a position in which the
brake fluid reservoir is horizontal and secure the
handlebars in this position.
e
Attention:
Do not allow brake fluid to come into contact with
painted parts of the motorcycle as brake fluid destroys paint.
•
•
Wrap cloths around the reservoir.
Remove front reservoir cap with rubber diaphragm, draw off the old brake fluid and clean
the reservoir.
00.48
2
R28340110
•
Connect the brake bleeding device to bleed
screw (1) of the front metering cylinder, but do
not switch on.
d
Warning:
Do not use vacuum extraction to change the brake
fluid in the control circuits or bleed the control circuits.
e
Attention:
During the fluid-change and bleeding procedure,
make sure that the fluid replenishing hole is always
below the level of the brake fluid, or else air will be
drawn into the brake system.
Bleed the system again if this happens.
•
•
•
•
Recheck the brake-fluid level.
Place the motorcycle on its centre stand.
Turn the handlebars to the left.
Set the handbrake lever to position 4.
d
Warning:
When performing maintenance and repair work on
BMW Integral ABS, never pump quickly or vigorously.
1
R22000140
3
Required level
not below ......................................................... MIN
(top edge of the marking ring)
2
e Attention:
After all the work on the brake system has been
completed, run a bleed test using the
BMW MoDiTeC.
R28340110
Brake fluid ...................................................DOT 4
•
In the following sequence, bleed:
– front metering cylinder (1),
– front integral circuit (2)
– front control circuit (3) and
– front metering cylinder (1) for the second time
using ring spanner, BMW No. 34 2 532, in accordance with instructions for bleeding.
Instructions for bleeding:
1. Slowly pull brake lever until brake-light switch
clicks (blow-by bore closed).
2. Open the bleed screw.
3. Slowly pull brake lever to full extent of its travel
and close the bleed screw.
4. Slowly release the brake lever.
5. Repeat steps 1 to 4 until the bake fluid is clear
and free of bubbles.
•
•
•
Fit the protective caps on the bleed screws.
Top up the brake fluid until the level reaches the
“MAX” mark.
Wipe the rim of the reservoir, the rubber diaphragm and the cover to remove brake fluid, and
carefully reassemble the components.
00.49
34 00 082 Bleeding/changing
brake fluid
in rear control circuit
–
–
Place the motorcycle on its main (centre) stand.
Fuel tank removed.
d
Warning:
When performing maintenance and repair work on
BMW Integral ABS, never pump quickly or vigorously.
e
Attention:
Do not allow brake fluid to come into contact with
painted parts of the motorcycle as brake fluid destroys paint.
•
•
•
2
Remove right case, if necessary.
Remove small right side fairing panel.
Remove rear reservoir cap with rubber diaphragm, draw off the old brake fluid and clean
the reservoir.
1
3
R28340110
•
In the following sequence, bleed:
– rear metering cylinder (1),
– rear integral circuit (2),
– rear control circuit (3) and
– rear metering cylinder (1) for the second time
using ring spanner, BMW No. 34 2 532, in accordance with instructions for bleeding.
R22000151
•
•
Top up the brake fluid level to the “MAX” mark.
Connect the brake bleeding device to bleed
screw (1) of the rear metering cylinder, but do
not switch on.
d
Warning:
Do not use vacuum extraction to change the brake
fluid in the control circuits or bleed the control circuits.
e
Attention:
While bleeding the system, do not allow the brake
fluid level to drop below the “MIN” mark, as otherwise air will be drawn into the brake system.
Bleed the system again if this happens.
00.50
Instructions for bleeding:
1. Slowly depress brake lever until brake-light
switch clicks (blow-by bore closed).
2. Open the bleed screw.
3. Slowly depress brake lever to full extent of its travel and close the bleed screw.
4. Slowly release the brake lever.
5. Repeat steps 1 to 4 until the bake fluid is clear
and free of bubbles.
•
Fit the protective caps on the bleed screws.
•
•
–
Correct the brake fluid level.
Wipe the rim of the reservoir, the rubber diaphragm and the cover to remove brake fluid, and
carefully reassemble the components.
Place the motorcycle on its centre stand.
Checking clutch operating fluid
level
(Inspections II and III)
e
Attention:
Keep the brake fluid in the clutch operating system
away from painted surfaces on the motorcycle because brake fluid attacks paint.
•
•
Place motorcycle on its centre stand.
Move the handlebars to the straight-ahead
position.
R22000150
Required level
not below ......................................................... MIN
e Attention:
After all the work on the brake system has been
completed, run a bleed test using the
BMW MoDiTeC.
R22000190
•
Perform bleed test with BMW MoDiTeC.
(a 00.29)
Required level with a new clutch liner:
........................................... Half way up sight glass
•
Install fuel tank.
L Note:
Brake fluid....................................................DOT 4
As the clutch lining wears, the fluid level in the reservoir rises.
•
•
–
•
•
If necessary, remove reservoir cap with insert.
Correct the fluid level.
Mark in reservoir: same as brake circuit.
Reinstall the reservoir cap with insert.
Tighten the reservoir cap carefully and without
using force.
Brake fluid ...................................................DOT 4
00.51
21 52 005 Changing
the clutch fluid
(Inspection IV)
every 2 years at the latest
L
Note:
The description applies to a brake system filling and
bleeding device with vacuum extraction of brake fluid at the bleed line.
If other devices are used, comply with their manufacturers’ instructions.
•
•
•
Place the motorcycle on its main (centre) stand.
Turn the handlebars to a position in which the
clutch fluid reservoir is horizontal.
Secure front wheel in position.
Screw the bleed screw all the way into the filler
adapter (valve in filler adapter closed).
e
Attention:
While bleeding the system, do not allow the brake
fluid level to drop below the bottom edge of the ring
mark, as otherwise air will be drawn into the clutch
system. Bleed the system again if this happens.
•
•
•
•
Open the bleed screw by half a turn (valve open).
Draw off brake fluid until it emerges clear and
free from air bubbles.
Remove the bleed screw.
Disconnect the brake bleeding device from the
bleed screw.
L
Note:
On account of the vacuum extraction process, it
e Attention:
Keep the brake fluid in the clutch operating system
away from painted surfaces on the motorcycle because brake fluid attacks paint.
•
•
•
•
Remove reservoir cap with rubber diaphragm.
Draw off the brake fluid and clean the reservoir.
Top up the brake fluid.
might not be possible to tell whether there is brake
fluid in the hose of the brake bleeding device when
it is free of bubbles.
In this case bleed the system manually.
•
Reinstall socket-head grub screw (2) in the filler
adapter.
.
e
3
Attention:
The motorcycle is not permitted on the road without
the grub screw in place and secure in the filler
adapter.
•
•
1
2
•
R22210010
•
•
•
•
Pull back protective hose (1).
Wrap a cloth around the filler adapter.
Remove socket-head grub screw (2) from the filler adapter.
Connect the brake bleeding device to bleed
screw (3).
00.52
•
Correct the fluid level.
Reinstall the reservoir lid with rubber diaphragm
in position.
Tighten the reservoir cap carefully and without
using force.
Recheck the fluid level.
X
Tightening torque:
Grubscrew in filler adapter ........................... 10 Nm
Consumables
Brake fluid.....................................................DOT 4
Checking tightness of rear wheel
studs
Greasing the side stand pivot
(Inspections I, II and III)
(Inspection I)
•
Tighten the rear wheel studs with a torque
wrench.
X
Tightening torque:
Securing screws for rear wheel .................. 105 Nm
Checking rear wheel bearing play by
tilting wheel
(Inspection III)
•
–
a
Tilt the rear wheel to and fro across its axle.
If play is detected, fit new shims to rear wheel
drive or replace bearings.
.................................................... see Group 33
Checking swinging arm bearings,
adjusting if necessary
R22000310
•
•
Check free movement of side stand and grease
if necessary.
Grease pivot point (arrow).
Lubricant:
................................................... Shell Retinax EP2
(Inspections I and III)
•
–
a
Grip rear tyre and try to move it sideways, bracing against the frame.
If play is perceptible, remove fixed-bearing stud
and floating-bearing stud of the bearing in question, clean the threads and reinstall.
.................................................... see Group 33
Checking function of side stand
contact switch
(Inspections I, II, III and IV)
•
•
•
•
•
Place the motorcycle on its centre stand.
Retract the side stand, if extended.
Disengage the clutch and select a gear.
Start the engine, without releasing the clutch lever.
Extend the side stand.
L
Note:
The side-stand switch is in correct working order if
the engine stops when the side stand is extended.
00.53
12 12 011 Checking/replacing
spark
plugs
11 12 009
Tightening cylinder heads
(Inspection I)
(Inspection II) check/(Inspection III) replace
12 3 510
12 3 520
R21000330
R21000190
•
•
Pull off spark plug caps with special puller,
BMW No. 12 3 520.
Remove spark plugs with the spark plug wrench,
BMW No. 12 3 510.
•
Remove cylinder head cover.
e Attention:
Catch escaping oil.
e
Attention:
Do not bend electrodes - risk of breakage!
Spark plug:.................................. NGK BKR 7 EKC
Electrode gap: ........................ 0.8 mm (0.0314 in)
Wear limit: ................................ 1.0 mm (0.0393 in)
X
Tightening torque:
Spark plug NGK BKR7EKC .......................... 25 Nm
R21000370
•
Select a gear and turn the rear wheel, or set the
piston to TDC on the ignition stroke by turning
the belt pulley.
Top dead centre on ignition stroke:
The TDC mark is visible and the inlet and exhaust
valves in the cylinder concerned are closed.
• Tighten cylinder head nuts.
•
Tightening procedure after 1,000 km (600 miles)
1. Tighten the cylinder head nuts one after the
other in diagonally opposite sequence
1.1. Slacken off one nut at a time
1.2. Tighten nut to initial torque.................... 20 Nm
1.3. Tighten nut to specified wrench angle...... 180°
2. Slacken/retighten M10 screw................ 40 Nm
00.54
Checking/adjusting valve
clearances
11 34 004
(Inspections I, II and III)
Checking freedom of throttle
cable, checking for chaffing and
kinks, replacing if necessary
Checking throttle-cable play
Checking and adjusting idle speed
and throttle-valve synchronisation
13 60 110
(Inspections I, II and III)
•
•
•
Test-drive the motorcycle until the engine is
warm.
Remove the left side panel.
Remove the flap in the right side panel.
Oil temperature: ..................at least 90 °C (194 °F)
R21000340
•
Check valve clearance with feeler gauge and, if
necessary, correct with adjusting screw.
Valve clearances with engine cold
(max. 35 °C/95 °F):
Inlet ......................................... 0.15 mm (0.0059 in)
Exhaust ................................... 0.30 mm (0.0118 in)
X
Tightening torque:
Locknut .......................................................... 8 Nm
•
•
Recheck valve clearances after adjusting. Feeler
gauge must pull through between valve stem and
adjusting screw with slight resistance.
Assembly is the reverse of the disassembly
procedure.
e Attention:
R22000320
•
•
Push back rubber cap (arrow) on throttle and
choke cables.
Use the adjusting screws to adjust play of throttle
and choke cables.
Play of choke cable: .......approx. 1 mm (0.0393 in)
Play of throttle cable: .....approx. 1 mm (0.0393 in)
Make sure that all seals are correctly seated. Seals
and sealing faces must be free from oil and grease.
X
Tightening torque:
Cylinder head cover ....................................... 8 Nm
00.55
•
•
•
Carefully turn the adjusting screw of the left throttle valve and reduce play until the reading of the
Synchro tester changes.
Turn the adjusting screw very slightly in the opposite direction until the reading returns to its
original value.
Tighten the locknut to secure.
L Note:
S000100
•
Turn the adjusting screws to adjust the play of
the cables for the left and right throttle valves.
Play of throttle cable: .... approx. 2 mm (0.0787 in)
•
•
Make sure that the reading does not change when
you tighten the locknut.
Adjust throttle cable play at throttle valve so that no
play is perceptible, but the throttle valve reliably
contacts the stop screw (no strain on cable).
•
Adjust the right throttle valve in the same way.
L Note:
Zero play can cause the throttle valves to rattle.
Connect hose of BMW Synchro to vacuum
adapter and connect cables to BMW MoDiTeC.
Start the engine.
e
Attention:
Do not allow the engine to idle for longer than is necessary, because the trim panels near the exhaust
could be damaged.
•
Adjust idle speed by turning the air bypass
screws while checking that the carburettors are
balanced.
Idle speed: ........................................ 1,100
±50 rpm
L Note:
R22000320
Make sure that both throttle valves are closed.
•
e Attention:
Do not tamper with the sealed stop screws of the
Play of throttle cable:
.....................................approx. 0.5 mm (0.0197 in)
throttle valves, as otherwise the idle-speed volume
flow will have to be reset by the manufacturer.
•
00.56
Use the adjusting screws (arrow) to adjust play of
the throttle cables.
Push the rubber cap into position over the adjusting screw.
Final inspection with road safety
and functional check
(Inspections I, II, III and IV)
Road safety check
• Check wheels and tyres.
• Check/correct tyre pressures.
• Wait at least 10 minutes after heating the engine
to operating temperature in the trial run/road test
before checking/correcting engine oil level.
R22000330
•
•
•
•
Use the adjusting screw (arrow) to adjust play of
the choke cable to zero.
Push the rubber cap into position over the adjusting screw.
Move the handlebars all the way from left to right
and check the settings. Make sure that engine
speed does not vary when the handlebars are
moved in this way.
Repeatedly open the throttle gradually and increase engine speed from idle to approximately
n = 2,500 rpm to check throttle-valve synchronisation. (Readings shown by Synchro tester must
increase and decrease together). If necessary,
correct by turning the adjusting screws of the
throttle-valve Bowden cable.
Tyre pressures:
one-up ............................... front
........................................... rear
two-up ............................... front
........................................... rear
two-up + luggage ............... front
........................................... rear
2.2
2.5
2.5
2.9
2.5
2.9
bar
bar
bar
bar
bar
bar
(31.90
(36.26
(36.26
(42.06
(36.26
(42.06
psi)
psi)
psi)
psi)
psi)
psi)
Roadworthiness check
• Lights
• Telltale/warning lights
• Horn
• Instruments
• Special equipment
• Clutch
• Gear shift
• Steering
• Footbrake and handbrake, Integral ABS
• If necessary, take the motorcycle for a test ride.
L Note:
Make sure that when the throttle grip is released
both throttle valves return to their fully closed positions.
•
•
•
Tighten the locknuts and recheck carburettor
balance.
Seal off the vacuum bores.
Assembly is the reverse of the disassembly
procedure.
00.57
00.58
34 Brakes
34
Contents
Page
Technical Data 34 Brakes ........................................................................................................ 3
Removing and installing front brake caliper
.................................................................4
Disassembling and assembling front brake caliper
Removing and installing rear brake caliper
...................................................................6
Disassembling and assembling rear brake caliper
Disassembling rear brake caliper
Assembling rear brake caliper
..................................................5
...................................................7
............................................................................................7
..................................................................................................7
Removing and installing front brake discs
Removing and installing rear brake disc
.....................................................................8
.........................................................................8
Removing and installing Integral ABS sensor
..............................................................9
Removing and installing front Integral ABS sensor
Removing and installing rear Integral ABS sensor
Removing and installing footbrake lever
.........................................................9
......................................................... 10
....................................................................... 11
Removing and installing rear brake master cylinder
.............................................. 11
Checking and adjusting blow-by clearance of piston rod
........................................... 12
Checking blow-by clearance of piston rod ......................................................................................... 12
Adjusting blow-by clearance at piston rod ......................................................................................... 12
Checking and adjusting setting of rear brake light switch
.......................................... 13
Checking setting of brake light switch, rear ....................................................................................... 13
Adjusting brake light switch, rear ....................................................................................................... 13
Removing and installing piston in brake-lever fitting
............................................. 13
Removing and installing Integral ABS pressure modulator
Removing Integral ABS pressure modulator
Installing Integral ABS pressure modulator
................................ 14
.................................................................... 14
....................................................................... 15
34.1
Contents
Page
Draining the Integral ABS brake system
...................................................................... 16
Drain both wheel circuits
........................................................................................................... 16
Draining front wheel circuit ................................................................................................................ 16
Draining rear wheel circuit ................................................................................................................. 17
Draining control circuits
............................................................................................................. 18
Draining front control circuit .............................................................................................................. 18
Draining rear control circuit ............................................................................................................... 18
Filling and bleeding Integral ABS system
..................................................................... 19
Filling and bleeding control circuits
...................................................................................... 19
Filling the front control circuit ............................................................................................................ 19
Bleeding front control circuit .............................................................................................................20
Filling the rear control circuit .............................................................................................................21
Bleeding the rear control circuit .........................................................................................................21
Filling and bleeding wheel circuits
........................................................................................23
Filling and bleeding front wheel circuit ...............................................................................................23
Instructions for filling front wheel circuit reservoir ..............................................................................25
Filling and bleeding rear wheel circuit ................................................................................................26
Instructions for filling rear wheel circuit reservoir ...............................................................................28
Integral ABS
Reading fault memory with BMW MoDiTeC
.................................................................29
Integral ABS
Performing bleed test with BMW MoDiTeC
..................................................................29
Integral ABS
Removing and installing bleed lines, wheel circuit reservoirs
Integral ABS: Removing and installing brake lines
..........................30
..................................................31
Installed position of front brake line
......................................................................................32
Installed position of rear brake line
.......................................................................................33
34.2
34
Technical Data 34 Brakes
R 1150 RT
Brake fluid
DOT 4
Front wheel
Type
Hydraulically operated twin disc brake with 4-piston fixed calipers and floating brake discs
Colour of identification mark on brake calipers/brake pads
white
Brake pad lining
Sintered metal
Minimum lining thickness
Brake pad surface area
mm (in) 1.0 (0.0393 in)
cm2 86 (13.33)
(sq in)
Brake disc dia.
mm (in) 320 (12.5987)
Brake disc thickness
mm (in) 5.0 (0.1969)
Minimum thickness of brake discs
mm (in) 4.5 (0.1772)
Permissible lateral runout
mm (in) 0.15 (0.0059)
Piston dia. in brake caliper
mm (in) 32/36 (1.2599/1.4173)
Piston dia. in handlebar lever cylinder
mm (in) 16 (0.6299)
Rear wheel
Type
Hydraulically operated disc brake with 2-piston
floating caliper and fixed disc
Brake pad lining
Sintered metal
Minimum lining thickness
Brake pad surface area
mm (in) 1.0 (0.0393) (If the brake disc is visible through
the bore in the wheel-side brake pad, the brake
lining is worn to its minimum permissible thickness)
cm2 33.8 (5.23)
(sq in)
Brake disc dia.
mm (in) 276 (10.8661)
Brake disc thickness
mm (in) 5.0 (0.1968)
Minimum thickness of brake disc
mm (in) 4.5 (0.1772)
Permissible lateral runout
mm (in) 0.15 (0.0059)
Piston dia. in brake caliper
mm (in) 26/28 (1.0236/1.1023)
Piston dia. in actuating cylinder
mm (in) 13 (0.5118)
BMW Integral ABS
Type
Active fully integral system
Sensor gap, front
mm (in) 0.2...1.7 (0.0079...0.0670) (active sensor)
Sensor gap, rear
mm (in) 0.2...1.7 (0.0079...0.0670) (active sensor)
34.3
Removing and installing front
brake caliper
34 11
e
Attention:
Do not allow brake fluid to come into contact with
painted parts of the motorcycle as brake fluid destroys paint.
•
Integral ABS Drain front wheel circuit
(a 34.16).
1
d
Suds
2
R28340010
•
•
•
Disconnect brake line (1).
Remove the brake caliper securing screws.
Carefully remove the brake caliper.
e
Attention:
Replace the sealing rings (2) in the brake line.
Do not damage the brake pads when installing.
•
•
Installation is the reverse of the removal procedure.
Integral ABS Fill and bleed front wheel circuit
(a 34.23).
X
Tightening torque:
Brake caliper to fork slider............................ 30
Brake hose to brake caliper ......................... 18
Bleed screw to brake caliper .......................... 7
Grub screw in front brake caliper ................... 7
Nm
Nm
Nm
Nm
Colour code:
Brake pads/brake calipers ............................. white
34.4
3
2
34 1 531
1
34 1 532
S340220
Disassembling and assembling front brake caliper
34 11 521
e Attention:
Do not separate the brake caliper halves!
–
–
Integral ABS Drain front wheel circuit (a 34.16).
Remove the brake caliper.
•
•
•
Remove the brake pads.
Close the bleed screw.
Secure two opposing brake pistons with
spacer, BMW No. 34 1 520.
Insert a piece of cloth between the two brake pistons not secured by the resetting tool.
•
e
Attention:
Do not insert your fingers between the pistons; risk
e
Attention:
Keep the brake pistons parallel with their bores
when installing.
•
•
•
•
Remove and install the other two brake pistons
in the same way.
Using piston resetting tool, BMW No. 34 1 531,
press the pistons fully back.
Install brake caliper.
Integral ABS Fill and bleed front wheel circuit
(a 34.23).
X
Tightening torque:
Bleed screw to brake caliper .......................... 7 Nm
Grub screw in front brake caliper ................... 7 Nm
Colour code:
Brake pads/brake calipers ..............................white
of injury.
•
•
•
•
•
Carefully press out brake pistons (1), using a
compressed air gun at the brake line connection.
Remove the two sealing rings from each brake
cylinder bore.
Inspect the brake caliper piston for hairline
cracks, score-marks and other damage.
Coat new sealing rings (2, 3) with brake fluid and
install.
Coat brake caliper pistons (1) with brake fluid
and insert.
34.5
2
2
1
R22340090
Removing and installing rear
brake caliper
34 21
e
Attention:
Do not allow brake fluid to come into contact with
painted parts of the motorcycle as brake fluid destroys paint.
•
•
•
Integral ABS Drain rear wheel circuit (a 34.17).
Disconnect brake line (1) from brake caliper.
Remove the brake caliper.
e
Attention:
Replace the sealing rings (2) in the brake line.
Do not damage the brake pads.
•
Installation is the reverse of the removal procedure.
L Note:
To bleed, position the brake caliper with the bleed
nipple at the highest point.
•
Integral ABS Fill and bleed rear wheel circuit
(a 34.26).
34.6
X
Tightening torque:
Brake caliper to rear wheel drive .................. 40 Nm
Brake hose to brake caliper ......................... 18 Nm
Bleed screw to brake caliper .......................... 5 Nm
1
5
2
3
4
R21340010
Disassembling and assembling
rear brake caliper
34 21
Assembling rear brake caliper
•
Disassembling rear brake caliper
–
–
Integral ABS Drain rear wheel circuit (a 34.17).
Remove the brake caliper.
•
•
•
Close the bleed screw.
Hold a cloth over the brake caliper piston.
Carefully press out brake piston (3) with a compressed air gun applied to the connecting bore;
work at low air pressure.
e
Attention:
Keep fingers away from gap between piston and
side contact face of brake pads; risk of injury.
•
•
Remove sealing rings (4) from left and right
bores.
Inspect the brake caliper piston for hairline
cracks, score-marks and other damage.
X
Tightening torque:
Bleed screw to brake caliper .......................... 5 Nm
•
Coat the new sealing rings with brake fluid and
insert them into the left and right brake caliper
bores.
Coat both brake caliper pistons with brake fluid
and install them.
e
Attention:
Keep the brake pistons parallel with their bores
when installing.
•
•
Coat the adapter plate locating pins with
Shell Retinax A and install the adapter plate.
Insert locating plate (5) into brake caliper.
L Note:
The installed position must be correct (arrow pointing in forward-travel direction).
•
•
Using piston resetting tool, BMW No. 34 1 531,
press the pistons fully back.
Integral ABS Fill and bleed rear wheel circuit
(a 34.26).
X
Tightening torque:
Brake caliper to rear wheel drive .................. 40 Nm
Brake hose to brake caliper ......................... 18 Nm
Bleed screw to brake caliper .......................... 5 Nm
34.7
Removing and installing front
brake discs
Removing and installing rear
brake disc
34 21
34 11
d
d
Warning:
When removing and installing the brake calipers,
force back the pistons carefully to ensure that the
wheel-circuit reservoir does not overflow.
If fluid escapes, proceed in accordance with “instructions for filling reservoir” (a 34.25).
Warning:
When removing and installing the brake caliper,
force back the pistons carefully to ensure that the
wheel-circuit reservoir does not overflow.
If fluid escapes, proceed in accordance with “instructions for filling reservoir” (a 34.28).
•
•
•
•
Remove the brake calipers.
Remove front wheel.
1
Remove the brake caliper.
Remove rear wheel.
1
2
1
3
R28340150
R28340130
L Note:
L Note:
•
•
•
Retaining screws (1) are secured with thread-locking compound and should be heated if necessary
before removal.
Remove brake discs.
e
Attention:
Note thrust washers between right brake disc and
front wheel, and note ABS sensor ring between left
brake disc and front wheel.
•
•
Install ABS sensor ring (2) on left and thrust
washers (3) on right beneath brake disc.
Degrease brake discs before installing.
e Attention:
Install brake discs right way round (inscriptions on
brake discs facing toward the outside).
X
Tightening torque:
Brake disc to front wheel
(clean thread + Loctite 2701)....................... 21 Nm
34.8
Retaining screws (1) are secured with thread-locking compound and should be heated if necessary
before removal.
•
Remove brake disc.
Installation is the reverse of the removal procedure.
Degrease the brake disc before installing.
e
Attention:
Make sure the spacer is fitted when the rear wheel
is installed.
X
Tightening torque:
Brake disc to rear wheel drive
(clean thread + Loctite 2701)....................... 21 Nm
3
1
2
3
R22340060
Removing and installing Integral
ABS sensor
Removing and installing front
Integral ABS sensor
34 52 044
•
•
•
•
•
Remove the cable ties securing the sensor cable.
Disconnect plug (1) of sensor cable.
Guide the sensor cable down until clear.
Remove sensor (2).
Installation is the reverse of the removal procedure.
e
Attention:
Route the sensor cable correctly.
Ensure that clips (3) are correctly seated.
X
Tightening torque:
Sensor ........................................ hand-tight, 4 Nm
34.9
1
2
R22340070
Removing and installing rear
Integral ABS sensor
34 52 111
•
•
•
•
•
•
•
•
•
Remove front and rear seats.
Remove right case, if necessary.
Remove small right side fairing panel.
Remove the cable ties securing the sensor cable.
Disconnect plug (1) of sensor cable.
Before removing/installing, clean the sensor
bore.
Remove sensor (2).
Installation is the reverse of the removal procedure.
Coat O-rings with oil before installing.
e Attention:
Route the sensor cable correctly.
X
Tightening torque:
Sensor ........................................ hand-tight, 4 Nm
34.10
5
6
7
3
2
4
1
R22460140
35 21
Removing and installing footbrake lever
34 31
•
•
•
•
•
•
Release and remove stud (1).
Remove bolt (2) of footbrake lever with nut (3).
Remove footbrake lever with torsion spring (4).
Installation is the reverse of the removal procedure.
Lubricate pivot bushing with Shell Retinax A.
e Attention:
Check and, if necessary, adjust the blow-by clearance of the piston rod and the setting of the brakelight switch (a 34.12).
X
Tightening torque:
Footbrake lever to footrest plate
(clean thread + apply Loctite 2701) .............. 21 Nm
Removing and installing rear
brake master cylinder
Remove right side panel.
e
Attention:
Do not allow brake fluid to come into contact with
painted parts of the motorcycle as brake fluid destroys paint.
•
•
•
•
•
•
•
Integral ABS Drain rear control circuit
(a 34.18).
Disconnect brake line (5) and hose (6).
Release and remove stud (1).
Remove brake master cylinder.
Installation is the reverse of the removal procedure.
Tighten non-reusable hose clip (7) with pliers,
BMW No. 13 1 500.
Integral ABS Fill and bleed rear control circuit
(a 34.21).
e Attention:
Bleed the brake system carefully.
Check and, if necessary, adjust the blow-by clearance of the piston rod and the setting of the brakelight switch (a 34.12).
X
Tightening torque:
Master brake cylinder to footrest.................... 9 Nm
34.11
Checking and adjusting blow-by clearance of piston rod
Adjusting blow-by clearance at piston rod
Checking blow-by clearance of piston rod
2
1
A
3
R22340010
R22340020
•
•
•
Set the adjusting screw of the footbrake lever to
distance A.
Press the footbrake lever.
Insert feeler gauge at right angles to direction of
travel between the brake-light switch lever (3)
and the stop on the footrest plate (arrow).
Slowly release the footbrake lever and check
play.
Distance A: .... 13.6 +/- 0.5 mm (0.5354+/-0.1969 in)
(Top edge of footbrake lever to top edge of adjusting
screw.)
• Insert feeler gauge at right angles to direction of
travel between the brake-light switch lever and
the stop on the footrest plate (arrow).
Play must be perceptible
Feeler gauge thickness: ........ 0.15 mm (0.0059 in)
Feeler gauge thickness:.......... 0.2 mm (0.0078 in)
•
No play perceptible
Feeler gauge thickness: ........ 0.35 mm (0.0137 in)
•
•
•
•
•
•
34.12
Slacken locknut (1).
Turn piston rod (2) clockwise toward the footbrake lever to obtain play.
Carefully back off piston rod to take up play and
tighten locknut.
Remove the feeler gauge.
Recheck play.
Apply coloured sealing lacquer to the locknut.
Checking and adjusting setting of rear
brake light switch
Adjusting brake light switch, rear
Checking setting of brake light switch, rear
4
B
3
R22340030
R22340020
•
Switch on the ignition.
•
•
Depress the footbrake lever and secure it in this
position.
Slacken screw (4).
L
Note:
After switching on the ignition, always wait for the
BMW Integral ABS to complete its self-diagnosis.
Do not operate the brake lever until self-diagnosis
has completed.
•
•
•
Depress the footbrake lever (brake light comes
on and pump starts up).
Insert feeler gauge at right angles to direction of
travel between the brake-light switch lever (3)
and the stop on the footrest plate (arrow).
Slowly release the footbrake lever and check the
point at which the switch trips.
Brake light switch must switch off
Feeler gauge thickness: ........ 0.90 mm (0.0354 in)
Brake light switch must remain on
Feeler gauge thickness: ........ 1.60 mm (0.0629 in)
•
B
Switch off the ignition.
R22340020
•
•
•
Turn the brake light switch until the switch trips
at distance (B).
Hold the brake light switch and tighten the
screw.
Recheck the setting.
Distance B: ......... 1 + 0.5 mm (0.0393 + 0.1968 in)
(clearance at switching point between brake-light
switch lever and footrest plate).
Removing and installing piston in
brake-lever fitting
a
....................................................See Group 32
34.13
3
4
2
1
R28340060
34 00 Removing and installing Integral ABS pressure modulator
d Warning:
All repair and maintenance work on the
BMW Integral ABS must be performed by trained,
qualified specialists.
Comply with all maintenance and repair instructions
and always work through the various steps in the
correct order.
Use only new brake fluid from freshly opened containers.
34.14
Removing Integral ABS pressure modulator
e Attention:
Do not allow brake fluid to come into contact with
painted parts of the motorcycle as brake fluid destroys paint.
•
•
•
•
Drain the brake system (a 34.16).
Disconnect ground lead from battery and insulate.
Push protective caps (1) up.
Remove spring clips (2).
e Attention:
Do not bend the brake lines.
•
Disconnect the brake lines from the ABS pressure modulator.
e Attention:
Do not permit brake fluid to enter the plugs.
•
•
•
•
•
Disconnect plugs (3) of the front and rear wheel
circuit reservoirs.
Unlock plug (4) (arrow) and disconnect the plug.
Disconnect plug from Hall sensor.
Remove Motronic control unit.
Release ABS pressure modulator and pull it
carefully to the left to remove.
Installing Integral ABS pressure modulator
•
Installation is the reverse of the removal procedure: pay particular attention to the following.
L Note:
Always replace the seals (square-section rings) between the brake lines and the pressure modulator
when you replace the brake lines.
d Warning:
Always fit new spring clips each time the plugs are
disconnected. Ensure correct positioning.
•
•
•
•
•
•
•
•
Install new spring clips.
Slip the protective caps up the brake lines.
Clip in brake lines.
Check that spring clips are correctly positioned
(arrows).
Seat the protective caps on the connectors.
Connect the battery.
Fill and bleed the brake system (a 34.19).
After all the work on the brake system has been
completed, run a bleed test using the
BMW MoDiTeC (a 34.29).
L Note:
Disconnecting the battery means that the entries in
the fault memory of the Motronic MA2.4 control unit
are deleted and the adaptation values are reset.
This can temporarily impair the operating characteristics when the engine is restarted.
•
•
Switch on the ignition.
Without starting the engine, fully open the throttle
once or twice so that the Motronic control unit
can register the throttle-valve positions.
X
Tightening torque:
ABS pressure modulator to battery carrier ... 10 Nm
ABS pressure modulator to holder ................. 7 Nm
34.15
34 00 Draining the Integral ABS brake
system
•
•
Draw off the old brake fluid from the wheel-circuit
reservoir and reinstall the cap.
Remove front brake pads.
d
Warning:
All repair and maintenance work on the
BMW Integral ABS must be performed by trained,
qualified specialists.
Comply with all maintenance and repair instructions
and always work through the various steps in the
correct order.
Use only new brake fluid from freshly opened containers.
34 1 531
L Note:
34 1 532
This description applies for the brake filling and
bleeding unit with extraction of the brake fluid by
partial vacuum.
If other devices are used, comply with their manufacturers’ instructions.
R28000180
e Attention:
Do not scrape the wheel – mask it off if necessary.
•
•
Remove front and rear seats.
Remove fuel tank.
•
Drain both wheel circuits
•
e
Attention:
Do not allow brake fluid to come into contact with
painted parts of the motorcycle as brake fluid destroys paint.
•
•
Use resetting tool, BMW No. 34 1 531, and
locator, BMW No. 34 1 532, to force the pistons
in the left and right brake calipers all the way
back and hold them in this position.
Wrap cloths around the left and right brake calipers.
Connect the brake bleeding device to the bleed
screw of the left brake caliper, but do not switch
on the device.
Switch on the ignition.
Draining front wheel circuit
L
Note:
After switching on the ignition, always wait for the
e Attention:
Integral brakes, the rear brake must be ready for
BMW Integral ABS to complete its self-diagnosis.
Do not operate the brake lever until self-diagnosis
has completed.
use.
•
•
•
•
•
•
1
•
•
•
•
R28340110
•
Open front wheel-circuit reservoir (1).
e
Attention:
To prevent brake fluid entering plugs, do not disconnect plugs from the ABS pressure modulator.
34.16
Gently pull the handbrake lever until the pump
just starts up.
Open the bleed screw.
Drain the wheel circuit with the pump.
Close the bleed screw.
Release the brake.
Disconnect the brake bleeding device from the
bleed screw.
The procedure for draining the right brake caliper
is the same as that for the left caliper.
Close the bleed screw.
Release the brake and switch off the ignition.
Disconnect the brake bleeding device from the
bleed screw.
Draining rear wheel circuit
e
Attention:
Integral brakes, the rear brake must be ready for
use.
–
L Note:
After switching on the ignition, always wait for the
BMW Integral ABS to complete its self-diagnosis.
Do not operate the brake lever until self-diagnosis
has completed.
Install front brake pads, if applicable.
•
•
•
•
•
•
Gently press the footbrake lever until the pump
just starts up.
Open the bleed screw.
Drain the wheel circuit with the pump.
Close the bleed screw.
Release the brake and switch off the ignition.
Disconnect the brake bleeding device from the
bleed screw.
1
R28340110
•
Open rear wheel-circuit reservoir (1).
e Attention:
To prevent brake fluid entering the plugs, do not disconnect the plugs from the ABS pressure modulator.
•
•
Draw off the old brake fluid from the wheel-circuit
reservoir and reinstall the cap.
Remove rear brake pads.
34 1 536
34 1 531
R28000170
•
•
•
•
•
Install adapter, BMW No. 34 1 536, instead of
the outboard brake pad.
Install resetting tool, BMW No. 34 1 531, with
the handle toward the outside in the rear brake
caliper, press the pistons fully back and secure
them in this position.
Wrap a cloth around the brake caliper.
Connect the brake bleeding device to the bleed
screw, but do not switch on the device.
Switch on the ignition.
34.17
Draining control circuits
Draining rear control circuit
e Attention:
Do not allow brake fluid to come into contact with
•
Remove rear reservoir cap with rubber diaphragm, draw off the old brake fluid and clean
the reservoir.
painted parts of the motorcycle as brake fluid destroys paint.
Draining front control circuit
•
•
•
•
5
Turn the front wheel to a position in which the
brake fluid reservoir is horizontal and secure the
handlebars in this position.
Wrap cloths around the reservoir.
Remove front reservoir cap with rubber diaphragm.
Draw off old brake fluid and clean the reservoir.
6
4
1
R28340110
3
•
2
–
–
–
R28340110
•
–
–
–
Draw off the brake fluid from the circuits in the
correct sequence, using ring
spanner, BMW No. 34 2 532:
front metering cylinder (1),
front integral circuit (2) and
front control circuit (3).
34.18
Draw off the brake fluid from the circuits in the
correct sequence, using ring
spanner, BMW No. 34 2 532:
rear metering cylinder (4),
rear integral circuit (5) and
rear control circuit (6).
Filling and bleeding Integral
ABS system
34 00
d
Warning:
All repair and maintenance work on the
BMW Integral ABS must be performed by trained,
qualified specialists.
Comply with all maintenance and repair instructions
and always work through the various steps in the
correct order.
Use only new brake fluid from freshly opened containers.
e Attention:
During the filling and bleeding procedure, make sure
that the fluid replenishing hole is always below the
level of the brake fluid, or else air will be drawn into
the brake system.
1
3
2
L Note:
This description applies for the brake filling and
bleeding unit with extraction of the brake fluid by
partial vacuum.
If other devices are used, comply with their manufacturers’ instructions.
–
–
–
Place motorcycle on its centre stand.
Remove front and rear seats.
Remove fuel tank.
R28340110
•
Filling and bleeding control circuits
e
Attention:
Do not allow brake fluid to come into contact with
painted parts of the motorcycle as brake fluid destroys paint.
Filling the front control circuit
–
–
–
Turn the front wheel to a position in which the
brake fluid reservoir is horizontal and secure the
handlebars in this position.
Wrap cloths around the reservoir.
Remove front reservoir cap with rubber diaphragm.
•
•
•
•
Draw off the brake fluid from the circuits in the
correct sequence while topping up continuously
with fresh brake fluid and using ring
spanner, BMW No. 34 2 532:
front metering cylinder (1),
front integral circuit (2),
front control circuit (3) and
front metering cylinder (1) for the second time.
e Attention:
On account of the vacuum extraction process, it is
not possible to tell whether there is brake fluid in the
hose of the brake bleeding device when it is free of
bubbles.
Consequently, the system must be bled again
manually in the specified sequence and in accordance with the instructions for bleeding the
brakes.
KR340280
•
Top up the brake fluid level to the “MAX”
mark (arrow).
34.19
Bleeding front control circuit
•
•
•
•
•
Seal the reservoir by installing the rubber diaphragm and the reservoir cap.
Turn the handlebars to full left lock.
Repeatedly pull front brake lever lightly to expel
air from brake master cylinder.
Switch off the brake bleeding device.
Set the handbrake lever to position 4.
•
•
•
Recheck the brake-fluid level.
Place the motorcycle on its centre stand.
Turn the handlebars fully to the left.
d
Warning:
When performing maintenance and repair work on
BMW Integral ABS, never pump quickly or vigorously.
1
R22000140
3
Specified level
not below ......................................................... MIN
(top edge of the marking ring)
2
e
Attention:
After all the work on the brake system has been
completed, run a bleed test using the
BMW MoDiTeC.
R28340110
•
•
Remove reservoir cap with rubber diaphragm.
In the following sequence, bleed:
– front metering cylinder (1),
– front integral circuit (2),
– front control circuit (3) and
– front metering cylinder (1) for the second time
using ring spanner, BMW No. 34 2 532, in accordance with instructions for bleeding.
Instructions for bleeding:
1. Slowly pull brake lever until brake-light switch
clicks (blow-by bore closed).
2. Open the bleed screw.
3. Slowly pull brake lever to full extent of its travel
and close the bleed screw.
4. Slowly release the brake lever.
5. Repeat steps 1 to 4 until the bake fluid is clear
and free of bubbles.
•
•
•
Fit the protective caps on the bleed screws.
Add brake fluid up to the “MAX” mark.
Wipe the rim of the reservoir, the rubber diaphragm and the cover to remove brake fluid, and
carefully re-assemble the components.
34.20
Brake fluid ...................................................DOT 4
Filling the rear control circuit
•
Remove rear reservoir cap with rubber diaphragm.
e Attention:
On account of the vacuum extraction process, it is
not possible to tell whether there is brake fluid in the
hose of the brake bleeding device when it is free of
bubbles.
Consequently, the system must be bled again
manually in the specified sequence and in accordance with the instructions for bleeding the
brakes.
Bleeding the rear control circuit
•
•
R22000151
•
Top up the brake fluid level to the “MAX” mark.
e
Attention:
While filling and bleeding the system, do not allow
the brake fluid level to drop below the “MIN” mark,
as otherwise air will be drawn into the brake system.
d
Warning:
When performing maintenance and repair work on
BMW Integral ABS, never pump quickly or vigorously.
Switch off the brake bleeding device.
In the following sequence, bleed:
– rear metering cylinder (1),
– rear integral circuit (2),
– rear control circuit (3) and
– rear metering cylinder (1) for the second time
using ring spanner, BMW No. 34 2 532, in accordance with instructions for bleeding.
Instructions for bleeding:
1. Slowly depress brake lever until brake-light
switch clicks (blow-by bore closed).
2. Open the bleed screw.
3. Slowly depress brake lever to full extent of its travel and close the bleed screw.
4. Slowly release the brake lever.
5. Repeat steps 1 to 4 until the bake fluid is clear
and free of bubbles.
2
1
3
R28340110
•
–
–
–
–
Draw off the brake fluid from the circuits in the
correct sequence while topping up continuously
with fresh brake fluid and using ring
spanner, BMW No. 34 2 532:
rear metering cylinder (1),
rear integral circuit (2),
rear control circuit (3) and
rear metering cylinder (1) for the second time.
34.21
•
•
•
•
–
Fit the protective caps on the bleed screws.
Top up the brake fluid at least until the level
reaches the “MIN” mark.
Wipe the rim of the reservoir, the rubber diaphragm and the cover to remove brake fluid, and
carefully re-assemble the components.
Recheck the brake-fluid level.
Place the motorcycle on its centre stand.
R22000150
Specified level
not below ......................................................... MIN
e
Attention:
After all the work on the brake system has been
completed, run a bleed test using the
BMW MoDiTeC.
Brake fluid....................................................DOT 4
34.22
Filling and bleeding wheel circuits
e
Attention:
Do not allow brake fluid to come into contact with
painted parts of the motorcycle as brake fluid destroys paint.
e Attention:
To prevent brake fluid entering the plugs, do not disconnect the plugs from the ABS pressure modulator.
Filling and bleeding front wheel circuit
e Attention:
34 1 581
Integral brakes, the rear brake must be ready for
use.
–
–
Install rear brake pads and brake caliper, if applicable.
Place the motorcycle on its centre stand.
R22000340
1
•
•
•
R28340110
•
•
•
Open front wheel-circuit reservoir (1).
Remove front brake pads.
Wrap cloths around the left and right brake calipers.
Screw container, BMW No. 34 1 581,
onto front wheel circuit reservoir.
Slowly fill container, BMW No. 34 1 581, with
new brake fluid until it is approximately 1/2 full.
Connect the brake bleeding device to the bleed
screw of the left brake caliper, but do not switch
on the device.
L Note:
If necessary, use a cable tie to secure the bleed
hose to the bleed screw.
•
Switch on the ignition.
L Note:
After switching on the ignition, always wait for the
BMW Integral ABS to complete its self-diagnosis.
Do not operate the brake lever until self-diagnosis
has completed.
34 1 531
34 1 532
R22000290
e Attention:
Do not scrape the wheel – mask it off if necessary.
•
Use resetting tool, BMW No. 34 1 531, and
locator, BMW No. 34 1 532, to force the pistons
in the left and right brake calipers all the way
back and hold them in this position.
34.23
•
•
•
•
•
MAX
Pump off brake fluid until it emerges clear and
free from air bubbles.
Close the bleed screw.
Release the brake.
Disconnect the brake bleeding device from the
bleed screw.
Connect the brake bleeding device to the bleed
screw of the right brake caliper, but do not
switch on the device.
L
Note:
If necessary, use a cable tie to secure the bleed
MIN
hose to the bleed screw.
R28340090
e Attention:
The brake fluid must always be visible in the container, because the piston in the base of the wheel-circuit reservoir must always be covered by the fluid.
The procedure must be repeated if the fluid drops
below the “min” level.
•
•
•
Gently pull the handbrake lever until the pump
just starts up.
Open the bleed screw, while topping up the
container with new brake fluid if necessary.
Pump out the brake fluid with virtually no pressure to begin with, then vary the brake pressure.
L Note:
The higher the brake pressure the faster the fluid is
pumped through the system, which means that the
level in the wheel-circuit reservoir drops all the more
rapidly.
34.24
•
•
•
•
•
•
The procedure for changing the brake fluid in the
right brake caliper is the same as that for the
left caliper.
When the brake fluid is clear and free of bubbles,
continue pumping until the fluid in the container
just disappears from view.
Close the bleed screw.
Release the brake and switch off the ignition.
Disconnect the brake bleeding device from the
bleed screw.
Disconnect the container from the wheel-circuit
reservoir.
e
Attention:
After changing and/or bleeding the brakes, always
top up the fluid in the wheel-circuit reservoir to the
correct level in accordance with the instructions.
Instructions for filling front wheel
circuit reservoir
e Attention:
Integral brakes, the rear brake must be ready for
use.
–
MAX
Install front brake pads, if applicable.
MIN
R28340090
34 1 533
34 1 531
•
•
34 1 532
•
R22000300
•
•
Top up fluid in front wheel-circuit reservoir to
“MAX” if necessary
Install adapters 22, BMW No. 34 1 533, in resetting tool, BMW No. 34 1 531/532, for both front
brake calipers, and tighten the resetting tool until
the adapters are secure.
•
•
•
•
•
Top up the fluid in the wheel-circuit reservoir until
one of the three protrusions in the filler neck just
touches the surface of the fluid (arrow).
Screw container, BMW No. 34 1 581,
onto front wheel circuit reservoir.
Remove adapter, BMW No. 34 1 533, and force
back pistons far enough to allow the brake pads
to be fitted.
Install front brake pads.
With the ignition switched on, bed in the brake
pads against the brake discs.
Disconnect the container from the wheel-circuit
reservoir.
Hand-tighten cap of front wheel-circuit reservoir.
Check operation of the brake system with the ignition switched on.
e
Attention:
The piston in the base of the wheel-circuit reservoir
e Attention:
must always be covered by the fluid, as otherwise air
can be drawn into the brake system.
Bleed the system again if this happens.
•
After all the work on the brake system has been
completed, run a bleed test using the
BMW MoDiTeC and check the fault code memory!
Switch on the ignition.
Brake fluid ...................................................DOT 4
L
Note:
After switching on the ignition, always wait for the
X
BMW Integral ABS to complete its self-diagnosis.
Do not operate the brake lever until self-diagnosis
has completed.
•
Tightening torque:
Bleed screw in front brake caliper .................. 7 Nm
Pull handbrake lever until the pistons of the front
brake calipers are in contact with resetting
tool, BMW No. 34 1 531.
34.25
Filling and bleeding rear wheel circuit
e
Attention:
Integral brakes, the front brake must be ready for
use.
–
34 1 581
Place the motorcycle on its centre stand.
R22000350
•
•
1
•
R28340110
•
•
Open rear wheel-circuit reservoir (1).
Remove rear brake pads.
Screw container, BMW No. 34 1 581,
onto rear wheel circuit reservoir.
Slowly fill container, BMW No. 34 1 581, with
new brake fluid until it is approximately 1/3 full.
Connect the brake bleeding device to the bleed
screw, but do not switch on the device.
L
Note:
If necessary, use a cable tie to secure the bleed
hose to the bleed screw.
•
Switch on the ignition
L
Note:
After switching on the ignition, always wait for the
BMW Integral ABS to complete its self-diagnosis.
Do not operate the brake lever until self-diagnosis
has completed.
34 1 536
34 1 531
R28000170
•
•
Install adapter, BMW No. 34 1 536, instead of
the outboard brake pad.
Install resetting tool, BMW No. 34 1 531, with
the handle toward the outside in the rear brake
caliper, press the pistons fully back and secure
them in this position.
e
Attention:
To prevent brake fluid entering the plugs, do not disconnect the plugs from the ABS pressure modulator.
34.26
•
•
•
•
MAX
Close the bleed screw.
Release the brake and switch off the ignition.
Disconnect the brake bleeding device from the
bleed screw.
Disconnect the container from the wheel-circuit
reservoir.
e
Attention:
After changing and/or bleeding the brakes, always
top up the fluid in the wheel-circuit reservoir to the
correct level in accordance with the instructions.
MIN
R28340090
e Attention:
The brake fluid must always be visible in the container, because the piston in the base of the wheel-circuit reservoir must always be covered by the fluid.
The procedure must be repeated if the fluid drops
below the “min” level.
•
•
•
Very gently press the footbrake lever until the
pump just starts up.
Open the bleed screw, while topping up the container with new brake fluid if necessary.
Pump out the brake fluid with virtually no pressure to begin with, then vary the brake pressure.
L Note:
The higher the brake pressure the faster the fluid is
pumped through the system, which means that the
level in the wheel-circuit reservoir drops all the more
rapidly.
•
When the brake fluid is clear and free of bubbles,
continue pumping until the fluid in the container
just disappears from view.
34.27
•
Instructions for filling rear wheel
circuit reservoir
Switch on the ignition.
L
Note:
After switching on the ignition, always wait for the
e Attention:
Integral brakes, the front brake must be ready for
use.
BMW Integral ABS to complete its self-diagnosis.
Do not operate the brake lever until self-diagnosis
has completed.
•
Operate the footbrake lever until the pistons of
the rear brake caliper are in contact with
resetting tool, BMW No. 34 1 531, and
adapter, BMW No. 34 1 536.
34 1 536
34 1 531
MAX
R28000170
•
•
Top up fluid in rear wheel-circuit reservoir to
“MAX” if necessary.
Fully tighten resetting tool, BMW No. 34 1 531,
and adapter, BMW No. 34 1 536.
e
Attention:
The piston in the base of the wheel-circuit reservoir
must always be covered by the fluid, as otherwise air
can be drawn into the brake system.
Bleed the system again if this happens.
MIN
R28340090
•
•
Top up the fluid in the wheel-circuit reservoir until
one of the three protrusions in the filler neck just
touches the surface of the fluid (arrow).
Remove resetting tool, BMW No. 34 1 531, and
adapter, BMW No. 34 1 536.
d
Warning:
Make sure that the wheel-circuit reservoir does not
overflow when the brake pads/brake calipers are installed.
34.28
•
•
•
•
Install rear brake pads and brake caliper.
Disconnect the container from the wheel-circuit
reservoir.
Hand-tighten cap of rear wheel-circuit reservoir.
Check operation of the brake system with the ignition switched on.
e
Attention:
After all the work on the brake system has been
completed, run a bleed test using the
BMW MoDiTeC.
Integral ABS
Reading fault memory with
BMW MoDiTeC
34 00
•
•
•
•
Remove front and rear seats.
Connect the BMW MoDiTeC to the diagnosis
connector.
Read out the fault memory.
Clear the fault memory if applicable, or perform
all requisite repair work.
Brake fluid....................................................DOT 4
Integral ABS
Performing bleed test with
BMW MoDiTeC
X
•
•
•
•
Perform bleed test with BMW MoDiTeC.
Install fuel tank.
Tightening torque:
Bleed screw in rear brake caliper ................... 5 Nm
Brake caliper to rear wheel drive .................. 40 Nm
34 00
Remove front and rear seats.
Connect the BMW MoDiTeC to the diagnosis
connector.
d
Warning:
When performing maintenance and repair work on
BMW Integral ABS, never pump quickly or
vigorously.
•
•
Perform bleed test.
Perform all requisite repair work.
34.29
R22340080
Integral ABS
Removing and installing bleed lines,
wheel circuit reservoirs
34 51
•
•
•
•
Remove caps of wheel circuit reservoirs complete with bleed lines.
Installation is the reverse of the removal procedure. Pay particular attention to the following:
Make sure the bleed lines are free of kinks.
Cut the bleed lines to length if necessary, and cut
the ends at an angle.
34.30
1
3
2
34 2 561
R28340160
Integral ABS: Removing and installing brake lines
•
•
•
•
•
Drain the brake system (a 34.16).
Push protective caps (1) up.
Remove spring clips (2).
Remove brake lines.
Installation is the reverse of the removal procedure: pay particular attention to the following.
d Warning:
Always fit new spring clips each time the plugs are
disconnected. Ensure correct positioning.
•
•
•
•
•
•
•
Check that square-section rings are correctly
seated.
Install new spring clips.
Slip the protective caps up the brake lines.
Clip in brake lines.
Check that spring clips are correctly positioned
(arrows).
Seat the protective caps on the connectors.
Fill and bleed the brake system (a 34.19).
X
Tightening torque:
Brake hose and brake line............................ 18 Nm
Bleed screws in front brake calipers............... 7 Nm
Bleed screw in rear brake caliper ................... 5 Nm
e Attention:
Fit new sealing rings for brake line.
Secure brake line to master cylinder so that it cannot become kinked or abraded when the handlebars
are turned.
L
Note:
Always replace the seals (square-section rings) between the brake lines and the pressure modulator
when you replace the brake lines.
•
•
Carefully remove square-section rings (3) using
disassembly tool, BMW No. 34 2 561.
Install square-section rings with brake lines.
34.31
Installed position of front brake line
R22340100
34.32
Installed position of rear brake line
R22340110
34.33