Maintenance BMW Integral ABS

Maintenance BMW Integral ABS
R 1150 R
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 R
Item
Desired value
Oil capacities
Engine
(with filter)
(without filter)
Transmission
3.75 (6.6)
3.50 (6.15)
Initial filling
Oil changes
Rear wheel drive
approx. 1.0 (1.76)
approx. 0.8 (1.41)
of oil to bottom edge of
filler neck
approx. 0.25 (0.44)
Initial filling/oil change
Valve clearances
measured cold (max. 35 °C/95 °F)
Ignition timing
static setting
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
litres (Imp. pints)
litres (Imp. pints)
Brand-name hypoid gear oil, SAE
class GL 5 SAE 90
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
green
1.0 (0.039)
1.0 (0.039) (wear mark)
4.5 (0.177)
4.5 (0.177)
mm (in)
mm (in)
rpm
mm (in) free travel
DOT 4 brake fluid
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 0 026 973
UX-VS-2, 07.00
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 .........................................................................................................................6
21 Clutch ............................................................................................................................................6
23 Transmission ..............................................................................................................................7
31 Front fork ......................................................................................................................................7
32 Steering ........................................................................................................................................8
33 Rear wheel drive .......................................................................................................................8
34 Brakes ...........................................................................................................................................9
36 Wheels and tyres .................................................................................................................... 10
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 R
Connection
11 Engine
Cylinder head
Tightening sequence:
1 Tighten cylinder head nuts (oiled) in gonally opposite sequence
1.1 Tighten all nuts to closing torque
Nm
20
1.2 Tighten all nuts to correct angle
°
90
1.3 Tighten all nuts to correct 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 R
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 lines to oil cooler
Nm
25
Oil cooler to bracket
Nm
8
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 R
Connection
12 Engine electrics
Starter motor to engine
Nm
20
Starter cover to gearbox housing
Nm
7
Positive lead to starter motor
Nm
10
Alternator to alternator 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
Spark plug NGK BKR 7 EKC
Nm
25
Model
R 1150 R
Connection
13 Fuel preparation and control
Temperature sensor, oil, in crankcase
Nm
25
Temperature sensor, air, in air-filter housing
Nm
10
Model
R 1150 R
Connection
16 Fuel tank and lines
Fuel tank to rear frame
Nm
22
Fuel pump assembly to tank
Nm
5
00.5
Model
R 1150 R
Connection
18 Exhaust system
Manifold to cylinder head
Nm
21
Clamp for manifold
Nm
45
(apply Optimoly TA to clamp seat)
Front silencer to manifold
Nm
45
(apply Optimoly TA to clamp seat)
Silencer to main stand lugs
Nm
20
Silencer to rear frame at top
Nm
35
Oxygen sensor to silencer
Nm
45
(apply Optimoly TA to thread)
End cap to rear silencer
Nm
8
(threads greased)
Bracket to rear silencer
Nm
15
(threads greased)
Model
R 1150 R
Connection
21 Clutch
Clutch housing
Closing 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
Wrench angle
00.6
Model
R 1150 R
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. clamp block, frame tube to gearbox
Nm
9
3. to gearbox and right footrest plate
Nm
42
(clean thread + Loctite 243)
Frame tube to gearbox
Model
R 1150 R
Connection
31 Front fork
Quick-release axle clamp screws
Nm
22
Clamp, fork fixed tube to fork bridge
Nm
45
(free from oil and grease)
Slider tube bridge to slider tube
Nm
25
(clean thread + Loctite 243)
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 to engine
Nm
130
Spring strut to front frame
Nm
43
Spring strut to leading link
Nm
50
Leading link to ball joint
00.7
Model
R 1150 R
Connection
32 Steering
Handlebars to fork bridge, tightening sequence:
1. Front fastener (as viewed in forward
direction of travel) until seated
Nm
21
2. Rear fastener (as viewed in forward
direction of travel)
Nm
21
Handlebar weight to handlebars
Nm
21
Pivot screw, handlebar lever
Nm
11
(Tuflok Blue thread-locking compound; screw
can be released and tightened a number of
times)
Model
R 1150 R
Connection
33 Rear wheel drive
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
Fixed bearing stud bolt, swinging arm to
gearbox
Nm
160
Nm
9
Nm
7
Locknut, floating bearing stud bolt,
swinging arm to gearbox
Nm
160
Fixed bearing stud bolt,
swinging arm to rear axle housing
Nm
160
(clean thread + Loctite 2701)
Nm
9
Nm
7
Nm
160
(clean thread + Loctite 2701)
Floating bearing stud bolt, swinging arm to
gearbox
1. initial torque
2. slacken
3. final torque
Floating bearing stud bolt,
swinging arm to rear axle housing
1. initial torque
2. slacken
3. final torque
Locknut, floating bearing stud bolt,
swinging arm to rear axle housing
00.8
Model
R 1150 R
Connection
33 Rear wheel drive
Reaction link to rear wheel drive / gearbox
Nm
43
(load approx. 85 kg (187 lbs) onto motorcycle
and tighten loose reaction link)
Spring strut to rear frame
Nm
50
Spring strut to rear swinging arm
Nm
58
(clean thread + Loctite 243)
Hydraulic spring preload adjuster to footrest plate
Nm
22
Model
R 1150 R
Connection
34 Brakes
Brake caliper to fork slider tube, Evo
brakes
Nm
30
Brake caliper to rear wheel drive
Nm
40
Brake disc to front wheel
Nm
21
(clean thread + Loctite 2701)
Brake disc to rear wheel drive
Nm
21
(clean thread + Loctite 2701)
Master cylinder to footrest assembly
Nm
9
Footbrake lever to footrest assembly
Nm
21
(clean thread + Loctite 2701)
Footbrake-lever stop
Nm
9
Ball socket to thrust rod
Nm
9
Brake lines/brake hose to brake components
Nm
18
Brake hose to bracket
Nm
9
Brake hose to brake lever fitting
Nm
18
Bracket to front frame
Nm
9
Bracket to rear frame
Nm
9
(clean thread + Loctite 2701)
Front brake caliper bleed screw
Nm
9
Rear brake caliper bleed screw
Nm
6
Filler adapter to brake line
Nm
18
ABS hydraulic unit to bracket
Nm
8
ABS hydraulic unit to battery carrier
Nm
8
00.9
Model
R 1150 R
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
Hand-tighten wheel studs and tighten in
diagonally opposite sequence
[Integral ABS] Note spacer
Nm
105
Model
R 1150 R
Connection
46 Frame
Frame to engine
Nm
82
Struts to frame
Nm
58
Strut to engine
Nm
58
(clean thread + Loctite 2701)
to gearbox and footrest plate
Nm
42
(clean thread + Loctite 2701)
to engine
Nm
42
Nm
72
(clean thread + Loctite 2701)
M 12 screw
Nm
72
(clean thread + Loctite 2701)
M 8 screw
Nm
21
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)
Footrest plate to gearbox
Nm
21
Rear footrest plate to rear frame
Nm
21
Front mudguard to fork slider tube bridge
Nm
6
(Tuflok Blue thread-locking compound; screw
can be released and tightened a number of
times
alternatively: clean thread + Loctite 243)
Rear frame to gearbox/engine
Carrier plate for main stand to engine, right
M 12 screw
Pivot mount to engine, left
00.10
Model
R 1150 R
Connection
46 Frame
Front and rear sections of front mudguard
to slider tube
Nm
3
(Tuflok Blue thread-locking compound; screw
can be released and tightened a number of
times
alternatively: clean thread + Loctite 243)
Headlight bracket to fork bridge
Nm
20
Model
R 1150 R
Connection
51 Equipment
Mirrors
Nm
15
Ignition/steering lock to fork bridge
Nm
20
(micro-encapsulated)
Model
R 1150 R
Connection
61 General electrical equipment
Horn to holder
Nm
8
(clean thread + Loctite 243)
Ground (earth) strap to engine block
Nm
9
Battery carrier to rubber-metal element
Nm
8
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 shipping pallet for damage
In case of damage in Germany
...............................................................................................16
In case of damage in importer markets
Unpacking the motorcycle
..................................................................... 16
..............................................................................16
....................................................................................................16
Installing remaining items on motorcycle
Mounting the Speedster fairing
..................................................................... 16
..............................................................................................16
Inspecting motorcycle for damage
...................................................................................16
Checking that delivery is complete
..................................................................................16
Filling and charging the battery
Removing the fuel tank
.........................................................................................17
............................................................................................................... 17
Filling and charging the battery ...............................................................................................17
Checking engine oil when engine is cold, topping up if necessary
Checking headlight beam angle, adjusting if necessary
Checking tightness of rear wheel studs
............... 18
......................................19
........................................................................19
Checking tyre pressures .........................................................................................................19
[Integral ABS] Performing bleed test with BMW MoDiTeC
Final inspection and function check
..................................20
................................................................................20
Final cleaning ................................................................................................................................20
Handing over the motorcycle
...............................................................................................21
00.13
00.14
00
General view of crated motorcycle
00.15
Checking the shipping pallet for
damage
00 11 Installing
•
•
When the motorcycle arrives, check the packing
material 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 supplier (e.g. freight company or DB) and
Bavaria Wirtschaftsagentur GmbH
Abteilung ZW - 12
80788 München
Tel. 089/14327-632
Fax 089/14327-709
without delay.
motorcycle
remaining items on
Fit the rear-view mirror.
X
Tightening torque:
Mirror on handlebar fitting ............................ 10 Nm
71 63 099 Mounting
ing
the Speedster fair-
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 11 Unpacking
•
•
–
–
–
•
the motorcycle
Lever off the cover.
Take out the separate pack of items:
Documentation
Optional Speedster fairing, if applicable
Optional seat cover, if applicable
Force off cross-struts with a suitable lever.
e
Important:
Do not knock the cross-struts out or the motorcycle
may be damaged.
•
•
Remove the end-walls.
Remove the side-walls.
e
Important:
Remove any nails projecting from the base of the
packing or lying on the base or on the floor.
•
•
•
•
•
Loosen the front tensioning straps.
Loosen the rear tensioning straps.
Push the motorcycle forwards off the pallet.
Remove the set of keys from the left rear footrest.
Dispose of the packing materials in an environmentally responsible manner as described in Circular 23/91 - Sales.
00.16
R28000010
•
Carefully tighten the Speedster fairing securing
screws by hand.
X
Tightening torque:
Fairing on fairing bracket ................................ 2 Nm
00 11 Inspecting
age
•
•
•
•
•
–
–
–
motorcycle for dam-
Check for faults.
“Express handling service” to:
BMW Motorrad
UX-VS-1
Fax number +49 (0)89-382-33220
Rectify the fault.
If parts are needed, order them through the usual
channel.
Costs are to be processed through 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
MAX
MIN
MIN
R28000020
61 21 Filling
16 11 533
•
•
•
•
•
and charging the battery
Removing the fuel tank
Remove front/rear seat.
Lever off the right-hand and left-hand front trim
sections from the tank.
Remove the right-hand and left-hand oil cooler
trims.
Remove the right-hand cable trim.
Remove oil cooler with air ducting and fold forwards.
e
Important:
Fuel is flammable and a hazard to health. Observe
61 21
Filling and charging the battery
d Warning:
Battery acid is highly caustic.
Protect your eyes, face, hands, clothing and the
paintwork.
•
•
•
•
•
Disengage the rubber strap holding the battery.
Disconnect the battery breather hose.
Remove the battery.
Fill all the cells to the upper mark with pure battery acid of density 1.28.
Allow the battery to stand for approximately
30 minutes.
relevant safety regulations.
•
•
•
•
Remove fuel tank retaining screw.
Remove bleed line and overflow pipe.
Disconnect the fuel line quick-release coupling.
Disconnect the fuel pump plug connection.
L
Note:
Place a cloth between the fork stabilizer and the fuel
tank to prevent paintwork damage to the front of the
fuel tank.
•
Remove the fuel tank upwards from the rear.
00.17
•
The battery does not achieve full charge capacity
from being filled, so it has to be charged with a
battery charger.
00 00 Checking
engine oil when
engine is cold, topping up if necessary
L Note:
Follow the instructions for use supplied with the battery charger.
MAX
Charge current (A)
.........................10 % of rated battery capacity (Ah)
Charging time
............................................................. 5-10 hours
•
MIN
Battery charge can be measured by checking
the density of the battery acid.
Acid density
Battery fully charged .......1.26-1.30 at 20 °C (68 °F)
•
•
•
•
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.
Refit the plugs.
Make a note of the charging date on the battery.
R28000030
•
Check oil level with the motorcycle upright.
e Important:
Never top up the engine-oil level past the “MAX”
mark.
e
Important:
Connect the positive battery terminal first, then the
negative terminal.
•
•
•
•
•
•
•
•
•
•
•
•
•
Required level:............................................... MAX
Fit the battery.
Apply acid-proof grease to the battery terminals.
Connect the battery breather line.
Fit the fuel tank.
Connect the fuel pump connector and the fuel
line quick-release couplings.
Connect bleed line and overflow pipe.
Fit oil cooler with air ducting.
Fit cable trim.
Fit oil cooler trim.
Secure the right-hand and left-hand front trim
sections to the tank.
Fit front/rear seat.
Switch on the ignition.
Without starting the engine, fully open the throttle
once or twice so that the Motronic control unit
can record the throttle-valve positions.
L Note:
Disconnecting the battery deletes all entries (e.g.
faults, settings) stored in the Motronic control unit’s
memory.
Loss of settings can temporarily impair the operating characteristics when the engine is restarted.
X
Tightening torque:
Fuel tank to frame ........................................ 22 Nm
BMW recommends Castrol
00.18
Checking headlight beam
angle, adjusting if necessary
Checking tightness of rear wheel
studs
63 10 500
X
Tightening torque:
Securing screws for rear wheel .................. 105 Nm
2
1
Checking tyre pressures
•
Check/correct tyre pressures.
Tyre pressures:
Solo ..................................... front 2.2 bar (31.3 psi)
............................................. rear 2.5 bar (35.6 psi)
R28000070
•
•
•
•
•
Motorcycle must be on a level surface.
Motorcycle with driver (approximately 85 kg/
187 lbs).
Remove trim (1).
Remove headlight (2) retaining bolts.
Correct the headlight range by swivelling the
headlight.
With pillion passenger .......... front 2.5 bar (35.6 psi)
............................................. rear 2.7 bar (38.4 psi)
With pillion passenger and
luggage ................................ front 2.5 bar (35.6 psi)
............................................. rear 2.9 bar (41.2 psi)
R28000080
Setting for headlight beam angle adjuster
.. .-25 cm (9.8425 in) at a distance of 10 m (32.8 ft)
00.19
[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
the conclusion of the self-diagnosis, only RESIDUAL BRAKE FUNCTION is available.
Performing BMW Integral ABS self-diagnosis:
• Release the brake levers if necessary.
• Switch on the ignition.
ABS warning light.............................flashes at 4 Hz
General warning lamp ........................is continuous
–
Self-diagnosis is in progress
ABS warning light.............................flashes at 1 Hz
General warning lamp ............................... goes out
– Self-diagnosis successfully completed.
Performing a bleed test using the
BMW MoDiTeC:
• Remove front/rear seat.
• Connect the BMW MoDiTeC to the diagnostic
connector.
d Warning:
Avoid rapid and forceful pumping of the brakes
when performing maintenance and repair work on
the BMW Integral ABS.
•
•
Perform bleed test.
Perform all requisite repair work.
Performing BMW Integral ABS pull-away test:
The ABS warning light must go out when a
speed of 5 km/h (approx. 3 mph) is reached.
•
L
Note:
The ABS warning light and the general warning light
must both be OFF after successful self-diagnosis
and the pull-away test.
00.20
Final inspection and function check
•
•
•
•
–
–
–
–
–
–
–
–
–
•
•
•
•
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
Brake light (operate brake at front and rear)
Turn signals left/right
Hazard warning flashers
Horn
Indicator and warning lights
Instruments
Where necessary, check function 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.
00 11 459 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.
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 handlebar lever positions
how to adjust the mirrors
controls
instruments and indicator 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:
partially 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)
before checking the engine oil level, the engine
must be switched off for at least 10 minutes and
the motorcycle must be standing on a flat, level
surface.
00.21
00.22
00
00 Maintenance
Contents
Key to maintenance intervals
Page
..............................................................................................27
Reading the BMW MoDiTeC fault code memory
.......................................................27
(Inspections I, II, III and IV)
[Integral ABS] Performing bleed test with BMW MoDiTeC
..................................27
(Inspections I, II, III and IV)
Changing engine oil, replacing oil filter element
......................................................28
(Inspections I, II, III and IV)
Changing the transmission oil
.............................................................................................29
(Inspections III and IV)
or at least every 2 years
Changing the oil in the rear wheel drive
........................................................................29
(Inspections I, III and IV)
Every 40,000 km (24,000 miles) or at the latest every 2 years
Replacing fuel filter
...................................................................................................................30
(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)
Checking battery fluid level and topping up if necessary; cleaning and
greasing the battery terminals ............................................................................................32
(Inspections III and IV)
Replacing intake air filter element
....................................................................................32
(Inspection III)
In very dirty and dusty operating conditions, replace every 10,000 km (6,000 miles) or even more
frequently if necessary
Replacing poly-V belt
...............................................................................................................33
(Inspection III)
every 60,000 km (36,000 miles)
[Without Integral ABS] Checking brake fluid level
...................................................34
(Inspections II and III)
Front brake
.......................................................................................................................................34
Rear brake
........................................................................................................................................34
[Integral ABS] Checking brake fluid level
.....................................................................35
(Inspections II and III)
Front brake
.......................................................................................................................................35
Rear brake
........................................................................................................................................35
00.23
Contents
Page
Checking brake system for correct operation and freedom from leaks;
repairing/replacing if necessary ........................................................................................35
(Inspection III)
Checking brake pads and discs for wear/replacing
...............................................35
(Inspections II and III)
Checking front brake pad wear ...............................................................................................35
Checking rear brake pad wear
................................................................................................36
Checking brake disc wear .........................................................................................................36
Replacing brake pads, front brake
Replacing brake pads, rear brake
........................................................................................37
..........................................................................................38
[Without Integral ABS] Changing brake fluid and bleeding
the brake system ........................................................................................................................39
Change the brake fluid annually
(Inspection IV)
[Without Integral ABS]
Bleeding/changing brake fluid in front system
.................................................................39
[Without Integral ABS]
Bleeding/changing brake fluid in rear system
..................................................................40
[Integral ABS] Changing/bleeding brake fluid in wheel circuit
........................42
Change brake fluid in wheel circuit once a year
(Inspection IV)
[Integral ABS]
Bleeding/changing brake fluid in front wheel circuit ......................................................42
[Integral ABS]
Bleeding/changing brake fluid in front wheel circuit ......................................................46
[Integral ABS] Changing/bleeding brake fluid in control circuit
......................50
Change brake fluid in control circuit every 2 years
(Inspection IV)
[Integral ABS]
Bleeding/changing brake fluid in front control circuit
[Integral ABS]
Bleeding/changing brake fluid in rear control circuit
Checking clutch operating fluid level
...................................................50
.....................................................52
..............................................................................53
(Inspections II and III)
Changing the clutch fluid
.......................................................................................................54
(Inspection IV)
at least every 2 years
Checking tightness of rear wheel studs
(Inspection I)
00.24
........................................................................55
Contents
Page
Checking rear wheel bearing play by tilting wheel
..................................................55
(Inspection III)
Checking swinging arm bearings, adjusting if necessary
...................................55
(Inspections I and III)
Greasing the side stand pivot
..............................................................................................55
(Inspections I, II and III)
Checking function of side stand contact switch
......................................................55
(Inspections I, II, III and IV)
Checking/replacing spark plugs
........................................................................................55
(Inspection II) check/(Inspection III) replace
Tightening cylinder heads
.....................................................................................................56
(Inspection I)
Checking/adjusting valve clearances
.............................................................................56
(Inspections I, II and III)
Checking throttle cable freedom of movement, checking for chafes
and kinks, replacing if necessary, checking throttle cable play
Checking/adjusting idle speed and throttle valve synchronization ................57
(Inspections I, II and III)
Final inspection with road safety and functional check
.......................................59
(Inspections I, II, III and IV)
Road safety check
Roadworthiness check
00.25
00.26
00
Key to maintenance intervals
–
–
–
–
BMW Inspection at 1,000 km
(approximately 600 miles)
BMW Service every 10,000 km
(approximately 6,000 miles)
BMW Inspection every 20,000 km
(approximately 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/rear seat.
Connect the BMW MoDiTeC to the diagnostic
connector.
Read all fault code memories.
Perform all requisite repair work.
[Integral ABS] Performing bleed test
with BMW MoDiTeC
(Inspections I, II, III and IV)
•
•
Remove front/rear seat.
Connect the BMW MoDiTeC to the diagnostic
connector.
d Warning:
Avoid rapid and forceful pumping of the brakes
when performing maintenance and repair work on
the BMW Integral ABS.
•
•
Perform bleed test.
Perform all requisite repair work.
00.27
00 11 209 Changing
engine oil, replacing oil filter element
•
(Inspections I, II, III and IV)
e
Important:
Never top up the engine-oil level past the “MAX”
Insert and tighten the screw plug.
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 less than every 3,000 km
(1,800 miles).
•
Change the engine oil at operating temperature.
X
Tightening torque:
Oil filter......................................................... 11 Nm
Oil drain plug................................................ 32 Nm
Engine oil quantities:
with oil filter change
........... 3.75 l (6.6026 Imp. pints/3.9626 US quarts)
without oil filter change
........... 3.50 l (6.1624 Imp. pints/3.6985 US quarts)
oil between
MIN and MAX mark
........... 0.50 l (0.8803 Imp. pints/0.5283 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.
R28000030
•
Remove screw plug.
11 4 650
C000030
•
•
•
•
•
Remove oil drain plug and drain off oil.
Refit the oil drain plug with a new sealing ring.
Use the oil filter wrench, BMW No. 11 4 650, to
remove the oil filter.
Coat the sealing ring on the new oil filter element
with oil and install filter.
Refill with oil to correct level.
BMW recommends Castrol
00.28
00 11 229
oil
Changing the transmission
(Inspections III and IV)
or at least every 2 years
•
Change the transmission 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 transmission oil at operating temperature.
1
1
2
2
R28000090
R28000100
•
•
•
•
•
Remove oil filler plug (1).
Remove oil drain plug (2) and allow the oil to
drain out.
Refit the oil drain plug with a new sealing ring.
Fill with gearbox oil.
Insert oil filler plug with new seal.
X
e
Important:
Do not let oil drip on the rear tyres.
•
•
Remove oil filler plug (1).
Remove oil drain plug (2) and allow the oil to
drain out.
Refit the oil drain plug with a new sealing ring.
Fill with gearbox oil.
Insert oil filler plug with new seal.
Tightening torque:
Oil drain plug................................................ 30 Nm
Oil filler plug ................................................. 30 Nm
•
•
•
Quantity:
Refill
to bottom of filler neck......................... approx. 1.0 l
.....................(1.7607 Imp. pints/1.0567 US quarts)
Oil change
to bottom of filler neck......................... approx. 0.8 l
.....................(1.4086 Imp. pints/0.8454 US quarts)
X
Oil grade for transmission:
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 filler neck ...................... approx. 0.25 l
.....................(0.4401 Imp. pints/0.2641 US quarts)
Oil grade for rear wheel drive:
Brand-name hypoid gear oil, SAE 90, API class GL 5
00.29
B
MW
R28160021
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/rear seat.
Lever off the right-hand and left-hand front trim
sections from the tank.
Remove the right-hand and left-hand oil cooler
trims.
Remove the right-hand cable trim.
Remove oil cooler with air ducting and fold forwards.
e
Important:
Fuel is flammable and a hazard to health. Observe
relevant safety regulations.
•
•
•
•
Remove fuel tank retaining screw.
Remove bleed line and overflow pipe.
Disconnect the fuel line quick-release coupling.
Disconnect the fuel pump plug connection.
L Note:
Place a cloth between the fork stabilizer and the fuel
tank to prevent damage to the paintwork on the front
of the fuel tank.
•
•
•
Remove the fuel tank upwards from the rear.
Drain fuel tank.
Remove fuel pump unit.
00.30
1
2
3
•
•
Disconnect hoses from fuel filter (1).
Replace the fuel filter
e Important:
Note correct direction of flow through fuel filter.
•
Tighten one-time hose clips with pliers,
BMW No. 13 1 500.
e Important:
R28160010
e Important:
After installing, check fuel pump unit for leaks.
L
Note:
Make sure that breather lines are correctly routed.
L Note:
Pay attention to washers (3).
Make sure that O-ring (2) is in perfect condition.
•
Installation is the reverse of the removal procedure.
X
Tightening torque:
Fuel pump unit .............................................. 5 Nm
00.31
MAX
MIN
MIN
R28000020
61 20 029 Checking
battery fluid level
and topping up if necessary; cleaning and greasing the battery terminals
(Inspections III and IV)
•
•
•
•
•
13 72 000 Replacing
element
intake air filter
(Inspection III)
In very dirty and dusty operating conditions,
replace every 10,000 km (6,000 miles) or even
more frequently if necessary
If necessary, disengage fuel tank and lift it at rear.
Disengage the rubber strap holding the battery.
Check the battery fluid level.
Top up the acid level to the “MAX” mark with distilled water.
Grease the battery terminals.
Acid proof battery-terminal grease:
................................................e.g. Bosch Ft 40 V1
R28000240
•
•
•
•
•
Open clips securing air filter cover.
Replace air filter element.
Close air filter cover.
Install fuel tank.
Make sure that breather lines are correctly routed.
X
Tightening torque:
Fuel tank to frame ........................................ 22 Nm
00.32
12 31 240
Replacing poly-V belt
(Inspection III)
every 60,000 km (36,000 miles)
•
Remove left-hand oil cooler trim.
RS110490
•
•
.
Remove front cover.
Slacken alternator mounting screws and nuts
(1,3,4) and install a new poly-V belt if necessary.
3
2
4
1
RS110480
Poly-V belt adjustment procedure:
Poly-V belt installation procedure:
•
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:
Poly-V belt preload......................................... 8 Nm
Alternator
to alternator support cover ........................... 20 Nm
00.33
[Without Integral ABS] Checking
brake fluid level
•
Turn the handlebars to the left.
(Inspections II and III)
MIN
L
Note:
The volume of the brake fluid (MIN/MAX) is sufficient
for lining thicknesses from new to the wear limit.
It is not normally necessary to top up the fluid to accommodate lining wear.
If the level drops below the MIN mark, this indicates
some other fault.
Front brake
•
•
Place the motorcycle on its centre stand.
Turn the handlebars to the right.
MAX
R28000110
Required level
Brake pads worn
not less than ................................................... MIN
(Top edge of the marking ring)
Brake fluid ...................................................DOT 4
Rear brake
•
The motorcycle must be upright.
R28000111
Required level:
with new brake pads ....................................... MAX
(exactly between the centre (point) of the sight glass
and the top edge of the marking ring)
MAX
MIN
R28000050
Required level
with new brake pads ....................................... MAX
brake pads worn not less than ......................... MIN
Brake fluid ...................................................DOT 4
00.34
[Integral ABS] Checking brake fluid
level
(Inspections II and III)
L
Note:
The brake fluid level in the sight glass/brake fluid
level remains constant despite wear of the brake
pads.
If the level drops below the MIN mark, this indicates
some other fault.
(Inspection III)
•
Check brake system for leaks.
Checking brake pads and discs for
wear/replacing
(Inspections II and III)
Front brake
•
•
Checking brake system for correct
operation and freedom from leaks;
repairing/replacing if necessary
Place the motorcycle on its centre stand.
Turn the handlebars to the left.
Checking front brake pad wear
MIN
1
2
R28000120
R28000110
Required level
not below ......................................................... MIN
(Top edge of the marking ring)
Brake fluid....................................................DOT 4
Rear brake
•
Place the motorcycle on its centre stand.
•
•
Wear indicators ( 1) must be clearly visible.
If necessary, check/measure thickness of brake
pads.
e
Important:
Brake pad thickness must not fall below the minimum
value. Always replace the brake pads as a complete
set.
Minimum pad thickness: ......... 1.0 mm (0.3937 in)
•
Check that colour codes of brake pads and
brake calipers (2) match.
Colour code: .................................................green
MIN
R28000050
Required level
not below ......................................................... MIN
Brake fluid....................................................DOT 4
00.35
Checking rear brake pad wear
Checking brake disc wear
R28000130
•
•
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
Important:
Brake pad thickness must not fall below the minimum
value. Always replace the brake pads as a complete
set.
Minimum pad thickness: ........ 1.0 mm (0.3937 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.
00.36
R28000140
•
Examine the brake discs carefully for cracks,
damage, distortion, wear and score-marks.
Brake disc wear limit:
front:......................................... 4.5 mm (0.1771 in)
rear:.......................................... 4.5 mm (0.1771 in)
34 11 008
brake
Replacing brake pads, front
•
e Important:
Integral brakes, the rear brake must be ready for
use.
•
•
Installation is the reverse of the removal procedure.
Perform a function check on the brake system
with the ignition switched on.
Colour code:
Brake pads, brake calipers............................ green
Remove retaining plate.
R28000150
•
•
Remove keeper (arrow) from retaining pin.
Remove retaining pin.
e
Important:
[Integral ABS] Press back pistons on one side of
the brake caliper only. Allow the brake pad on the
opposite side to remain in the caliper during this
process.
The fluid in the wheel circuit reservoir must not rise
above “MAX”.
Risk of fluid loss.
If fluid escapes, proceed in accordance with the instructions for filling the reservoir.
•
•
Pistons with old brake pads should only be
pressed back just far enough for the new brake
pads to fit in.
Remove old brake pad and insert new brake pad.
L
Note:
Always wait for the BMW Integral ABS to complete
its self-diagnosis after the ignition is switched on.
Do not operate the brake lever until self-diagnosis is
complete.
•
After replacing the pads of a caliper, always bed
in the new brake pads with the ignition switched
on.
00.37
34 21 200 Replacing
brake
brake pads, rear
•
Installation is the reverse of the removal procedure.
L Note:
Always wait for the BMW Integral ABS to complete
its self-diagnosis after the ignition is switched on.
Do not operate the brake lever until self-diagnosis is
complete.
•
Perform a function check on the brake system
with the ignition switched on.
X
Tightening torque:
Brake caliper to rear wheel drive .................. 40 Nm
R28000160
•
•
•
•
Remove keeper (arrow) from retaining pin.
Drive the retaining pin out towards the wheel
side.
Remove brake caliper.
Remove brake pads.
e
Important:
[Integral ABS] Press back pistons in brake caliper
brake pad just far enough to allow the brake disc to
be slipped in.
The fluid in the wheel circuit reservoir must not rise
above “MAX”.
Risk of fluid loss.
If fluid escapes, proceed in accordance with the instructions for filling the reservoir.
•
Force back the pistons.
R22000280
•
–
Check the springs for correct seating and installation position.
The engraved arrow indicates the direction of
travel.
00.38
[Without Integral ABS]
Changing brake fluid and bleeding
the brake system
34 00 010
•
Remove reservoir cap with rubber diaphragm,
draw off the old brake fluid and clean the reservoir.
Change the brake fluid annually
(Inspection IV)
[Without Integral ABS]
Bleeding/changing brake fluid in front
system
34 00 033
L Note:
This description applies to brake filling and bleeding
devices with vacuum extraction of the brake fluid at
the brake caliper.
If other devices are used, comply with their manufacturers’ instructions.
•
•
•
•
•
Place the motorcycle on its side stand and turn
the handlebars all the way to the left.
Repeatedly pull front brake lever lightly to expel
air from brake master cylinder.
Place motorcycle on its centre stand.
Place the front wheel and the handlebars such
that the brake fluid expansion tank is level.
Tighten the handlebar and secure the front wheel
in this position.
R21000020
e Important:
When adding brake fluid, do not allow it to enter the
holes for the reservoir lid screws.
•
•
Top up the brake fluid level to the “MAX”
mark (arrow).
Connect the brake bleeding device to the bleed
screw of the left-hand brake caliper.
e
Important:
e
Important:
Do not allow brake fluid to come into contact with
During the fluid-change and bleeding procedure,
painted motorcycle parts as brake fluid destroys
paint.
•
•
•
Remove front reservoir cap with rubber diaphragm, draw off the old brake fluid and clean
the reservoir.
Refit the reservoir cap with rubber diaphragm.
Remove the brake pads.
make sure that the fluid replenishing hole is always
below the level of the brake fluid, otherwise air will
be drawn into the brake system.
Bleed the system again if this happens.
•
•
Open the bleed screw.
Draw off brake fluid until it emerges clear and
free from air bubbles.
e
Important:
On account of the vacuum extraction process, it
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.
34 1 531
34 1 532
R28000180
•
Use the reset device, BMW No. 34 1 531, and
the positioning piece, BMW No. 34 1 532, to
press back and position the brake caliper pistons on the left and right.
00.39
•
•
•
•
•
•
•
•
•
•
•
Close the bleed screw.
Disconnect the brake bleeding device from the
bleed screw.
The procedure for changing the brake fluid in the
right brake caliper is the same as that for the
left caliper.
Assembly is the reverse of the disassembly procedure.
Top up the brake fluid until the level reaches the
“MAX” mark.
Wipe the rim of the reservoir, the rubber gaiter
and the cover to remove brake fluid, and carefully
reassemble the components.
If necessary, resecure the handlebars in the correct position (punch marks aligned) in accordance with the tightening sequence.
Check the function of the brake system.
Recheck the brake-fluid level.
Place the motorcycle on its centre stand.
Turn the handlebars to the right.
34 00 035 [Without
Integral ABS]
Bleeding/changing brake fluid in rear
system
L
Note:
This description applies to brake filling and bleeding
devices with vacuum extraction of the brake fluid at
the brake caliper.
If other devices are used, comply with their manufacturers’ instructions.
e
Important:
Do not allow brake fluid to come into contact with
painted motorcycle parts as brake fluid destroys
paint.
•
•
•
•
•
•
•
MAX
34 1 536
R28000111
Required level with new brake pads:
(Initial fill quantity) ............................................ MAX
(exactly between the centre (point) of the sight glass
and the top edge of the marking ring)
•
•
34 1 531
Handlebar centred.
Check that the front wheel is on the ground.
Minimum fluid level
Brake pads worn
not less than .............. the centre of the sight glass
Brake fluid....................................................DOT 4
X
Tightening torque:
Front brake caliper bleed screw ..................... 9 Nm
Handlebars tightening sequence:
1. Front connection to system
in direction of travel ...................................... 21 Nm
2. Rear connection in direction of travel ....... 21 Nm
00.40
Place motorcycle on its centre stand.
Remove right-hand rear panel if necessary.
Remove rear reservoir cap, draw off the
old brake fluid and clean the reservoir.
Refit the reservoir cap.
Remove the brake caliper.
Remove rear brake pads.
Move the brake caliper to a horizontal position.
R28000170
•
•
Use the reset device, BMW No. 34 1 531, and
the adapter, BMW No. 34 1 536, to press the
pistons completely back and to position them.
Remove reservoir cap with rubber diaphragm,
draw off the old brake fluid and clean the reservoir.
•
•
•
Assembly is the reverse of the disassembly procedure.
Check the function of the brake system.
Recheck the brake-fluid level.
Minimum fluid level
Brake pads worn not less than
..................................................................... “MIN”
Brake fluid ...................................................DOT 4
MAX
MIN
X
R28000050
•
Tightening torque:
Rear brake caliper bleed screw ...................... 6 Nm
Brake caliper to rear wheel drive .................. 40 Nm
Top up the brake fluid level to the “MAX” mark.
e
Important:
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.
•
•
Connect the brake bleeding device and open the
bleed screw.
Draw off brake fluid until it emerges clear and
free from air bubbles.
e
Important:
On account of the vacuum extraction process, it
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.
•
•
Close the bleed screw.
Top up the brake fluid until the level reaches the
“MAX” mark.
00.41
34 00 090 [Integral
ABS] Changing/
bleeding brake fluid in wheel circuit
•
Change brake fluid in wheel circuit once a year
(Inspection IV)
e Important:
d
Warning:
All repair and maintenance work on the
BMW Integral ABS should be carried out by specially trained personnel.
Maintenance and repair procedures and processes
should be strictly observed.
Use only new brake fluid from an unopened container.
•
Draw off the old brake fluid from the wheel circuit
reservoir.
Remove the front left and right brake pads.
Only use the piston reset
device, BMW No. 34 1 531, if the wheel circuit reservoir cover is open.
L Note:
34 1 531
This description applies to brake filling and bleeding
devices with vacuum extraction of the brake fluid.
If other devices are used, comply with their manufacturers’ instructions.
34 00 070 [Integral
34 1 532
R28000180
ABS]
Bleeding/changing brake fluid in front
wheel circuit
•
e
•
Important:
Integral brakes, the rear brake must be ready for
use.
•
Remove fuel tank.
•
e Important:
Do not allow brake fluid to come into contact with
painted motorcycle parts as brake fluid destroys
paint.
•
hose to the bleed screw.
R28340110
Open front wheel circuit reservoir (1).
00.42
•
Draw off the old brake fluid from the wheel circuit
reservoir.
Refill the front wheel circuit reservoir (1) with new
brake fluid.
Connect the brake bleeding device to the bleed
screw of the left brake caliper, but do not switch
it on.
L
Note:
If necessary, use a cable tie to secure the bleed
1
•
–
Use the reset device, BMW No. 34 1 531, and
the positioning piece, BMW No. 34 1 532, to
press the brake caliper pistons completely back
and to position them.
Wrap cloths around the left and right brake calipers.
[bleed only] The front wheel circuit should be
bled only.
(a 00.45)
•
•
Switch on the ignition.
L
Note:
Always wait for the BMW Integral ABS to complete
its self-diagnosis after the ignition is switched on.
Do not operate the brake lever until self-diagnosis is
complete.
L Note:
If necessary, use a cable tie to secure the bleed
hose to the bleed screw.
•
•
•
•
MAX
Connect the brake bleeding device to the bleed
screw of the right brake caliper, but do not
switch it on.
The procedure for changing the brake fluid in 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.
e
Important:
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
Important:
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.
•
•
•
Very gently pull the handbrake lever until the
pump just starts up.
Open the bleed screw, while continuously topping up the wheel circuit reservoir with new
brake fluid.
Pump out the brake fluid under 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.
•
•
•
•
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.
00.43
Front wheel circuit reservoir filling instructions
e
Important:
Integral brakes, the rear brake must be ready for
use.
MAX
MIN
34 1 534
R28340090
34 1 531
•
34 1 532
R28000190
•
•
Top up fluid in front wheel circuit reservoir to
“MAX”
Use adapter 23, BMW No. 34 1 534, in the reset
device, BMW No. 34 1 531/532, on both front
brake calipers, and screw on the reset device
until the adapter is secure.
e
Important:
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:
Always wait for the BMW Integral ABS to complete
its self-diagnosis after the ignition is switched on.
Do not operate the brake lever until self-diagnosis is
complete.
•
•
Squeeze the handbrake lever until the front
brake caliper pistons are butt against the reset
device, BMW No. 34 1 531.
Switch off the ignition.
00.44
•
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 the reset device, BMW No. 34 1 531/
532, with adapter, BMW No. 34 1 534.
d
Warning:
The wheel circuit reservoir may not overflow while
the brake pads/brake calipers are being fitted.
•
•
•
•
If necessary, carefully press back the pistons so
that the pad just fits in.
Install front brake pads.
Hand-tighten front wheel circuit reservoir cap.
Perform a function check on the brake system
with the ignition switched on.
e Important:
Once all the work has been completed, perform a
bleed test using the BMW MoDiTeC.
•
Install fuel tank.
Brake fluid ...................................................DOT 4
X
Tightening torque:
Front brake caliper bleed screw ..................... 9 Nm
The front wheel circuit should be bled only
–
–
–
Draw off the old brake fluid from the wheel circuit
reservoir.
Remove the front right and left brake pads, press
back and position the pistons.
Wrap cloths around the left and right brake calipers.
d Warning:
The brake fluid must not foam in the hose.
If this should happen, follow the procedure for
bleeding/changing brake fluid in the front wheel circuit.
(a 00.42)
•
e Important:
Integral brakes, the rear brake must be ready for
use.
•
•
•
34 1 561
•
•
•
•
34 2 541
R28000220
•
•
Fill the front wheel circuit reservoir to the “MAX”
marking and screw on the
cover, BMW No. 34 2 541.
Connect the 1.5 m (4.9214 ft) silicone hose,
BMW No. 34 1 561, to the left brake caliper
bleed screw.
L
Note:
If necessary, use a cable tie to secure the bleed
hose to the bleed screw.
•
Switch on the ignition.
•
Pump brake fluid through the system until it is
clear and free from air bubbles.
Close the bleed screw.
Release the brake and remove the silicone
hose, BMW No. 34 1 561.
Fill the front wheel circuit reservoir to the “MAX”
marking and screw on the
cover, BMW No. 34 2 541.
Connect the 1.5 m (4.9214 ft) silicone hose,
BMW No. 34 1 561, to the right brake caliper
bleed screw.
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.
Detach the silicone hose, BMW No. 34 1 561,
from the bleed screw and empty it.
Remove the cover, BMW No. 34 2 541.
e
Important:
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.
•
•
Fill front wheel circuit reservoir with brake fluid in
accordance with instructions.
(a 00.44)
Perform a function check on the brake system
with the ignition switched on.
e
Important:
Once all the work has been completed, perform a
bleed test using the BMW MoDiTeC.
Brake fluid ...................................................DOT 4
L
Note:
Always wait for the BMW Integral ABS to complete
X
its self-diagnosis after the ignition is switched on.
Do not operate the brake lever until self-diagnosis is
complete.
•
•
•
•
•
Tightening torque:
Front brake caliper bleed screw ..................... 9 Nm
Very gently pull the handbrake lever until the
pump just starts up.
Open the bleed screw.
Pump the brake fluid at virtually no pressure until
the hose is full of brake fluid.
Position the end of the hose on the
cover, BMW No. 34 2 541.
Pump the brake fluid under virtually no pressure
to begin with, then vary the brake pressure.
00.45
34 00 080 [Integral
ABS]
Bleeding/changing brake fluid in front
wheel circuit
•
•
•
Remove fuel tank.
–
e
Important:
Do not allow brake fluid to come into contact with
painted motorcycle parts as brake fluid destroys
paint.
•
•
•
With the handle outwards, use the reset
device, BMW No. 34 1 531, on the rear brake
caliper to press back the pistons completely and
to position them.
Wrap a cloth around the brake caliper.
[bleed only] The rear wheel circuit should be
bled only.
(a 00.49)
Draw off the old brake fluid from the wheel circuit
reservoir.
Refill the rear wheel circuit reservoir (1) with new
brake fluid.
Connect the brake bleeding device to the bleed
screw, but do not switch it on.
L Note:
If necessary, use a cable tie to secure the bleed
hose to the bleed screw.
•
L
Note:
After switching on the ignition, always wait for the
1
BMW Integral ABS to complete its self-diagnosis.
Do not operate the brake lever until self-diagnosis is
complete.
R28340110
•
•
•
•
Open rear wheel circuit reservoir (1).
Draw off the old brake fluid from the wheel circuit
reservoir.
Remove rear brake pads.
If necessary, press the brake pistons back by
hand so that the reset
device, BMW No. 34 1 531, can be used.
e
Important:
Only use the piston reset
device, BMW No. 34 1 531, if the wheel circuit reservoir cover is open.
34 1 536
34 1 531
R28000170
•
Use the adapter, BMW No. 34 1 536, instead of
the external brake pad.
00.46
Switch on the ignition
MAX
MIN
R28340090
e
Important:
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.
•
•
•
Very gently press the footbrake until the pump
just starts up.
Open the bleed screw, while continuously topping up the wheel circuit reservoir with new
brake fluid.
Pump out the brake fluid under 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.
•
•
•
•
Pump off brake fluid until it emerges clear and
free from air bubbles.
Close the bleed screw.
Release the brake and switch off the ignition.
Disconnect the brake bleeding device from the
bleed screw.
e
Important:
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.
00.47
Rear wheel circuit reservoir filling instructions
MAX
34 1 536
MIN
34 1 531
R28340090
R28000170
•
•
Top up fluid in rear wheel circuit reservoir to
“MAX”.
Screw the reset device, BMW No. 34 1 531, to
the adapter, BMW No. 34 1 536.
e Important:
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:
Always wait for the BMW Integral ABS to complete
its self-diagnosis after the ignition is switched on.
Do not operate the brake lever until self-diagnosis is
complete.
•
•
Press the foot brake lever until the rear brake caliper pistons rest on the
reset device, BMW No. 34 1 531, and the
adapter, BMW No. 34 1 536.
Switch off the ignition.
•
•
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 the reset device, BMW No. 34 1 531
with adapter, BMW No. 34 1 536.
d
Warning:
The wheel circuit reservoir may not overflow while
the brake pads/brake calipers are being fitted.
•
•
•
•
If necessary, carefully press back the pistons until the brake disc just fits between the brake
pads.
Fit the brake pads and brake caliper at the rear.
Hand-tighten rear wheel circuit reservoir cap.
Perform a function check on the brake system
with the ignition switched on.
e
Important:
Once all the work has been completed, perform a
bleed test using the BMW MoDiTeC.
•
•
Performing a bleed test with BMW MoDiTeC.
(a 00.27)
Install fuel tank.
Brake fluid ...................................................DOT 4
X
Tightening torque:
Rear brake caliper bleed screw ...................... 6 Nm
Brake caliper to rear wheel drive .................. 40 Nm
00.48
The front wheel circuit should be bled only
–
–
–
Draw off the old brake fluid from the wheel circuit
reservoir.
Remove the rear brake pads, press back and position the pistons.
Wrap a cloth around the rear brake caliper.
d Warning:
The brake fluid must not foam in the hose.
If this should happen, follow the procedure for
bleeding/changing brake fluid in the rear wheel circuit.
(a 00.46)
•
•
•
•
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.
Detach the silicone hose, BMW No. 34 1 561,
from the bleed screw and empty it.
Remove the cover, BMW No. 34 2 541.
e
Important:
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 the rear wheel circuit reservoir to the “MAX”
marking and screw on the
cover, BMW No. 34 2 541.
Connect the 1.5 m (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
hose to the bleed screw.
•
Switch on the ignition.
L Note:
Always wait for the BMW Integral ABS to complete
its self-diagnosis after the ignition is switched on.
Do not operate the brake lever until self-diagnosis is
complete.
•
•
•
•
•
•
•
Fill rear wheel circuit reservoir with brake fluid in
accordance with instructions.
(a 00.48)
Perform a function check on the brake system
with the ignition switched on.
e
Important:
Once all the work has been completed, perform a
bleed test using the BMW MoDiTeC.
Brake fluid ...................................................DOT 4
X
Tightening torque:
Rear brake caliper bleed screw ...................... 6 Nm
Brake caliper to rear wheel drive .................. 40 Nm
Very gently press the footbrake until the pump
just starts up.
Open the bleed screw.
Pump the brake fluid at virtually no pressure until
the hose is full of brake fluid.
Position the end of the hose on the
cover, BMW No. 34 2 541.
Pump the brake fluid under virtually no pressure
to begin with, then vary the brake pressure.
00.49
34 00 091 [Integral
ABS] 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 should be carried out by specially trained personnel.
Maintenance and repair procedures and processes
should be strictly observed.
Use only new brake fluid from an unopened container.
R21000020
•
34 00 072 [Integral
ABS]
Bleeding/changing brake fluid in front
control circuit
Top up the brake fluid level to the “MAX”
mark (arrow).
1
3
d
Warning:
Avoid rapid and forceful pumping of the brakes
when performing maintenance and repair work on
the BMW Integral ABS.
•
•
•
•
•
•
Place the motorcycle on its side stand and turn
the handlebars all the way to the left.
Repeatedly and slowly pull the front brake
lever lightly to expel air from brake master cylinder.
Place motorcycle on its centre stand.
Remove fuel tank.
Place the front wheel and the handlebars such
that the brake fluid expansion tank is level.
Tighten the handlebar and secure the front wheel
in this position.
e
Important:
Do not allow brake fluid to come into contact with
painted motorcycle parts as brake fluid destroys
paint.
•
•
Wrap a cloth around the expansion tank.
Remove front reservoir cap with rubber
diaphragm, draw off the old brake fluid and clean
the reservoir.
00.50
2
R28340110
•
Connect the bleed device to the front dosing
cylinder bleed screw (1), but do not switch it on.
d
Warning:
When changing and bleeding the control circuit
brake fluid, do not use vacuum extraction.
e Important:
During the fluid-change and bleeding procedure,
make sure that the fluid replenishing hole is always
below the level of the brake fluid, otherwise 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.
MIN
Shift the handbrake lever to position 4.
d
Warning:
Avoid rapid and forceful pumping of the brakes
when performing maintenance and repair work on
the BMW Integral ABS.
R28000110
1
3
2
Required level
not below ......................................................... MIN
(Top edge of the marking ring)
e Important:
Once all the work has been completed, perform a
bleed test using the BMW MoDiTeC.
•
R28340110
•
In sequence, bleed the:
– front dosing cylinder (1),
– front integral circuit (2)
– front control circuit (3) and,
– again, front dosing cylinder (1)
using the ring spanner, BMW No. 34 2 532, and in
accordance with rules for bleeding.
Fit fuel tank.
Brake fluid ...................................................DOT 4
X
Tightening torque:
Handlebars tightening sequence:
1. Front connection to system
in direction of travel...................................... 21 Nm
2. Rear connection in direction of travel ....... 21 Nm
Rules for bleeding:
1. Pull the brake lever slowly until the brake light
switch clicks (snifter hole closed).
2. Open the bleed screw.
3. Pull the brake lever fully and close the bleed
screw.
4. Release the brake lever slowly.
5. Repeat steps 1 to 4 until the brake fluid is clear
and has no 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 gaiter
and the cover to remove brake fluid, and carefully
reassemble the components.
Resecure the handlebars in the correct position
(punch marks aligned) in accordance with the
tightening sequence.
00.51
34 00 082 [Integral
ABS]
Bleeding/changing brake fluid in rear
control circuit
•
•
Place motorcycle on its centre stand.
Remove fuel tank.
e
Important:
Do not allow brake fluid to come into contact with
painted motorcycle parts as brake fluid destroys
paint.
•
•
Remove right-hand rear panel if necessary.
Remove rear reservoir cap with rubber
diaphragm, draw off the old brake fluid and clean
the reservoir.
e Important:
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.
d
Warning:
Avoid rapid and forceful pumping of the brakes
when performing maintenance and repair work on
the BMW Integral ABS.
2
1
MAX
MIN
R28340110
R28000050
•
Top up the brake fluid level to the “MAX” mark.
2
1
3
•
In sequence, bleed the:
– rear dosing cylinder (1),
– rear integral circuit (2)
– front control circuit (3) and,
– again, front dosing cylinder (1)
using the ring spanner, BMW No. 34 2 532, and in
accordance with the rules for bleeding.
Rules for bleeding:
1. Press the brake lever slowly until the brake light
switch clicks (snifter hole closed).
2. Open the bleed screw.
3. Press the brake lever fully and close the bleed
screw.
4. Release the brake lever slowly.
5. Repeat steps 1 to 4 until the brake fluid is clear
and has no bubbles.
•
R28340110
•
Connect the bleed device to the rear dosing
cylinder bleed screw (1), but do not switch it on.
d
Warning:
When changing and bleeding the control circuit
brake fluid, do not use vacuum extraction.
00.52
3
Fit the protective caps on the bleed screws.
•
•
•
Correct the brake fluid level.
Wipe the rim of the reservoir, the rubber gaiter
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
Important:
Keep the brake fluid in the clutch operating system
away from painted motorcycle parts as brake fluid
attacks paint.
•
•
Support the motorcycle on its side stand.
Turn the handlebars to the right.
MIN
MIN
R28000050
Required level
not below ......................................................... MIN
e Important:
Once all the work has been completed, perform a
bleed test using the BMW MoDiTeC.
•
•
Performing a bleed test with BMW MoDiTeC.
(a 00.27)
Fit fuel tank.
Brake fluid....................................................DOT 4
R28000040
Required level with a new clutch liner:
........................................... Half way up sight glass
L
Note:
As the clutch lining wears, the fluid level in the reservoir rises.
•
•
•
•
If necessary, remove reservoir cover with insert.
Correct the fluid level. Mark in reservoir: same as
brake circuit.
Reinstall the reservoir cover with insert.
Tighten the reservoir cover carefully and without
using force.
Brake fluid ...................................................DOT 4
00.53
21 52 005 Changing
the clutch fluid
•
(Inspection IV)
at least every 2 years
e Important:
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 motorcycle on its centre stand.
Place the handlebars and the clutch fitting so
that the clutch fluid expansion tank is level.
Tighten the clutch fitting and secure the front
wheel in the position.
e
Important:
Keep the brake fluid in the clutch operating system
away from painted motorcycle parts as brake fluid
attacks paint.
•
•
•
.
Screw the bleed screw all the way into the filler
adapter (valve in filler adapter closed).
Remove reservoir cover with rubber diaphragm.
Draw off brake fluid and clean the reservoir.
Top up the brake fluid.
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
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 Important:
The motorcycle is not permitted on the road without
the grub screw in place and secure in the filler
adapter.
1
3
•
•
•
•
•
2
R21000310
•
•
•
•
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).
00.54
•
Correct the fluid level.
Reinstall the reservoir lid with rubber diaphragm
in position.
Tighten the reservoir cover carefully and without
using force.
Align the clutch fitting with the mark on the handlebar.
Resecure the handlebar in the correct position
(punch marks aligned).
Recheck the fluid level.
X
Tightening torque:
Grubscrew in filler adapter ........................... 10 Nm
Consumables
Brake fluid.....................................................DOT 4
Checking tightness of rear wheel
studs
Checking function of side stand
contact switch
(Inspection I)
(Inspections I, II, III and IV)
•
•
•
•
•
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
L
Note:
The side-stand switch is in correct working order if
the engine stops when the side stand is extended.
(Inspection III)
•
•
•
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.
Tilt the rear wheel to and fro across its axle.
If play is detected, fit new shims to rear wheel
drive or replace bearings.
Checking swinging arm bearings,
adjusting if necessary
12 12 011
plugs
Checking/replacing spark
(Inspection II) check/(Inspection III) replace
(Inspections I and III)
•
Grip rear tyre and try to move it sideways, bracing against the frame.
12 3 510
Greasing the side stand pivot
(Inspections I, II and III)
12 3 520
R21000190
•
•
Pull off spark the plug caps using the special
puller, BMW No. 12 3 520.
Remove the spark plugs using the spark plug
wrench, BMW No. 12 3 510.
e Important:
Do not bend electrodes, there is a risk of breaking
them.
R21000320
•
•
Check free movement of side stand and grease
if necessary.
Grease pivot point (arrow).
Lubricant:
................................................... Shell Retinax EP2
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:
NGK BKR7EKC spark plug .......................... 25 Nm
00.55
11 12 009 Tightening
cylinder heads
(Inspection I)
11 34 004 Checking/adjusting
clearances
valve
(Inspections I, II and III)
R21000330
R21000340
•
Remove cylinder head cover.
•
e Important:
Check valve clearance with feeler gauge and, if
necessary, correct with adjusting screw.
Valve clearances with engine cold
(max. 35 °C/95 °F):
Intake valve ............................. 0.15 mm (0.0059 in)
Exhaust valve .......................... 0.30 mm (0.0118 in)
Catch escaping oil.
X
Tightening torque:
Locknut.......................................................... 8 Nm
• Check valve clearance, it should be possible to
pull the feeler gauge between the valve stem and
adjusting screw with little resistance.
• Assembly is the reverse of the disassembly procedure.
e
Important:
Make sure that all seals are correctly seated. Seals
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
in a crosswise pattern one by one
1.1. Slacken off one nut at a time
1.2. Tighten nut to initial torque.................... 20 Nm
1.3. Angle tighten nut ...................................... 180°
2. Undo/tighten M 10 bolt ......................... 40 Nm
00.56
and sealing faces must be free from oil and grease.
X
Tightening torque:
Cylinder head cover ....................................... 8 Nm
Checking throttle cable freedom of movement, checking for
chafes and kinks, replacing if necessary, checking throttle cable play
Checking/adjusting idle speed and
throttle valve synchronization
13 60 110
(Inspections I, II and III)
•
Test-ride the motorcycle until the engine is
warm, or allow the engine to idle for approximately 10 minutes.
e
Important:
Do not allow the engine to idle for longer than
S000100
20 minutes.
•
Oil temperature:...................at least 90 °C (130 °F)
Play of throttle cable: .....approx. 2 mm (0.0787 in)
•
•
Turn the adjusting screws to adjust the play of
the cables for the left and right throttle valves.
Connect the BMW Synchro hose to the vacuum
adapter and connect the cables to
BMW MoDiTeC.
Adjust idle speed by turning the air bypass
screws while checking that the carburettors are
balanced.
Idle speed: ........................................ 1,100 ±50 rpm
L
Note:
Make sure that both throttle valves are closed.
R21000350
•
•
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)
e
Important:
The sealed throttle valve stop screws may not be altered since this may result in the manufacturer having to readjust the basic idling flow rate
•
•
•
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:
Make sure that the reading does not change when
you tighten the locknut.
Adjust Bowden 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).
00.57
•
Adjust the right throttle valve in the same way.
L
Note:
If play is zero, the throttle butterflies may chatter.
•
•
•
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.
L
Note:
Make sure that when the throttle grip is released
both throttle valves return to their fully closed positions.
•
R21000350
•
•
Adjust the throttle cable play using the adjusting
screw (arrow).
Push the rubber cap into position over the adjusting screw.
Throttle cable play:
.................................... approx. 0.5 mm (0.0197 in)
R21000360
•
Use the adjusting screw (arrow) to adjust play of
the choke cable to zero.
00.58
•
Tighten the locknuts and recheck carburettor
balance.
Seal off the vacuum bores.
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 the trial run/road
test before checking/correcting engine oil level.
Tyre pressures:
Solo ....................................front 2.2 bar (31.3 bar)
............................................. rear 2.5 bar (35.6 psi)
With pillion passenger ......... front 2.5 bar (35.6 psi)
............................................. rear 2.7 bar (38.4 psi)
With pillion passenger and
luggage ............................... front 2.5 bar (35.6 psi)
............................................. rear 2.9 bar (41.2 psi)
Roadworthiness check
Lights
Indicator/warning lights
Horn
Instruments
Special equipment
Clutch
Gear shift
Steering
Foot brake and handbrake
If necessary, take the motorcycle for a test ride.
•
•
•
•
•
•
•
•
•
•
00.59
00.60
34 Brakes
34
Contents
Page
Technical Data ............................................................................................................................... 3
Removing and refitting front brake caliper
....................................................................4
Disassembling and assembling front brake caliper
Removing and refitting rear brake caliper
..................................................5
......................................................................6
Disassembling and assembling rear brake caliper
...................................................7
Dismantling rear brake caliper
..................................................................................................7
Assembling rear brake caliper
..................................................................................................7
Removing and refitting front brake discs
Removing and refitting rear brake disc
........................................................................8
............................................................................8
[Integral ABS] Removing and refitting front ABS sensor
[Integral ABS] Removing and refitting rear ABS sensor
Removing and refitting footbrake lever
....................................... 10
.......................................................................... 11
Removing and refitting brake master cylinder
Checking and adjusting piston rod play
.......................................9
........................................................... 11
............................................................................. 12
Removing and refitting brake piston in handlebar fitting (a 32.7)
[Integral ABS]
Removing/installing the ABS pressure modulator
Removing the ABS pressure modulator
Installing the ABS pressure modulator
[Integral ABS]
Draining brake system
................... 12
................................................... 13
............................................................................. 13
................................................................................ 14
............................................................................................................. 15
Bleeding wheel circuits
.............................................................................................................. 15
Bleeding front wheel circuit ............................................................................................................... 15
Bleeding rear wheel circuit ................................................................................................................ 16
Bleeding control circuits
............................................................................................................ 17
Bleeding front control circuit ............................................................................................................. 17
Bleeding rear control circuit ............................................................................................................... 17
34.1
Contents
[Integral ABS]
Filling the brake system
Page
.......................................................................................................... 18
Filling control circuits
.................................................................................................................. 18
Filling the front control circuit ............................................................................................................ 18
Filling the rear control circuit .............................................................................................................20
Filling wheel circuits
.....................................................................................................................21
Filling the front wheel circuit ..............................................................................................................21
Front wheel circuit reservoir filling instructions ...................................................................................22
Filling rear wheel circuit .....................................................................................................................23
Rear wheel circuit filling instructions ..................................................................................................24
[Integral ABS]
Reading fault code memory with BMW MoDiTeC
[Integral ABS]
Performing a bleed test with BMW MoDiTeC
.....................................................24
............................................................24
[Integral ABS]
Removing/installing wheel circuit reservoir bleed lines .......................................25
Removing/installing brake lines
.........................................................................................26
[Integral ABS] Removing/installing brake lines
Removing and refitting front brake line
Removing and refitting rear brake line
34.2
.................................................................27
...............................................................................28
.................................................................................29
34
Technical Data
R 1150 R
Brake fluid
DOT 4
Front wheel
Colour of identification mark on brake calipers/brake pads
green
Brake disc diameter
mm (in) 320 (12.5987)
Brake disc thickness
mm (in) 5.0 (0.1969)
Minimum thickness
mm (in) 4.5 (0.1772)
Brake pad surface area
cm2 86 (13.33)
(sq in)
Piston diameter in brake caliper
mm (in) 32/36 (1.2599/1.4173)
Piston diameter in handlebar lever cylinder
mm (in) 16 (0.6299)
Sensor gap, front
mm (in) 0.2...1.7 (0.0079...0.0670) (active sensor)
Brake pad lining
Minimum lining thickness, front
Sintered metal
mm (in) 1.0 (0.0393)
Rear wheel
Brake disc diameter
mm (in) 276 (10.8663)
Brake disc thickness
mm (in) 5.0 (0.1969)
Minimum thickness
mm (in) 4.5 (0.1772)
Brake pad surface area
cm2 34 (5.27)
(sq in)
Piston diameter in brake caliper
mm (in) 26/28 (1.0236/1.1023) with insulating piston
Piston diameter in foot brake cylinder
mm (in) 12 (0.4724)
mm (in) [Integral ABS] 16 (0.6299)
Sensor gap, rear
Brake pad lining
Minimum lining thickness, rear
mm (in) 0.2…1.7 (0.0079...0.0670) (active sensor)
Organic
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.
[ABS] Braking system
BMW Integral ABS, partially integrated
34.3
Removing and refitting front
brake caliper
34 11
e
Important:
Do not allow brake fluid to come into contact with
painted motorcycle parts as brake fluid destroys
paint.
•
•
Drain the brake system.
[Integral ABS] Draining front wheel circuit
(a 34.15).
1
d
Suds
2
R28340010
•
•
Disconnect brake line (1).
Remove screws securing the brake caliper.
S340200
•
Press the brake pads/pistons back against the
brake disc (arrow) by pressing the brake caliper.
e Important:
Do not damage brake pads.
•
•
Carefully remove the brake caliper.
Installation is the reverse of the removal procedure.
e
Important:
Replace the sealing rings (2) in the brake line.
Do not damage the brake pads when installing.
34.4
•
•
Fill and bleed the brake system.
[Integral ABS] Bleeding/filling the front wheel
circuit (a 34.21).
X
Tightening torque:
Brake caliper to fork slider ........................... 30 Nm
Brake hose to brake caliper ......................... 18 Nm
Brake caliper bleed screw ............................. 9 Nm
3
4
5
2
1
S340120
Disassembling and assembling front brake caliper
34 11 521
e
Important:
Keep the brake pistons parallel with their bores
e Important:
when fitting them.
Do not separate the brake caliper halves.
•
•
•
•
•
•
•
•
•
Remove retaining plate.
Remove the split-pin keeper (1) from retaining
pin.
Remove retaining pin (2).
Remove brake pads.
Close the bleed screw.
Use the spacer, BMW No. 34 1 520, to secure
the two opposite brake pistons.
Place a cloth between the other pair of pistons.
•
Remove and install the other two brake pistons
in the same way.
If necessary, press back the pistons fully using
the resetting tool, BMW No. 34 1 531.
Fit the brake pads.
X
Tightening torque:
Bleed screw to brake caliper .......................... 9 Nm
e
Important:
Ensure that fingers do not become trapped between
the pistons; there is a risk of injury.
•
•
•
•
•
Using the compressed-air gun on the brake line
connection, carefully force out the brake
pistons (5).
Remove the two sealing rings from the brake piston holes.
Inspect the brake caliper piston for hairline
cracks, score-marks and other damage.
Coat the new sealing rings (3, 4) with brake fluid
and fit them.
Coat the brake caliper pistons (5) with brake fluid
and fit them.
34.5
2
2
1
S340010
Removing and refitting rear
brake caliper
34 21
e
Important:
Do not allow brake fluid to come into contact with
painted motorcycle parts as brake fluid destroys
paint.
•
•
•
•
•
•
•
•
•
Drain the brake system.
[Integral ABS] Drain rear wheel circuit
(a 34.16).
Disconnect brake line (1) from brake caliper.
Carefully press back the brake pads/pistons.
Remove the brake caliper.
Installation is the reverse of the removal procedure.
Fill and bleed the brake system.
[Integral ABS] Bleed/fill the rear wheel circuit
(a 34.23).
To bleed, undo the brake caliper and place it so
that the bleed nipple is as high as possible.
e
Important:
Replace the sealing rings (2) in the brake line.
Do not damage brake pads.
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 .......................... 7 Nm
1
5
2
3
4
Disassembling and assembling
rear brake caliper
34 21
Dismantling rear brake caliper
•
•
•
•
•
•
Remove retaining washer (1).
Drive out retaining pin (2) towards the wheel side.
Remove brake pads.
Close the bleed screw.
Hold a cloth over the brake caliper piston.
Using the compressed-air gun on the connection
hole, carefully force out the brake pistons (3) using minimum pressure.
e
Important:
Keep fingers away from gap between piston and
side contact face of brake pads; there is a risk of injury.
•
•
Remove sealing rings (4) from left/right cylinder.
Inspect the brake caliper piston for hairline
cracks, score-marks and other damage.
R21340010
Assembling rear brake caliper
•
•
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 fit them.
e
Important:
Keep the brake pistons parallel with their bores
when fitting them.
•
•
Coat the adapter plate locating pins with
Shell Retinax A and install the adapter plate.
Insert locating plate (5) into brake caliper.
L Note:
Ensure that the installed position is correct (arrow
pointing in forward-travel direction).
•
Insert the brake pads and secure them with retainers.
X
Tightening torque:
Bleed screw to brake caliper .......................... 7 Nm
34.7
Removing and refitting front
brake discs
34 11
•
•
e Important:
Note direction of installation for the brake disc (lettering to the outside).
Remove the brake caliper.
Remove front wheel.
X
Tightening torque:
Brake disc to front wheel
(Clean thread + Loctite 2701) ....................... 21 Nm
2
1
1
Removing and refitting rear
brake disc
34 21
•
•
2
Remove the brake caliper.
Remove rear wheel.
R28340140
L Note:
1
The retaining bolts (1) are secured and may have to
be heated before being undone.
•
•
Remove brake discs.
Installation is the reverse of the removal procedure, pay particular attention to the thrust washers (2) below the brake discs.
R28340130
1
L Note:
The retaining bolts (1) are secured and may have to
be heated before being undone.
•
•
2
•
R28340150
•
•
[Integral ABS] Fit the left-hand ABS sensor
ring (1) and the right-hand thrust washers (2) below the brake disc.
Degrease the brake discs before fitting them.
e
Important:
Pay attention to the thrust washers between the
brake discs and the front wheel.
[Integral ABS] Pay attention to the thrust washers
between the right brake disc and the front wheel,
and to the ABS sensor ring between the left brake
disc and the front wheel.
34.8
Remove brake disc.
Installation is the reverse of the removal procedure.
Degrease the brake disc before installing it.
e Important:
[Integral ABS] Pay attention to the shim when installing the rear wheel.
X
Tightening torque:
Brake disc to rear wheel drive
(Clean thread + Loctite 2701) ....................... 21 Nm
1
3
2
R28340040
[Integral ABS] Removing
and refitting front ABS sensor
34 52 044
•
•
•
•
•
Remove fuel tank (a 16.5).
Separate plug connector (1) in sensor line.
Remove the left brake caliper.
Remove the sensor (2).
Installation is the reverse of the removal procedure.
e Important:
Route the sensor cable correctly.
Check that the clips (3) are correctly seated.
X
Tightening torque:
Tighten the sensor ...................... hand-tight, 4 Nm
Brake caliper to fork slider............................ 30 Nm
34.9
1
2
R28340050
[Integral ABS] Removing
and refitting rear ABS sensor
34 52 111
•
•
•
•
•
•
Remove front/rear seat.
Separate plug connector (1) in sensor line.
Before removing/refitting, clean the sensor and
bore.
Remove the sensor (2).
Installation is the reverse of the removal procedure.
Coat the O-rings with oil before fitting them.
e
Important:
Route the sensor cable correctly.
X
Tightening torque:
Tighten the sensor ...................... hand-tight, 4 Nm
34.10
2
1
3
5
4
R28460060
Removing and refitting footbrake lever
35 21
•
•
•
•
•
Release the pin in the brake linkage.
Remove fasteners securing footbrake lever.
Remove footbrake lever with torsion spring.
Installation is the reverse of the removal procedure.
Lubricate pivot bushing with Shell Retinax A.
e Important:
Piston rod play must be checked and adjusted.
See removal and refitting of brake master cylinder.
The brake light should light up when the rear brake
is activated.
X
Tightening torque:
Brake pedal to footrest plate
(Clean thread + Loctite 2701) ....................... 21 Nm
Removing and refitting brake
master cylinder
34 31
e Important:
Do not allow brake fluid to come into contact with
painted motorcycle parts as brake fluid destroys
paint.
•
•
•
•
•
•
•
•
•
Drain the brake system.
[Integral ABS] Drain rear control circuit
(a 34.17).
Disconnect brake line (1) and hose (2).
Release and remove pin (3).
Remove brake master cylinder (4).
Installation is the reverse of the removal procedure.
Tighten one-time hose clip (5) with pliers,
BMW No. 13 1 500.
Fill and bleed the brake system.
[Integral ABS] Bleed/fill the rear control circuit
(a 34.20).
e Important:
Bleed the brake system carefully.
Check/adjust piston rod play.
X
Tightening torque:
Master cylinder to footrest assembly .............. 9 Nm
34.11
Checking and adjusting piston rod
play
2
1
A
R21340040
•
Set the adjusting screw of the footbrake lever to
distance A.
Distance A:... 14 +/- 0.5 mm (0.5512 +/- 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).
Feeler gauge thickness: .......... 0.2 mm (0.0078 in)
•
•
•
•
•
•
Slacken locknut (1).
Turn the piston rod (2) to the right in the direction
of the brake pedal until there is play.
Carefully back off piston rod to take up play and
tighten locknut.
Remove feeler gauge.
Check play.
Apply coloured sealing lacquer to the locknut.
34.12
Removing and refitting brake piston
in handlebar fitting (a 32.7)
3
4
2
1
R28340060
34 00 [Integral
ABS]
Removing/installing the ABS pressure modulator
Removing the ABS pressure modulator
d Warning:
Do not allow brake fluid to come into contact with
painted motorcycle parts as brake fluid destroys
paint.
All repair and maintenance work on the
BMW Integral ABS should be carried out by specially trained personnel.
Maintenance and repair procedures and processes
should be strictly observed.
Use only new brake fluid from an unopened container.
e Important:
•
•
•
•
Drain the brake system (a 34.15).
Disconnect earth cable from battery and insulate
it.
Push the protective caps (1) upwards.
Remove spring clips (2).
34.13
Installing the ABS pressure modulator
e Important:
•
•
L
Note:
When replacing the brake lines, always replace the
Do not bend brake lines.
Disconnect the brake lines from the ABS pressure modulator.
e Important:
Ensure that there is no brake fluid in the connector.
•
•
•
•
•
Remove the connector (3) for the front and rear
wheel circuit reservoirs.
Release (arrow) the connector (4) and remove it.
Disconnect plug from Hall sensor.
Remove Motronic control unit.
Release the ABS pressure modulator and carefully remove it to the left.
Install in reverse order, noting the following activities.
seals (Quad rings) between the brake lines and the
pressure modulator.
d
Warning:
Replace the spring clips each time the plug connection is opened. Ensure correct positioning.
•
•
•
•
•
•
•
Install new spring clips.
Fit the protective caps to the brake line.
Clip in the brake lines.
Check that the spring clips (arrows) are seated
correctly.
Pull the protective caps over the plug connection.
Fill and bleed the brake system (a 34.18).
Once all the work on the brake system has been
completed, read the fault code memory and perform a bleed test using BMW MoDiTeC
(a 34.24).
L Note:
Disconnecting the battery deletes all entries (e.g.
faults, settings) stored in the Motronic control unit’s
memory.
Loss of settings 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 record the throttle-valve positions.
X
Tightening torque:
ABS pressure modulator on battery holder..... 8 Nm
34.14
34 00 [Integral
ABS]
Draining brake system
•
d
e Important:
•
Warning:
All repair and maintenance work on the
BMW Integral ABS should be carried out by specially trained personnel.
Maintenance and repair procedures and processes
should be strictly observed.
Use only new brake fluid from an unopened container.
Draw off the old brake fluid from the wheel circuit
reservoir.
Remove front brake pads.
Only use the piston reset
device, BMW No. 34 1 531, if the wheel circuit reservoir cover is open.
L Note:
This description applies to brake filling and bleeding
devices with vacuum extraction of the brake fluid at
the brake caliper.
If other devices are used, comply with their manufacturers’ instructions.
•
•
34 1 531
Remove front/rear seat.
Remove fuel tank (a 16.5).
34 1 532
R28000180
Bleeding wheel circuits
e
Important:
Do not allow brake fluid to come into contact with
painted motorcycle parts as brake fluid destroys
paint.
Bleeding front wheel circuit
•
•
•
•
e Important:
Integral brakes, the rear brake must be ready for
use.
L
Note:
Always wait for the BMW Integral ABS to complete
its self-diagnosis after the ignition is switched on.
Do not operate the brake lever until self-diagnosis
has completed.
•
1
•
•
•
•
•
•
R28340110
•
Open front wheel circuit reservoir (1).
Use the reset device, BMW No. 34 1 531, and
the positioning piece, BMW No. 34 1 532, to
press the brake caliper pistons completely back
and to position them.
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
it on.
Switch on the ignition.
•
•
•
Gently pull the handbrake lever until the pump
just starts up.
Open the bleed screw.
Drain wheel circuit using a 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.
e
Important:
To prevent brake fluid from entering the connector,
do not release the ABS pressure modulator plug
connections.
34.15
Bleeding rear wheel circuit
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.
•
•
•
•
•
•
1
R28340110
•
Open rear wheel circuit reservoir (1).
e
Important:
To prevent brake fluid from entering the connector,
do not release the ABS pressure modulator plug
connections.
•
•
Draw off the old brake fluid from the wheel circuit
reservoir.
Remove rear brake pads.
e
Important:
Only use the piston reset
device, BMW No. 34 1 531, if the wheel circuit reservoir cover is open.
34 1 536
34 1 531
R28000170
•
•
•
•
•
Use the adapter, BMW No. 34 1 536, instead of
the external brake pad.
With the handle outwards, use the reset
device, BMW No. 34 1 531, on the rear brake
caliper to press back the pistons completely and
to position them.
Wrap a cloth around the brake caliper.
Connect the brake bleeding device to the bleed
screw, but do not switch it on.
Switch on the ignition.
34.16
Gently press the footbrake until the pump just
starts up.
Open the bleed screw.
Drain wheel circuit using a pump.
Close the bleed screw.
Release the brake and switch off the ignition.
Disconnect the brake bleeding device from the
bleed screw.
Bleeding control circuits
Bleeding rear control circuit
e
Important:
Do not allow brake fluid to come into contact with
•
•
painted motorcycle parts as brake fluid destroys
paint.
Remove right-hand rear panel.
Remove rear reservoir cap with rubber
diaphragm, draw off the old brake fluid and clean
the reservoir.
Bleeding front control circuit
•
•
•
•
•
•
Turn the handlebars to the left.
Release clamps securing handlebar.
Place the handlebars such that the brake fluid
expansion tank is level.
Tighten the handlebar and secure the front wheel
in this position.
Remove front reservoir cover with rubber
diaphragm.
Draw off old brake fluid and clean the reservoir.
5
4
6
R28340110
1
3
•
–
–
–
2
Draw off the brake fluid in accordance with the
sequence, using the ring spanner,
BMW No. 34 2 532.
Rear dosing cylinder (4),
rear integral circuit (5) and
rear control circuit (6).
R28340110
•
–
–
–
Draw off the brake fluid in accordance with the
sequence, using the ring spanner,
BMW No. 34 2 532.
Front dosing cylinder (1),
front integral circuit (2) and
front control circuit (3).
34.17
[Integral ABS]
Filling the brake system
34 00
e Important:
d
Warning:
All repair and maintenance work on the
BMW Integral ABS should be carried out by specially trained personnel.
Maintenance and repair procedures and processes
should be strictly observed.
Use only new brake fluid from an unopened container.
During the filling and bleeding procedure, make sure
that the fluid replenishing hole is always below the
level of the brake fluid, otherwise air will be drawn
into the brake system.
1
3
2
L Note:
This description applies to brake filling and bleeding
devices with vacuum extraction of the brake fluid at
the brake caliper.
If other devices are used, comply with their manufacturers’ instructions.
R28340110
Filling control circuits
•
e
Important:
Do not allow brake fluid to come into contact with
painted motorcycle parts as brake fluid destroys
paint.
Filling the front control circuit
•
•
•
•
•
•
•
Level the handlebar fitting as necessary.
•
•
Draw off the brake fluid and simultaneously add
the new brake fluid in accordance with the sequence, using the ring spanner,
BMW No. 34 2 532.
Front dosing cylinder (1),
front integral circuit (2),
front control circuit (3) and
again, front dosing cylinder (1).
Close expansion tank with rubber diaphragm
and reservoir cap.
Place the motorcycle carefully on its side stand
and turn the handlebars fullly to the left.
Repeatedly pull front brake lever lightly to expel
air from brake master cylinder.
Place motorcycle on its centre stand.
e Important:
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.
It is therefore necessary to bleed the hose by hand
in the specified sequence and in accordance
with the rules for bleeding.
KR340280
e
Important:
When adding brake fluid, do not allow it to enter the
holes for the reservoir lid screws.
•
Top up the brake fluid level to the “MAX”
mark (arrow).
34.18
•
•
•
•
•
Switch off the bleed device.
Shift the handbrake lever to position 4.
d
Warning:
Avoid rapid and forceful pumping of the brakes
when performing maintenance and repair work on
the BMW Integral ABS.
Recheck the brake-fluid level.
Place the motorcycle on its centre stand.
Turn the handlebars to the left.
MIN
1
3
2
R28000110
Required level
not below ......................................................... MIN
(Top edge of the marking ring)
R28340110
Brake fluid ...................................................DOT 4
•
Remove the reservoir cap with rubber diaphragm.
• In sequence, bleed the:
– Front dosing cylinder (1),
– front integral circuit (2),
– front control circuit (3) and
– again, front dosing cylinder (1)
using the ring spanner, BMW No. 34 2 532, and in
accordance with the rules for bleeding.
Rules for bleeding:
1. Pull the brake lever slowly until the brake light
switch clicks (snifter hole closed).
2. Open the bleed screw.
3. Pull the brake lever fully and close the bleed
screw.
4. Release the brake lever slowly.
5. Repeat steps 1 to 4 until the brake fluid is clear
and has no bubbles.
•
•
•
•
Fit the protective caps on the bleed screws.
Top up the brake fluid level to the “MAX”
mark (arrow).
Wipe the rim of the reservoir, the rubber gaiter
and the cover to remove brake fluid, and carefully
reassemble the components.
Resecure the handlebars in the correct position
(punch marks aligned) in accordance with the
tightening sequence.
X
Tightening torque:
Handlebars tightening sequence:
1. Front connection to system
in direction of travel ...................................... 21 Nm
2. Rear connection in direction of travel ....... 21 Nm
34.19
Filling the rear control circuit
•
e Important:
Remove rear reservoir cap with rubber
diaphragm.
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.
It is therefore necessary to bleed the hose by hand
in the predefined sequence and in accordance
with the rules for bleeding.
•
•
–
–
–
–
MAX
MIN
R28000050
•
Top up the brake fluid level to the “MAX” mark.
e
Important:
While filling and bleeding the system, do not allow
the brake fluid level to drop below the “MIN” mark,
air will otherwise be drawn into the brake system.
d
Warning:
Avoid rapid and forceful pumping of the brakes
when performing maintenance and repair work on
the BMW Integral ABS.
Switch off the bleed device.
In sequence, bleed the:
rear dosing cylinder (1),
rear integral circuit (2)
front control circuit (3) and,
again, rear dosing cylinder (1)
using the ring spanner, BMW No. 34 2 532, and
in accordance with the rules for bleeding.
Rules for bleeding:
1. Press the brake lever slowly until the brake light
switch clicks (snifter hole closed).
2. Open the bleed screw.
3. Press the brake lever fully and close the bleed
screw.
4. Release the brake lever slowly.
5. Repeat steps 1 to 4 until the brake fluid is clear
and has no bubbles.
•
•
•
•
•
Fit the protective caps on the bleed screws.
Top up the brake fluid until it reaches at least to
the “MIN” mark.
Wipe the rim of the reservoir, the rubber gaiter
and the cover to remove brake fluid, and carefully
reassemble the components.
Recheck the brake-fluid level.
Place the motorcycle on its centre stand.
2
1
3
MIN
R28340110
R28000050
•
–
–
–
–
Draw off the brake fluid and simultaneously add
the new brake fluid in accordance with the sequence, using the ring spanner,
BMW No. 34 2 532.
Rear dosing cylinder (1),
rear integral circuit(2)
rear control circuit (3) and
again, front dosing cylinder (1)
34.20
Required level
not below ......................................................... MIN
Brake fluid ...................................................DOT 4
Filling wheel circuits
•
e
Important:
Do not allow brake fluid to come into contact with
•
painted motorcycle parts as brake fluid destroys
paint.
•
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
it on.
Switch on the ignition.
L
Note:
Always wait for the BMW Integral ABS to complete
Filling the front wheel circuit
e Important:
Integral brakes, the rear brake must be ready for
use.
its self-diagnosis after the ignition is switched on.
Do not operate the brake lever until self-diagnosis is
complete.
1
MAX
MIN
R28340090
R28340110
•
•
Open front wheel circuit reservoir (1).
Remove front brake pads.
e Important:
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.
•
•
•
34 1 531
•
•
•
34 1 532
R28000180
•
Use the reset device, BMW No. 34 1 531, and
the positioning piece, BMW No. 34 1 532, to
press the brake caliper pistons completely back
and to position them.
e Important:
To prevent brake fluid from entering the connector,
do not release the ABS pressure modulator plug
connections.
•
•
•
•
•
Gently pull the handbrake lever until the pump
just starts up.
Open the bleed screw, while topping up the
wheel circuit reservoir (1) with new brake fluid.
Pump out the brake fluid under virtually no pressure to begin with, then vary the brake pressure.
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.
The procedure for topping up the brake fluid in
the right brake caliper is the same as that for the
left caliper.
Release the brake and switch off the ignition.
Disconnect the brake bleeding device from the
bleed screw.
e
Important:
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.
Refill the front wheel circuit reservoir (1) with new
brake fluid.
34.21
Front wheel circuit reservoir filling instructions
34 1 534
MAX
34 1 531
MIN
34 1 532
R28340090
R28000190
•
•
Top up fluid in front wheel circuit reservoir to
“MAX”
Use adapter 23, BMW No. 34 1 534, in the reset
device, BMW No. 34 1 531/532, on both front
brake calipers , and screw on the reset device
until the adapter is secure.
e
Important:
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:
Always wait for the BMW Integral ABS to complete
its self-diagnosis after the ignition is switched on.
Do not operate the brake lever until self-diagnosis is
complete.
•
•
Squeeze the handbrake lever until the front
brake caliper pistons are butt against the reset
device, BMW No. 34 1 531.
Switch off the ignition.
34.22
•
•
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 the reset device, BMW No. 34 1 531/
532, with adapter, BMW No. 34 1 534.
d
Warning:
The wheel circuit reservoir may not overflow while
the brake pads/brake calipers are being fitted.
•
•
•
•
If necessary, carefully press back the pistons so
that the pad just fits in.
Install front brake pads.
Hand-tighten the front wheel circuit reservoir
cap.
Perform a function check on the brake system
with the ignition switched on.
X
Tightening torque:
Front brake caliper bleed screw ..................... 9 Nm
•
Filling rear wheel circuit
•
•
•
Refill the rear wheel circuit reservoir (1) with new
brake fluid.
Wrap a cloth around the brake caliper.
Connect the brake bleeding device to the bleed
screw, but do not switch it on.
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.
1
R28340110
•
•
Open rear wheel circuit reservoir (1).
Remove rear brake pads.
MAX
34 1 536
MIN
R28340090
34 1 531
R28000170
•
•
Use the adapter, BMW No. 34 1 536, instead of
the external brake pad.
With the handle outwards, use the reset
device, BMW No. 34 1 531, on the rear brake
caliper to press back the pistons completely and
to position them.
e
Important:
To prevent brake fluid from entering the connector,
do not release the ABS pressure modulator plug
connections.
e Important:
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.
•
•
•
•
•
•
•
Gently press the footbrake until the pump just
starts up.
Open the bleed screw, while topping up the
wheel circuit reservoir (1) with new brake fluid.
Pump out the brake fluid under virtually no pressure to begin with, then vary the brake pressure.
Pump off brake fluid until it emerges clear and
free from air bubbles.
Close the bleed screw.
Release the brake and switch off the ignition.
Disconnect the brake bleeding device from the
bleed screw.
e Important:
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.
34.23
Rear wheel circuit filling instructions
d
Warning:
The wheel circuit reservoir may not overflow while
the brake pads/brake calipers are being fitted.
•
34 1 536
•
•
•
34 1 531
R28000170
•
•
Top up fluid in rear wheel circuit reservoir to
“MAX”.
Screw the reset device, BMW No. 34 1 531, to
the adapter, BMW No. 34 1 536.
e Important:
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:
Always wait for the BMW Integral ABS to complete
its self-diagnosis after the ignition is switched on.
Do not operate the brake lever until self-diagnosis is
complete.
•
•
Press the foot brake lever until the rear brake caliper pistons rest on the
reset device, BMW No. 34 1 531, and the
adapter, BMW No. 34 1 536.
Switch off the ignition.
•
•
•
•
If necessary, carefully press back the pistons until the brake disc just fits between the brake
pads.
Fit the brake pads and brake caliper at the rear.
Hand-tighten the rear wheel circuit reservoir cap.
Perform a function check on the brake system
with the ignition switched on.
Once all the work on the brake system has been
completed, read the fault code memory and perform a bleed test using BMW MoDiTeC.
Remove fuel tank (a 16.5).
Remove rear panel.
Install front/rear seat.
Brake fluid ...................................................DOT 4
X
Tightening torque:
Rear brake caliper bleed screw ...................... 7 Nm
Brake caliper to rear wheel drive .................. 40 Nm
[Integral ABS]
Reading fault code memory with
BMW MoDiTeC
34 00
•
•
•
•
Remove front/rear seat.
Connect the BMW MoDiTeC to the diagnostic
connector.
Read out the fault memory.
Clear fault code memory if necessary, or perform
all requisite repair work.
[Integral ABS]
Performing a bleed test with
BMW MoDiTeC
34 00
•
•
Remove front/rear seat.
Connect the BMW MoDiTeC to the diagnostic
connector.
d
Warning:
Avoid rapid and forceful pumping of the brakes
when performing maintenance and repair work on
the BMW Integral ABS.
MAX
•
•
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 the reset device, BMW No. 34 1 531,
with adapter, BMW No. 34 1 536.
34.24
Perform bleed test.
Perform all requisite repair work.
R28340121
[Integral ABS]
Removing/installing wheel circuit
reservoir bleed lines
34 51
•
•
•
•
Remove the cover of the wheel circuit reservoir
with bleed lines.
Install in reverse order, ensuring that:
the bleed lines are not kinked,
bleed lines which have been shortened and
bleed line ends are cut on the diagonal.
34.25
34 52
Removing/installing brake lines
e
Important:
Do not allow brake fluid to come into contact with
painted motorcycle parts as brake fluid destroys
paint.
•
•
•
Drain the brake system.
Remove brake lines.
Installation is the reverse of the removal procedure.
e
Important:
Remove sealing rings for brake line.
Secure the brake line to the brake master cylinder
such that it is not chafed or bent when the handlebars are turned.
•
Fill and bleed the brake system.
34.26
3
34 2 561
2
1
R28340160
[Integral ABS] Removing/installing
brake lines
•
•
•
•
•
Drain the brake system (a 34.15).
Push the protective caps (1) upwards.
Remove spring clips (2).
Remove brake lines.
Installation is the reverse of the removal procedure, pay particular attention to the following:
d
Warning:
Replace the spring clips each time the plug connection is opened. Ensure correct positioning.
•
•
•
Check that the spring clips (arrows) are seated
correctly.
Pull the protective caps over the plug connections.
Fill and bleed the brake system (a 34.18).
X
Tightening torque:
Brake hose and brake line............................ 18 Nm
Front brake caliper bleed screws ................... 9 Nm
Rear brake caliper bleed screw ...................... 7 Nm
e
Important:
Remove sealing rings for brake line.
Secure the brake line to the brake master cylinder
such that it is not chafed or bent when the handlebars are turned.
L Note:
When replacing the brake lines, always replace the
seals (Quad rings) between the brake lines and the
pressure modulator.
•
•
•
•
•
•
Carefully remove the quad rings (3) using the dismantling tool, BMW No. 34 2 561.
Install the quad rings with brake lines.
Check that the quad rings are correctly seated.
Install new spring clips.
Fit the protective caps to the brake lines.
Clip in the brake lines.
34.27
Removing and refitting front brake line
34.28
Removing and refitting rear brake line
34.29
34.30
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