Maintenance BMW Integral ABS R 1150 RT BMW Motorrad After Sales
Published by: © BMW Motorrad After Sales UX-VS-2 All rights reserved. Not to be reprinted, translated or duplicated either wholly or in part without prior written permission. Errors and omissions excepted; subject to technical amendment.
Mechanic’s signature BMW Annual Service Order No. BMW Inspection every 20,000 km (12,000 miles) Registration No.
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.
BMW Motorrad Service data R 1150 RT Item Desired value Oil capacities Engine (with filter) (without filter) 3.75 (6.6) 3.50 (6.15) Unit of measurement/specification litres (Imp. pints) litres (Imp. pints) [SI 11 048 90] Engine oil grade: brand-name HD oil for four-stroke spark-ignition engines, API classes SE, SF, SG; combination with CC or CD specification Transmission Initial filling Oil changes Rear wheel drive approx. 1.0 (1.76) approx. 0.8 (1.41) litres (Imp. pints) litres (Imp.
00 00 Tightening torque Table of operating fluids Contents Page Tightening torque .........................................................................................................................3 11 Engine ...........................................................................................................................................3 12 Engine electrics ........................................................................................................................
00.
00 Tightening torque Model R 1150 RT Connection 11 Engine Cylinder head Tightening sequence: 1 Tighten cylinder head nuts (oiled) in diagonally opposite sequence 1.1 Tighten all nuts to closing torque Nm 20 1.2 Tighten all nuts to correct wrench angle ° 90 1.
Model R 1150 RT Connection 11 Engine Oil filter Oil filter Nm 11 Oil drain plug Nm 32 Mesh filter basket to engine block Nm 10 Oil pump cover Nm 9 Pressure relief valve Nm 42 Oil pressure switch Nm 30 Cooling oil line to engine block Nm 10 Cooling oil line banjo screw with oil vent valve Nm 25 Oil cooler to bracket Nm 9 Oil cooler return line to engine block Nm 35 Oil cooler connection to crankcase Nm 9 1 M 8 screw Nm 20 2 M 6 screw Nm 9 3 Chain guide rail pivot scre
Model R 1150 RT Connection 12 Engine electrics Starter motor to engine Nm 20 Positive lead to starter motor Nm 10 Alternator to generator support cover Nm 20 Tensioning and retaining link to alternator Nm 21 Spacer to alternator Nm 21 Positive lead to alternator Nm 15 Belt pulley to alternator Nm 50 Belt pulley to crankshaft Nm 50 Poly-V belt preload Nm 8 NGK BKR 7 EKC spark plug Nm 25 Model R 1150 RT Connection 13 Fuel preparation and control Oil temperature sensor to cran
Model R 1150 RT Connection 21 Clutch Clutch housing Initial tightening torque Nm 40 (oil screw threads lightly) ° 32 Housing cover to housing Nm 12 Clutch line to handlebar fitting Nm 14 Slave cylinder to gearbox Nm 9 Grub screw in filler adapter Nm 10 + additional wrench angle Model R 1150 RT Connection 23 Transmission Oil drain plug Nm 30 Oil filler plug Nm 30 Gearbox to engine block Nm 22 Shift lever to footrest plate Nm 35 Selector lever to selector shaft Nm 9 Housin
Model R 1150 RT Connection 31 Front forks Quick-release axle clamp screws Nm 22 Sliding tube bridge to slider tube Nm 25 (clean thread + Loctite 243) Threaded connection, fork fixed tube to fork bridge Nm 45 (free from oil and grease) Threaded stud to frame Nm 130 (clean thread + Loctite 243) Ball joint to sliding tube bridge Nm 230 (lightly grease threads with Optimoly TA) Initial tightening Nm 80 Final tightening Nm 130 (clean thread + Loctite 2701) Leading link Leading link to ball
Model R 1150 RT Connection 33 Rear wheel drive Rear axle differential Oil filler plug Nm 23 Oil drain plug Nm 23 Threaded ring Nm 160 (clean thread + Loctite 577) Hexagon nut, input bevel gear Nm 200 (clean thread + Loctite 2701) Cover to rear-wheel drive housing Nm 35 Reaction link to rear wheel drive / gearbox Nm 43 (load approx.
Model R 1150 RT Connection 34 Brakes Front brake Brake caliper to EVO brake sliding tube Nm 30 Front brake caliper bleed screw Nm 7 Brake disc to front wheel Nm 21 (clean thread + Loctite 2701) Pivot screw, handlebar lever Nm 11 (Tuflok-Blau thread-locking compound; screw can be released and tightened a number of times) Brake caliper to rear wheel drive Nm 40 Rear brake caliper bleed screw Nm 5 Brake disc to rear wheel drive Nm 21 (clean thread + Loctite 2701) Master cylinder to footr
Model R 1150 RT Connection 46 Frame Frame Frame to engine Nm 82 Struts to frame Nm 58 Strut to engine Nm 58 (clean thread + Loctite 2701) Rear frame to left/right of engine Nm 42 (clean thread + Loctite 2701) Rear frame with footrest plate to left/right of transmission Nm 42 (clean thread + Loctite 2701) Fairing bracket to frame Nm 20 Nm 72 (clean thread + Loctite 2701) M 12 screw Nm 72 (clean thread + Loctite 2701) M 8 screw Nm 21 (clean thread + Loctite 2701) Pivot mount of mai
Model R 1150 RT Connection 51 Equipment Ignition/steering lock to fork bridge Nm Model 20 (micro-encapsulated) R 1150 RT Connection 61 General electrical equipment Horn to holder Nm 8 (clean thread + Loctite 243) Horn to fairing bracket Nm 10 Ground (earth) strap to engine block Nm 9 Battery carrier to rubber-metal element Nm 8 Strut to battery carrier Nm 10 00.
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 3
00 00 Pre-delivery check Contents Page General view of crated motorcycle ...................................................................................15 Checking the crated motorcycle for damage In case of damage in Germany ...............................................................................................16 In case of damage in importer markets Unpacking the motorcycle .............................................................16 ...............................................
00.
00 General view of crated motorcycle B M W BM W R22009010 00.
Checking the crated motorcycle for damage • When the motorcycle arrives, check the crated motorcycle immediately for damage and, if necessary, examine the contents for consequential damage. In case of damage in Germany • • • Note the damage on the delivery slip. Read the information sheet on damage in transit. Notify the supplier without delay (e.g. freight company or DB) and also Bavaria Wirtschaftsagentur GmbH Abteilung ZW - 12 80788 München Tel. +49 89/14327-632 Fax.
Assembling the motorcycle 1 Installing the front wheel 3 e Attention: 2 Degrease all brake discs. • A Remove front straps. B R22000020 • Install the front wheel with spacer (1) and speedometer drive (2). e Attention: Locate stop on slider tube (A) in recess in speedometer drive (B). R22000010 • Using the straps, secure the front of the motorcycle to the assembly crane, BMW No. 46 5 640. • • • • • Tighten the retaining screw (3). Install the front brake calipers.
4x 2x 4x 3x 4x R22460020 Filling and charging the battery • • • • • Remove seat. Remove left side fairing panel. Remove the air filter cover. Remove air intake pipe. Disengage the rubber strap holding the battery. d Warning: Battery acid is highly caustic. It must not contact the eyes, face hands, clothing or the motorcycle’s paintwork. • • R22000040 • • Disconnect the battery breather hose. Pull the battery to the left to remove. 00.18 Fill all the cells with pure battery acid of density 1.
• The battery does not achieve full charge capacity from being filled, so it has to be charged with a battery charger. L Note: Follow the instructions for use supplied with the battery charger. Charge current (amps) .........................10 % of rated battery capacity (Ah) Charging time ............................................................. 5-10 hours • Battery charge can be measured by checking the density of the battery acid. Acid density Battery full charged ............ 1.26-1.
Installing cover for windscreen adjuster and installing windscreen Assembling case R22000070 R22000060 • • • Install the cover for the windscreen adjuster. Install windscreen with washers. Install the aerial. Installing mirrors • • – – • • Position the lid on the case for alignment. Open the hinges of the lid and guide them into the base with the guide hook. From the inside, insert the pop rivets into the base and the hinges. 2x long rivets in hinge at rear, as viewed in forward direction of travel.
Inspecting motorcycle for damage • • • • • – – – Check for defects. Use the “express handling service” to notify BMW Motorrad, UX-VS-1 Fax: + 49 89-382-33220 Rectify the fault. If parts are needed, order them through the usual channel. Costs are to be processed by the warranty claim system (stage 4).
Checking headlight beam angle, adjusting if necessary 1 2 R22000110 R22000090 • • • • Motorcycle on level surface. Rider’s weight on motorcycle (approx. 85 kg/187.4 lbs). Turn knob (1) counter-clockwise as far as it will go. Check headlight beam throw. R22000100 Setting for headlight beam angle adjuster ... .-10 cm (-3.937 in) at a distance of 10 m (32.8 ft) 00.22 • Turn screw (2) to adjust beam throw, if necessary. Direction of rotation, left .....................
Integral ABS Performing bleed test with BMW MoDiTeC d Warning: Self-diagnosis is not performed unless both brake levers are in their fully released positions. Prior to conclusion of the self-diagnosis, only RESIDUAL BRAKING FUNCTION is available. Final inspection and function check • • • • Perform BMW Integral ABS self-diagnosis: • Release the brake levers, if necessary. • Switch on the ignition. • With the ignition switched on, bed in the brake pads against the brake discs.
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.
00 00 Maintenance Contents Page Key to maintenance intervals ...............................................................................................29 Reading the BMW MoDiTeC fault code memory .......................................................29 (Inspections I, II, III and IV) .................................................................................................................29 Integral ABS: Performing bleed test with BMW MoDiTeC ....................................
Contents Page Checking brake pads and discs for wear/replacing ...............................................37 (Inspections II and III) .........................................................................................................................37 Checking brake pads for wear ................................................................................................37 Brake pads, front brake .............................................................................................
Contents Page Checking/adjusting valve clearances .............................................................................55 (Inspections I, II and III) ......................................................................................................................55 Checking freedom of throttle cable, checking for chaffing and kinks, replacing if necessary, Checking throttle-cable play Checking and adjusting idle speed and throttle-valve synchronisation ......
00.
00 Key to maintenance intervals – – – – BMW Inspection at 1,000 km (600 miles) BMW Service every 10,000 km (6,000 miles) BMW Inspection every 20,000 km (12,000 miles) BMW Annual Service Reading the BMW MoDiTeC fault code memory 00 13 624 I (Inspections I, II, III and IV) II • • III IV • • Remove front and rear seats. Connect the BMW MoDiTeC to the diagnosis connector. Read all fault memories. Perform all requisite repair work.
00 11 209 Changing engine oil, replacing oil filter element • (Inspections I, II, III and IV) Attention: Never top up the engine-oil level past the “MAX” mark. L Note: If the motorcycle is ridden only for short distances or outside temperatures are below 0°C (32°F) change the oil and replace the oil filter element every 3 months, or not later than every 3,000 km (1,800 miles). • Change the oil at operating temperature. Insert and tighten the screw plug. e X Tightening torque: Oil filter...........
00 11 229 Changing oil in gearbox (Inspections III and IV) or at the latest every 2 years • Change the gearbox oil at operating temperature. Changing the oil in the rear wheel drive 00 11 229 (Inspections I, III and IV) every 40,000 km (24,000 miles) or at the latest every 2 years • Change the gearbox oil at operating temperature. 1 1 2 2 R22000250 • • • • • • Remove oil filler plug (1). Push in oil drain tube, BMW No. 23 4 680, and turn it to the right.
R22160010 16 12 008 Replacing fuel filter (Inspection III) In normal operating conditions every 40,000 km (24,000 miles); if fuel quality is poor every 20,000 km (12,000 miles) • • • • Remove front and rear seats. Remove left and right side sections of fairing. Disengage stowage compartment and lift it up to remove. Use a cable tie to secure the stowage compartment to the motorcycle. d Warning: Fuel is flammable and a hazard to health. Observe relevant safety regulations.
R22160021 • • Disconnect hoses from fuel filter. Install new fuel filter. e Attention: Note correct direction of flow through fuel filter. • Secure non-reusable hose clips with pliers, BMW No. 13 1 500. e Attention: Make sure O-ring (arrow) is in perfect condition. Af- • Installation is the reverse of the removal procedure. L Note: Make sure that breather lines are correctly routed. X Tightening torque: Fuel pump unit to fuel tank ............................. 5 Nm Fuel tank to rear frame ..........
R22000120 61 20 029 Checking battery fluid level and topping up if necessary; cleaning and greasing the battery posts (Inspections III and IV) d L Note: Disconnecting the battery means that the entries in the fault memory of the Motronic MA2.4 control unit are deleted and the adaptation values are reset. This can temporarily impair the operating characteristics when the engine is restarted. Warning: Battery acid is highly caustic.
Replacing intake air filter element 13 72 000 (Inspection III) in very dirty and dusty operating conditions, replace every 10,000 km (6,000 miles) or even more frequently if necessary 3 2 4 1 RS110480 • • Slacken alternator securing screws (1,3,4). Remove old Poly-V belt. L Note: R22000130 • • • • Open clips securing air filter cover. Replace air filter element. Close air filter cover. 12 31 240 Install new Poly-V belt.
Checking brake fluid level • (Inspections II and III) Brake fluid ...................................................DOT 4 L Note: Checking brake system for correct operation and freedom from leaks; repairing/replacing if necessary The brake fluid level in the sight glass/brake fluid reservoirs of control circuits remains constant despite wear of the brake pads. If the level drops below the MIN mark, this indicates some other fault.
Checking brake pads and discs for wear/replacing Brake pads, rear brake (Inspections II and III) Checking brake pads for wear Brake pads, front brake 1 R22000170 2 • – • R22000160 • – • Visually inspect the brake pads. Wear indicators (1) must be clearly visible. If necessary, check/measure thickness of brake pads. e Attention: Do not permit brake pad thickness to fall below the minimum value. Always replace the brake pads as a complete set. Visually inspect the brake pads.
Checking brake disc wear • • Carefully check the brake discs for cracks, damage, deformation and scoring. e Attention: Integral ABS Press back pistons on only one side of the brake caliper. Allow the brake pad on the opposite side to remain in the caliper during this process. Make sure that the fluid level in the wheel-circuit reservoir does not rise above “max”. Risk of fluid escaping. If fluid escapes, proceed in accordance with “instructions for filling reservoir”.
34 21 200 Brake pads, rear brake • e Attention: Integral brakes, the front brake must be ready for • use. X Tightening torque: Brake caliper to rear wheel drive .................. 40 Nm Installation is the reverse of the removal procedure. Check operation of the brake system with the ignition switched on. R22000180 • • • • Remove keeper (arrow) from retaining pin. Drive the retaining pin out towards the wheel side. Remove brake caliper. Remove brake pads.
Changing/bleeding brake fluid in wheel circuit 34 00 090 Change brake fluid in wheel circuit once a year (Inspection IV) d Warning: All repair and maintenance work on the BMW Integral ABS must be performed by trained, qualified specialists. Comply with all maintenance and repair instructions and always work through the various steps in the correct order. Use only new brake fluid from freshly opened containers. • • Draw off the old brake fluid from the wheel-circuit reservoir.
34 1 581 e Attention: The brake fluid must always be visible in the container, because the piston in the base of the wheel-circuit reservoir must always be covered by the fluid. The procedure must be repeated if the fluid drops below the “min” level. • • • R22000340 • • • Screw container, BMW No. 34 1 581, onto front wheel circuit reservoir. Slowly fill container, BMW No. 34 1 581, with new brake fluid until it is approximately 1/2 full.
Instructions for filling front wheel circuit reservoir e Attention: Integral brakes, the rear brake must be ready for use. MAX MIN 34 1 533 R28340090 34 1 531 • 34 1 532 • R22000300 • • Top up fluid in front wheel-circuit reservoir to “MAX” mark if necessary Install adapters 22, BMW No. 34 1 533, in resetting tool, BMW No. 34 1 531/532, for both front brake calipers, and tighten the resetting tool until the adapters are secure.
Only bleeding the front wheel circuit – – – Draw off the old brake fluid from the wheel-circuit reservoir. Remove left and right brake pads, force back the brake pistons and secure the pistons in this position. Wrap cloths around the left and right brake calipers. e Attention: Integral brakes, the rear brake must be ready for use. d Warning: Check that the brake fluid in the hose does not foam.
34 00 080 Bleeding/changing brake fluid in rear wheel circuit e Attention: Integral brakes, the front brake must be ready for use. • 34 1 536 Remove fuel tank. 34 1 531 e Attention: Do not allow brake fluid to come into contact with painted parts of the motorcycle as brake fluid destroys paint. R28000170 • • • – • 1 Install adapter, BMW No. 34 1 536, instead of the outboard brake pad. Install resetting tool, BMW No.
• Switch on the ignition L Note: After switching on the ignition, always wait for the BMW Integral ABS to complete its self-diagnosis. Do not operate the brake lever until self-diagnosis has completed. • • • • Close the bleed screw. Release the brake and switch off the ignition. Disconnect the brake bleeding device from the bleed screw. Disconnect the container from the wheel-circuit reservoir.
Instructions for filling rear wheel circuit reservoir e Attention: Integral brakes, the front brake must be ready for use. MAX MIN 34 1 536 R28340090 • 34 1 531 • R28000170 • • Top up fluid in rear wheel-circuit reservoir to “MAX” mark if necessary. Fully tighten resetting tool, BMW No. 34 1 531, and adapter, BMW No. 34 1 536. e Attention: The piston in the base of the wheel-circuit reservoir must always be covered by the fluid, as otherwise air can be drawn into the brake system.
Only bleeding the rear wheel circuit – – – Draw off the old brake fluid from the wheel-circuit reservoir. Remove rear brake pads, force back the brake pistons and secure the pistons in this position. Wrap a cloth around the rear brake caliper. d Warning: Check that the brake fluid in the hose does not foam. If the fluid foams, proceed as described in the section on bleeding and changing brake fluid in rear wheel circuit. (a 00.
34 00 091 Changing/bleeding brake fluid in control circuit Change brake fluid in control circuit every 2 years (Inspection IV) d Warning: All repair and maintenance work on the BMW Integral ABS must be performed by trained, qualified specialists. Comply with all maintenance and repair instructions and always work through the various steps in the correct order. Use only new brake fluid from freshly opened containers.
e Attention: During the fluid-change and bleeding procedure, make sure that the fluid replenishing hole is always below the level of the brake fluid, or else air will be drawn into the brake system. Bleed the system again if this happens. • • • • Recheck the brake-fluid level. Place the motorcycle on its centre stand. Turn the handlebars to the left. Set the handbrake lever to position 4. d Warning: When performing maintenance and repair work on BMW Integral ABS, never pump quickly or vigorously.
34 00 082 Bleeding/changing brake fluid in rear control circuit – – Place the motorcycle on its main (centre) stand. Fuel tank removed. d Warning: When performing maintenance and repair work on BMW Integral ABS, never pump quickly or vigorously. e Attention: Do not allow brake fluid to come into contact with painted parts of the motorcycle as brake fluid destroys paint. • • • 2 Remove right case, if necessary. Remove small right side fairing panel.
• • – Correct the brake fluid level. Wipe the rim of the reservoir, the rubber diaphragm and the cover to remove brake fluid, and carefully reassemble the components. Place the motorcycle on its centre stand. Checking clutch operating fluid level (Inspections II and III) e Attention: Keep the brake fluid in the clutch operating system away from painted surfaces on the motorcycle because brake fluid attacks paint. • • Place motorcycle on its centre stand.
21 52 005 Changing the clutch fluid (Inspection IV) every 2 years at the latest L Note: The description applies to a brake system filling and bleeding device with vacuum extraction of brake fluid at the bleed line. If other devices are used, comply with their manufacturers’ instructions. • • • Place the motorcycle on its main (centre) stand. Turn the handlebars to a position in which the clutch fluid reservoir is horizontal. Secure front wheel in position.
Checking tightness of rear wheel studs Greasing the side stand pivot (Inspections I, II and III) (Inspection I) • Tighten the rear wheel studs with a torque wrench. X Tightening torque: Securing screws for rear wheel .................. 105 Nm Checking rear wheel bearing play by tilting wheel (Inspection III) • – a Tilt the rear wheel to and fro across its axle. If play is detected, fit new shims to rear wheel drive or replace bearings. ....................................................
12 12 011 Checking/replacing spark plugs 11 12 009 Tightening cylinder heads (Inspection I) (Inspection II) check/(Inspection III) replace 12 3 510 12 3 520 R21000330 R21000190 • • Pull off spark plug caps with special puller, BMW No. 12 3 520. Remove spark plugs with the spark plug wrench, BMW No. 12 3 510. • Remove cylinder head cover. e Attention: Catch escaping oil. e Attention: Do not bend electrodes - risk of breakage! Spark plug:..................................
Checking/adjusting valve clearances 11 34 004 (Inspections I, II and III) Checking freedom of throttle cable, checking for chaffing and kinks, replacing if necessary Checking throttle-cable play Checking and adjusting idle speed and throttle-valve synchronisation 13 60 110 (Inspections I, II and III) • • • Test-drive the motorcycle until the engine is warm. Remove the left side panel. Remove the flap in the right side panel. Oil temperature: ..................
• • • Carefully turn the adjusting screw of the left throttle valve and reduce play until the reading of the Synchro tester changes. Turn the adjusting screw very slightly in the opposite direction until the reading returns to its original value. Tighten the locknut to secure. L Note: S000100 • Turn the adjusting screws to adjust the play of the cables for the left and right throttle valves. Play of throttle cable: .... approx. 2 mm (0.
Final inspection with road safety and functional check (Inspections I, II, III and IV) Road safety check • Check wheels and tyres. • Check/correct tyre pressures. • Wait at least 10 minutes after heating the engine to operating temperature in the trial run/road test before checking/correcting engine oil level. R22000330 • • • • Use the adjusting screw (arrow) to adjust play of the choke cable to zero. Push the rubber cap into position over the adjusting screw.
00.
34 Brakes 34 Contents Page Technical Data 34 Brakes ........................................................................................................ 3 Removing and installing front brake caliper .................................................................4 Disassembling and assembling front brake caliper Removing and installing rear brake caliper ...................................................................
Contents Page Draining the Integral ABS brake system ...................................................................... 16 Drain both wheel circuits ........................................................................................................... 16 Draining front wheel circuit ................................................................................................................ 16 Draining rear wheel circuit ......................................................................
34 Technical Data 34 Brakes R 1150 RT Brake fluid DOT 4 Front wheel Type Hydraulically operated twin disc brake with 4-piston fixed calipers and floating brake discs Colour of identification mark on brake calipers/brake pads white Brake pad lining Sintered metal Minimum lining thickness Brake pad surface area mm (in) 1.0 (0.0393 in) cm2 86 (13.33) (sq in) Brake disc dia. mm (in) 320 (12.5987) Brake disc thickness mm (in) 5.0 (0.1969) Minimum thickness of brake discs mm (in) 4.5 (0.
Removing and installing front brake caliper 34 11 e Attention: Do not allow brake fluid to come into contact with painted parts of the motorcycle as brake fluid destroys paint. • Integral ABS Drain front wheel circuit (a 34.16). 1 d Suds 2 R28340010 • • • Disconnect brake line (1). Remove the brake caliper securing screws. Carefully remove the brake caliper. e Attention: Replace the sealing rings (2) in the brake line. Do not damage the brake pads when installing.
3 2 34 1 531 1 34 1 532 S340220 Disassembling and assembling front brake caliper 34 11 521 e Attention: Do not separate the brake caliper halves! – – Integral ABS Drain front wheel circuit (a 34.16). Remove the brake caliper. • • • Remove the brake pads. Close the bleed screw. Secure two opposing brake pistons with spacer, BMW No. 34 1 520. Insert a piece of cloth between the two brake pistons not secured by the resetting tool.
2 2 1 R22340090 Removing and installing rear brake caliper 34 21 e Attention: Do not allow brake fluid to come into contact with painted parts of the motorcycle as brake fluid destroys paint. • • • Integral ABS Drain rear wheel circuit (a 34.17). Disconnect brake line (1) from brake caliper. Remove the brake caliper. e Attention: Replace the sealing rings (2) in the brake line. Do not damage the brake pads. • Installation is the reverse of the removal procedure.
1 5 2 3 4 R21340010 Disassembling and assembling rear brake caliper 34 21 Assembling rear brake caliper • Disassembling rear brake caliper – – Integral ABS Drain rear wheel circuit (a 34.17). Remove the brake caliper. • • • Close the bleed screw. Hold a cloth over the brake caliper piston. Carefully press out brake piston (3) with a compressed air gun applied to the connecting bore; work at low air pressure.
Removing and installing front brake discs Removing and installing rear brake disc 34 21 34 11 d d Warning: When removing and installing the brake calipers, force back the pistons carefully to ensure that the wheel-circuit reservoir does not overflow. If fluid escapes, proceed in accordance with “instructions for filling reservoir” (a 34.25). Warning: When removing and installing the brake caliper, force back the pistons carefully to ensure that the wheel-circuit reservoir does not overflow.
3 1 2 3 R22340060 Removing and installing Integral ABS sensor Removing and installing front Integral ABS sensor 34 52 044 • • • • • Remove the cable ties securing the sensor cable. Disconnect plug (1) of sensor cable. Guide the sensor cable down until clear. Remove sensor (2). Installation is the reverse of the removal procedure. e Attention: Route the sensor cable correctly. Ensure that clips (3) are correctly seated. X Tightening torque: Sensor ........................................
1 2 R22340070 Removing and installing rear Integral ABS sensor 34 52 111 • • • • • • • • • Remove front and rear seats. Remove right case, if necessary. Remove small right side fairing panel. Remove the cable ties securing the sensor cable. Disconnect plug (1) of sensor cable. Before removing/installing, clean the sensor bore. Remove sensor (2). Installation is the reverse of the removal procedure. Coat O-rings with oil before installing. e Attention: Route the sensor cable correctly.
5 6 7 3 2 4 1 R22460140 35 21 Removing and installing footbrake lever 34 31 • • • • • • Release and remove stud (1). Remove bolt (2) of footbrake lever with nut (3). Remove footbrake lever with torsion spring (4). Installation is the reverse of the removal procedure. Lubricate pivot bushing with Shell Retinax A. e Attention: Check and, if necessary, adjust the blow-by clearance of the piston rod and the setting of the brakelight switch (a 34.12).
Checking and adjusting blow-by clearance of piston rod Adjusting blow-by clearance at piston rod Checking blow-by clearance of piston rod 2 1 A 3 R22340010 R22340020 • • • Set the adjusting screw of the footbrake lever to distance A. Press the footbrake lever. Insert feeler gauge at right angles to direction of travel between the brake-light switch lever (3) and the stop on the footrest plate (arrow). Slowly release the footbrake lever and check play. Distance A: .... 13.6 +/- 0.5 mm (0.5354+/-0.
Checking and adjusting setting of rear brake light switch Adjusting brake light switch, rear Checking setting of brake light switch, rear 4 B 3 R22340030 R22340020 • Switch on the ignition. • • Depress the footbrake lever and secure it in this position. Slacken screw (4). L Note: After switching on the ignition, always wait for the BMW Integral ABS to complete its self-diagnosis. Do not operate the brake lever until self-diagnosis has completed.
3 4 2 1 R28340060 34 00 Removing and installing Integral ABS pressure modulator d Warning: All repair and maintenance work on the BMW Integral ABS must be performed by trained, qualified specialists. Comply with all maintenance and repair instructions and always work through the various steps in the correct order. Use only new brake fluid from freshly opened containers. 34.
e Attention: Do not bend the brake lines. • Disconnect the brake lines from the ABS pressure modulator. e Attention: Do not permit brake fluid to enter the plugs. • • • • • Disconnect plugs (3) of the front and rear wheel circuit reservoirs. Unlock plug (4) (arrow) and disconnect the plug. Disconnect plug from Hall sensor. Remove Motronic control unit. Release ABS pressure modulator and pull it carefully to the left to remove.
34 00 Draining the Integral ABS brake system • • Draw off the old brake fluid from the wheel-circuit reservoir and reinstall the cap. Remove front brake pads. d Warning: All repair and maintenance work on the BMW Integral ABS must be performed by trained, qualified specialists. Comply with all maintenance and repair instructions and always work through the various steps in the correct order. Use only new brake fluid from freshly opened containers.
Draining rear wheel circuit e Attention: Integral brakes, the rear brake must be ready for use. – L Note: After switching on the ignition, always wait for the BMW Integral ABS to complete its self-diagnosis. Do not operate the brake lever until self-diagnosis has completed. Install front brake pads, if applicable. • • • • • • Gently press the footbrake lever until the pump just starts up. Open the bleed screw. Drain the wheel circuit with the pump. Close the bleed screw.
Draining control circuits Draining rear control circuit e Attention: Do not allow brake fluid to come into contact with • Remove rear reservoir cap with rubber diaphragm, draw off the old brake fluid and clean the reservoir. painted parts of the motorcycle as brake fluid destroys paint. Draining front control circuit • • • • 5 Turn the front wheel to a position in which the brake fluid reservoir is horizontal and secure the handlebars in this position. Wrap cloths around the reservoir.
Filling and bleeding Integral ABS system 34 00 d Warning: All repair and maintenance work on the BMW Integral ABS must be performed by trained, qualified specialists. Comply with all maintenance and repair instructions and always work through the various steps in the correct order. Use only new brake fluid from freshly opened containers.
Bleeding front control circuit • • • • • Seal the reservoir by installing the rubber diaphragm and the reservoir cap. Turn the handlebars to full left lock. Repeatedly pull front brake lever lightly to expel air from brake master cylinder. Switch off the brake bleeding device. Set the handbrake lever to position 4. • • • Recheck the brake-fluid level. Place the motorcycle on its centre stand. Turn the handlebars fully to the left.
Filling the rear control circuit • Remove rear reservoir cap with rubber diaphragm. e Attention: On account of the vacuum extraction process, it is not possible to tell whether there is brake fluid in the hose of the brake bleeding device when it is free of bubbles. Consequently, the system must be bled again manually in the specified sequence and in accordance with the instructions for bleeding the brakes.
• • • • – Fit the protective caps on the bleed screws. Top up the brake fluid at least until the level reaches the “MIN” mark. Wipe the rim of the reservoir, the rubber diaphragm and the cover to remove brake fluid, and carefully re-assemble the components. Recheck the brake-fluid level. Place the motorcycle on its centre stand. R22000150 Specified level not below .........................................................
Filling and bleeding wheel circuits e Attention: Do not allow brake fluid to come into contact with painted parts of the motorcycle as brake fluid destroys paint. e Attention: To prevent brake fluid entering the plugs, do not disconnect the plugs from the ABS pressure modulator. Filling and bleeding front wheel circuit e Attention: 34 1 581 Integral brakes, the rear brake must be ready for use. – – Install rear brake pads and brake caliper, if applicable. Place the motorcycle on its centre stand.
• • • • • MAX Pump off brake fluid until it emerges clear and free from air bubbles. Close the bleed screw. Release the brake. Disconnect the brake bleeding device from the bleed screw. Connect the brake bleeding device to the bleed screw of the right brake caliper, but do not switch on the device. L Note: If necessary, use a cable tie to secure the bleed MIN hose to the bleed screw.
Instructions for filling front wheel circuit reservoir e Attention: Integral brakes, the rear brake must be ready for use. – MAX Install front brake pads, if applicable. MIN R28340090 34 1 533 34 1 531 • • 34 1 532 • R22000300 • • Top up fluid in front wheel-circuit reservoir to “MAX” if necessary Install adapters 22, BMW No. 34 1 533, in resetting tool, BMW No. 34 1 531/532, for both front brake calipers, and tighten the resetting tool until the adapters are secure.
Filling and bleeding rear wheel circuit e Attention: Integral brakes, the front brake must be ready for use. – 34 1 581 Place the motorcycle on its centre stand. R22000350 • • 1 • R28340110 • • Open rear wheel-circuit reservoir (1). Remove rear brake pads. Screw container, BMW No. 34 1 581, onto rear wheel circuit reservoir. Slowly fill container, BMW No. 34 1 581, with new brake fluid until it is approximately 1/3 full.
• • • • MAX Close the bleed screw. Release the brake and switch off the ignition. Disconnect the brake bleeding device from the bleed screw. Disconnect the container from the wheel-circuit reservoir. e Attention: After changing and/or bleeding the brakes, always top up the fluid in the wheel-circuit reservoir to the correct level in accordance with the instructions.
• Instructions for filling rear wheel circuit reservoir Switch on the ignition. L Note: After switching on the ignition, always wait for the e Attention: Integral brakes, the front brake must be ready for use. BMW Integral ABS to complete its self-diagnosis. Do not operate the brake lever until self-diagnosis has completed. • Operate the footbrake lever until the pistons of the rear brake caliper are in contact with resetting tool, BMW No. 34 1 531, and adapter, BMW No. 34 1 536.
• • • • Install rear brake pads and brake caliper. Disconnect the container from the wheel-circuit reservoir. Hand-tighten cap of rear wheel-circuit reservoir. Check operation of the brake system with the ignition switched on. e Attention: After all the work on the brake system has been completed, run a bleed test using the BMW MoDiTeC. Integral ABS Reading fault memory with BMW MoDiTeC 34 00 • • • • Remove front and rear seats. Connect the BMW MoDiTeC to the diagnosis connector.
R22340080 Integral ABS Removing and installing bleed lines, wheel circuit reservoirs 34 51 • • • • Remove caps of wheel circuit reservoirs complete with bleed lines. Installation is the reverse of the removal procedure. Pay particular attention to the following: Make sure the bleed lines are free of kinks. Cut the bleed lines to length if necessary, and cut the ends at an angle. 34.
1 3 2 34 2 561 R28340160 Integral ABS: Removing and installing brake lines • • • • • Drain the brake system (a 34.16). Push protective caps (1) up. Remove spring clips (2). Remove brake lines. Installation is the reverse of the removal procedure: pay particular attention to the following. d Warning: Always fit new spring clips each time the plugs are disconnected. Ensure correct positioning. • • • • • • • Check that square-section rings are correctly seated. Install new spring clips.
Installed position of front brake line R22340100 34.
Installed position of rear brake line R22340110 34.
