Table Of Contents - BMW 1987 K75 Owners Workshop Manual

Table of Contents

Contents3
Introduction5
Model Dimensions And Weights8
Ordering Spare Parts9
Location Of Engine Number9
Location Of Frame Number9
Safety10
Fire10
Asbestos10
Fumes10
Tools And Working Facilities11
Maintenance And Minor Repair Tool Kit12
Specialized Tools12
Repair And Overhaul Toolkit12
Fastening Systems12
Spanner Size Comparison13
Standard Torque Settings13
Choosing And Fitting Accessories14
Fairings And Windscreens14
Luggage Racks Or Carriers15
Handlebars15
Luggage15
Crashbars15
Electrical Equipment16
Accessories16
Fault Diagnosis17
Starter Motor Not Rotating18
No Fuel Flow To Engine18
Fuel Not Reaching Cylinder18
Engine Flooding18
Weak Spark At Plug19
Compression Low19
Fuel/Air Mixture Incorrect19
General Causes19
Knocking Or Pinking20
Overheating20
Clutch Operating Problems20
Gear Selection Problems20
Abnormal Engine Noise21
Abnormal Transmission Noise21
Jumping Out Of Gear21
Other Noises21
Exhaust Smokes Excessively22
Poor Handling Or Roadholding22
Oil Pressure Indicator Lamp Goes On22
Steering Bias To Left Or Right22
Abnormal Frame And Suspension Noise23
Brake Problems23
Handlebar Vibrates Or Oscillates23
Poor Front Fork Performance23
Electrical Problems24
Brakes Drag24
Drum Brakes24
Brake Pedal Pulsates In Operation24
Battery Overcharged25
Total Electrical Failure25
Circuit Failure25
Bulbs Blowing Repeatedly25
Routine Maintenance26
Specifications26
Cycle Parts26
Recommended Lubricants26
Cleaning The Machine27
Service Intervals27
Additional Recommendations27
Daily27
Check The Tyres28
Check The Engine Oil Level28
Engine Oil Viscosity Selection Chart28
Check The Fuel Level29
Check The Coolant Level29
Check The Controls29
Rear Suspension Settings29
Check The Battery30
Minor Service31
Change The Engine Oil And Filter31
Check The Gearbox Oil Level32
Check The Final Drive Case Oil Level32
Lubricate The Controls And Stand Pivots33
Gearbox Oil Level Dipstick33
Check And Adjust The Valve Clearances34
Checking The Valve Clearances34
Adjusting The Valve Clearances With Service Tools34
Adjusting The Valve Clearances Without Service Tools36
Check And Adjust The Spark Plugs36
Major Service37
Final Inspection37
Air Filter37
Change The Gearbox Oil38
Change The Final Drive Case Oil38
Change The Front Fork Oil38
Clean The Speedometer Impulse Transmitter38
Renew The Air Filter Element40
Check The Cooling System40
Check And Adjust The Clutch40
Renew The Spark Plugs41
Check The Fuel System41
Check And Overhaul The Brakes41
Disc Brakes41
Brake Fluid Renewal43
Drum Rear Brake44
Wheels44
Front Wheel Bearings44
Rear Wheel Bearings44
Renew The Fuel Filter45
Engine46
General Description49
Carrying Out A Compression Test49
Dismantling The Engine Unit50
Removing The Engine Unit From The Frame50
Dismantlinh The Engine Unit51
General Procedures52
Cylinder Head Cover52
Crankshaft Cover52
Cam Chain Cover52
Camshafts And Cam Chain54
Removing The Cylinder Head55
Removing The Pistons And Connecting Rods56
Method Of Removing Gummed Piston Rings58
Removing The Crankshaft59
Removing Bearings And Oil Seals60
Examination And Renovation60
Bearings And Oil Seals61
Engine Cases And Covers61
Crankshaft And Camshaft Drive Mechanism61
Cylinder Head63
Valves, Valve Seats And Valve Guides63
Cylinder Block65
Pistons And Piston Rings66
Connecting Rods And Big-End Bearings66
Crankshaft And Main Bearings67
Fabricated Small-End Bush Drawbolt Tool67
Output/Balancer Shaft68
Auxiliary Drive Shaft And Starter Clutch72
Auxiliary Drive Shaft And Starter Clutch Components73
Reassembling The Engine Unit74
Refitting Bearings And Oil Seals75
Refitting The Crankshaft75
Refitting The Output/Balancer Shaft76
Crankcae Lower Section76
Refitting The Cylinder Head81
Cylinder Head Bolt Tightening Sequence81
Refitting The Camshafts And Setting The Valve Timing82
Refitting The Auxiliary Drive Shaft Components And The Bellhousing86
Refitting The Outer Covers87
Refitting Ancillary Components89
Refitting The Engine Unit To The Frame89
Starting And Running The Rebuilt Engine91
Taking The Rebuilt Machine On The Road91
Clutch92
Clutch Removal92
Clutch Friction Plate92
Torque Wrench Settings92
Clutch Assembly93
Clutch Dismantling94
Clutch Examination And Renovation94
Clutch Reassembly95
Clutch Housing Locking Tool95
Measuring Clutch Friction Plate Thickness95
Clutch Release Mechanism98
Side Stand Retracting Mechanism98
Gearbox101
Gearbox Lubrication101
Gearbox General Description102
Removing The Gearbox From The Frame102
Gearbox Dismantling103
Gearbox Housing103
Removing And Refitting The Bearings And Seals104
Gearbox Shafts105
Input Shaft105
Output Shaft105
Layshaft105
Checking And Resetting The Gearbox Shafts, Endfloat And Preload109
Layshaft And Output Shaft109
Gearbox Reassembly110
Selector Drum And Forks110
Cooling System117
Coolant117
Cooling System Draining118
Cooling System Filling118
Cooling System Flushing118
Radiator Removal, Cleaning And Examination119
Radiator Pressure Cap121
Hoses And Connections122
Cooling System Hoses122
Thermostat123
Water Pump124
Cooling Fan125
Cooling System Electrical Component125
Coolant Temperature Sensor125
Temperature Sensing Switch Unit125
Coolant Overheat Warning Lamp126
Fuel System And Lubrication127
Fuel Tank Capacity127
Recommended Fuel Grade127
Fuel System Components129
Precautions130
Relieving Fuel System Pressure131
Fuel System Fault Finding131
Fuel Tank Removal And Refitting132
Fuel Tank Components135
Fuel Return Valve135
Tank Insulation135
Internal Hoses And Pipes135
Fuel Gauge Sender Unit136
Fuel Filter136
Fuel Pump136
Pressure Regulator138
Fuel Pressure: Testing138
Fuel Rail And Injectors138
Air Filter Housing140
Airflow Meter141
Throttle Butterfly Assembly And Plenum Chamber142
Fuel System Electrical Components144
Fuel Injection Relay144
Fuel Injection Control Unit144
Fast Idle Speed Control Cable145
Idle Speed And Throttle Cable146
Throttle Butterfly Synchronization146
Idle Mixture Adjustment146
Mixture Adjustment And Checks Using An Exhaust Gas Analyser147
Checking The Air Filter Element147
Checking For Instruction System Air Leaks147
Compensating For High Altitude148
Recommended Fuel148
Exhaust System148
Oil Pump Removal149
Oil/Water Pump150
Oil Pressure Relief Valve151
Oil Pump Pick-Up Filter Gauze152
Oil Filter152
Oil Pressure Warning Lamp153
Ignition System154
Precautions To Be Observed When Checking The Ignition System155
Ignition System Components155
Ignition Control Unit156
Ignition Trigger Assembly156
Ignition Ht Coils157
Ignition Ht Leads158
Spark Plugs158
Ignition System Fault Finding158
Vacuum Switch158
Frames And Forks160
Front Forks161
Front Forks Dismantling162
Front Forks Examination And Renovation164
Front Forks Reassembly165
Front Forks Refitting167
Front Forks Aligning The Damping Components168
Steering Head Bearings170
Steering Head Bearings Refitting170
Fluidbloc Steering Damper170
Fluidbloc Steering Damper Installation170
Frame Examination And Renovation171
Footrests General171
Stands And Controls171
Headlamp Surround171
Fairing172
Engine Spoiler/Belly Fairing172
Fairing Installation173
Seat Removal And Refitting177
Bodywork Removal And Refitting178
Rear Mudguard178
Front Mudguard178
Side Panels178
Mirrors179
Engine Protection Bars179
Instruments180
Panniers180
Top Box180
Final Drive And Rear Suspension182
Final Drive Removal183
Final Drive Assembly184
Final Drive Refitting186
Swinging Arm And Drive Shaft187
Swinging Arm Examination188
Final Drive Shaft189
Swinging Arm And Drive Shaft Refitting189
Rear Suspension Unit190
Nivomat Suspension Unit191
Wheels, Brakes And Tyres193
Front Wheel194
Rear Wheel196
Wheel Bearings197
Hydraulic Brake Overhaul198
Caliper199
Front Brake Master Cylinder199
Brake Caliper199
Rear Disc Brake Master Cylinder201
Bleeding The Hydraulic Brake System202
Rear Drum Brake204
Tyres205
Puncture Repair And Tyre Renewal206
Tyre Valves206
Wheel Balancing207
Electrical System208
Battery Examination209
Alternator210
Checking The Output210
Alternator Removal And Refitting210
Alternator Overhaul212
Starter Motor215
Starter Motor Overhaul216
Starter System217
Oil Pressure Warning Lamp Circuit218
Gear Position Indicator Switch218
Clutch Interlock Switch218
Interlock Circuit Diode218
Cold Start Device Indicator219
Tail Lamp Bulb Monitoring Device219
Switches219
Fuyel Level Gauge Circuit219
Relays220
Turn Signal Relay220
Horn220
Bulbs221
Headlamp And Parking Lamp221
Radio221
Turn Signal Lamps222
Stop And Tail Lamp222
Instrument Panel Bulbs222
Wiring Diagram225
Conversion Factors231
Index232