Installing Engine - BMW K 1200 LT 1999 Repair Manual

Installing engine

•
Install the clutch.
•
Secure engine to hoist, BMW No. 00 1 510, and
disengage engine from stand,
BMW No. 00 1 490.
Groups: frame and gearbox
e
Caution:
When maneuvering the engine below the motor-
cycle and raising and lowering the frame, always
take care not to damage components or scratch
surfaces.
•
Install the alternator.
•
Apply a coat of Optimoly MP 3 to the splines of
the gearbox input shaft.
•
Secure guide pins, BMW No. 23 1 820, to inter-
mediate flange.
•
Slide gearbox with starter motor over guide pins,
BMW No. 23 1 820, and into position against in-
termediate flange.
•
Install link for reverser, and secure mounts for
link and gearbox to intermediate flange.
•
Remove guide pins.
•
Use hoist, BMW No. 00 1 510, to raise engine
slightly and carefully lower frame just far enough
to allow cables to be connected to starter motor
and alternator: connect the cables.
•
Continue lowering frame until gearbox mounts
can be installed: install and tighten the gearbox
mounts.
•
Secure cross members on left and right.
•
Pull down the centre stand.
•
Fully lower hoist, BMW No. 00 1 510, and remo-
ve.
•
Fully lower the frame.
•
Remove workshop crane, BMW No. 46 5 640.
•
Connect inductive sensor for reverser.
•
Connect selector lever to gearshift linkage.
•
Install actuator unit for reverser.
Group: clutch
•
Connect switch for gear indicator.
•
Insert the clutch release rod.
•
Install clutch slave cylinder with new paper seal.
•
Insert clutch breather hose, working from rear to-
ward front.
11.16
Groups: engine electrical system and general
vehicle electrics
•
Connect cable for side-stand switch.
•
Connect ground cable to cylinder head.
•
Install and tighten temperature sensor for cylin-
der head and reconnect cable.
•
Connect cables for temperature sensor water
pump, oil-pressure indicator and magnetic gate;
use cable ties to secure.
•
Install spark plugs and ignition leads.
•
Install heat shield for cylinder head.
Groups: frame, rear-wheel drive, wheels and
tyres
•
Install transverse tube.
•
Install swinging arm.
•
Install the rear wheel drive.
•
Install the rear wheel.
•
Install rear brake and inductive sensor.
Group: exhaust system
•
Install lambda sensor and connect cable.
•
Install exhaust.
•
Install exhaust heat shield.
Groups: radiators, fuel tank and fuel lines
e
Caution:
Make sure that all lines and cables are correctly rou-
ted.
•
Secure fuel lines to engine.
•
Install throttle butterfly rail complete with intake
air silencer.
•
Install fuel injection rail.
•
Connect lines to injection valves and intake air
silencer.
•
Connect crankcase breather hose.
•
Install left-hand radiator bracket.
•
Install left and right radiators and coolant hoses.
•
Install intake air pipe for air filter.
•
Install fuel tank, connect lines and fuel hoses.
Group: frame
•
Install left and right front footrest systems.
•
Install front saddle.
•
Install tank cover.
•
Install left and right skirt brackets.
•
Use cable tie to secure clutch breather hose to
right-hand skirt bracket.
•
Install fairing panels and engine spoilers.
•
Install left and right rear footrests.
•
Install skirts.