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BMW HP2 ENDURO Maintenance Instructions Manual

Sporty off-roading
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Maintenance instructions for sporty off-roading
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Summary of Contents for BMW HP2 ENDURO

  • Page 1 Maintenance instructions for sporty off-roading HP2 Enduro...
  • Page 2 Motorcycle data/dealership details Motorcycle data Dealership details Model Person to contact in Service depart- ment Vehicle identification number Ms/Mr Colour code Phone number Date of first registration Dealership address/phone number Registration number (company stamp)
  • Page 3 The right to modify designs, equipment and accessories is reserved. Errors and omissions excep- ted. © 2005 BMW Motorrad Not to be reproduced either wholly or in part without writ- ten permission from BMW Motorrad, After Sales. Printed in Germany.
  • Page 4 BMW recommends MW Motorrad Order No: 01 41 7 698 321 08.2005 1st edition G /RF The Ultimate Riding Machine...
  • Page 5 Sporty off-roading inevitably who want to leave metalled specialist workshop, prefer- increases wear and tear on roads and use their motor- ably your authorised BMW the motorcycle, so extra cycles for sporty off-roading. Motorrad dealer. checks and maintenance Before you go off-roading,...

  • Page 6: Table Of Contents

    Table of Contents Installing mirrors ..12 Work to be undertaken Installing headlight once a year....29 You can also consult the in- guard .

  • Page 7: General Instructions

    General instructions Notes on these Maintenance Instructions ..... 4 Abbreviations and symbols ..4...

  • Page 8: Notes On These Maintenance Instructions

    Notes on these Main- Reference to a page You will find detailed informa- with more detailed in- tion on maintenance and re- tenance Instructions formation. pair work in the Repair Manu- The work explained in these al on the CD-ROM that ac- Maintenance Instructions companies your motorcycle.

  • Page 9: Overview

    Overview Conversion work preparatory to off-roading ..... . 6 Maintenance work ....6...

  • Page 10: Conversion Work Preparatory To Off-Roading

    Conversion work Checking brake pads for Checking ease of move- wear ( ment of footbrake lever preparatory to Checking spokes ( off-roading Checking ease of move- Work to be carried out Removing number-plate ment of shift lever ( after five hours of riding carrier ( Cleaning slider tubes ( in sand, dust or mud...
  • Page 11 Checking Paralever bearing for play ( Checking security of threaded fasteners ( Work to be undertaken once a year Changing telescopic-fork oil...

  • Page 13: Installing And Removing Components

    Installing and removing components Removing number-plate carrier ......10 Installing number-plate carrier ......11 Removing mirror.

  • Page 14: Carrier

    Removing number- Push wiring-harness end of plug 1 into the holder of plate carrier protective plug 2. Make sure the ground is level and firm and place the motorcycle on its stand. Remove the seat. Remove screws 4 and screw 5. Remove the number-plate carrier and thread out the Remove screws 3 on left...

  • Page 15: Carrier

    Installing number- plate carrier Install screws 4 and Install screws 3 on left and screw 5. right. Disconnect the number- Remove screws 4. plate plug and the protect- Manoeuvre the cables into ive plug. place and hold the number- plate carrier in position. Remove wiring-harness end of plug 1 from the holder.

  • Page 16: Removing Mirror

    Seat protective plug 2 in its Installing mirrors Installing headlight holder. guard Install the seat. Use the headlight guard only when off-roading. Removing mirror Riding on public roads with the headlight guard fitted to the motorcycle is prohibited. Install clamping piece 3. Clamping piece to clamping block 30 Nm...

  • Page 17: Installing Guard For Final Drive

    Installing guard for final drive Bend the headlight guard Position guard for final down at the front and use drive 3 on the attachment cable ties 3 to mudguard and secure it with screw 4. Insert attachment 1 long struts 4. Guard, final-drive housing end toward the rear into 8 Nm...

  • Page 18: Installing Cylinder Guard

    Installing cylinder In order to avoid injury, be sure to turn the cable guard tie so that the lock is at the back. Installing deflector for footbrake lever Working from the inside, insert the front reinforcing plate into the cylinder Remove screw 1.

  • Page 19: Installing Left And Right Hand Protectors

    Insert screw 3 through eye 4 and install it in the motorcycle's frame. Align the eye as shown in the illustration. Footbrake lever deflector to frame 5 Nm Remember to remove the deflector for the footbrake Remove screws 1 and Install screws 1 of the mirror lever before you next use remove top part of mirror...
  • Page 20 Use screws 6 and Use screw 7 and washer to washers to secure the secure the hand-protector Position holders 3 in such hand-protector holder to holder to the mirror clamp- a way that the cables pass the hand protector. Use ing block.
  • Page 21 holder is the same width at front and rear. Clamp to clamping block 4 Nm Installing mirrors (...

  • Page 22: Replacing Left And Right Hand Frame- Protector Strips

    Replacing left and right hand frame- protector strips Positions of the left and right protector strips to be checked and, if ne- cessary, replaced...

  • Page 23: Maintenance

    Maintenance Work to be carried out always before off-roading ... . . 20 Work to be carried out after five hours of riding in sand, dust or mud ......20 Work to be carried out after ten hours off-roading .

  • Page 24: Work To Be Carried Out Always Before Off-Roading

    Remove screws 1. BMW Motorrad dealer. Repair manual on CD-ROM Remove the cover of the / Construction group 34 / alternator drive belt. Work to be carried...
  • Page 25 Make sure the ground is for cracks and wear. level and firm and place the If the belt is cracked or badly motorcycle on its stand. worn: Have the alternator drive belt replaced by a special- ist workshop, preferably an authorised BMW Motorrad dealer.
  • Page 26 Check the air filter for dirt. If the air filter is dirty: Tap the air filter to remove foreign matter; replace if ne- cessary Remove retaining clips 1. Pull air intake 2 to one side out of mount 3 and remove it from the air filter box.
  • Page 27 the throttle valve is seated against the stop. Working from the side, slip Push in retaining clips 1. air intake 2 into mount 3 The retaining clips engage and the guides on the air with an audible click. Install right side panel with filter box.
  • Page 28 If parts of the deflector for the footbrake lever are bent: workshop, preferably an Check the ease of move- authorised BMW Motorrad Replace the deflector for ment of lever pivot 1. dealer. the footbrake lever. Check the ease of move- ment at pivots 2 and 3.

  • Page 29: Work To Be Carried Out After Ten Hours Off-Roading

    Cleaning slider tubes Work to be carried Make sure the ground is out after ten hours level and firm and place the off-roading motorcycle on its stand. Work already described Checking air filter for dirt Checking ease of move- ment of footbrake lever Push left and right sealing boots 1 down.
  • Page 30 BMW Motorrad dealer. in the bearing. If there is play in the wheel Checking wheel bearing bearing: for play...
  • Page 31 1 fork bridge. workshop, preferably an and check left and right authorised BMW Motorrad slip-rings 2 for wear. dealer. If evidence of wear is visible: Check operation of side- Have the condition of the...
  • Page 32 Have the side-stand switch Repeat this check at bottom checked by a specialist spring-strut mount 2. workshop, preferably an If the mounts are not free of authorised BMW Motorrad play: dealer. Have the spring-strut Checking spring-strut mounts checked by a...

  • Page 33: Work To Be Undertaken Once A

    Paralever bearing. cialist workshop, preferably of cracks. Move the rear wheel to left an authorised BMW Motor- If the flexible gaiter has and right, while checking for rad dealer. worked loose or if cracks are play in Paralever bearing 1.

  • Page 35: Threaded Fasteners

    Threaded fasteners Anchorage points, engine and swinging arm ....33 Anchorage points, frame and mounted components ..34 Anchorage points, front .

  • Page 37: Anchorage Points, Engine And Swinging Arm

    Anchorage points, en- gine and swinging arm Rear frame section to engine at top, left and right Frame front section to engine, left and right Rear frame section to en- gine at bottom, left and right Swinging arm to rear frame section, right Reaction link to frame Reaction link to final-...

  • Page 38: Anchorage Points, Frame And Mounted Components

    Anchorage points, frame and mounted components Frame front section to rear frame section, left and right Spring strut to rear frame Spring strut to rear swinging arm Rear carrier to rear frame section, left and right Rear wheel to wheel car- rier Rear silencer to rear frame section...
  • Page 39 If a locking compound is specified for a threaded fastener in the table of torques, be sure to comply with the instructions in the appropriate chapter of the Repair Manual on CD-ROM.

  • Page 40: Front

    Anchorage points, front Front mudguard to head- light, left and right Mudguard carrier to top fork bridge, left and right Handlebars to handlebar clamping blocks, left and right Handlebar clamping block to fork bridge Fork bridge to steering tube Top fork bridge to fixed fork tube, left and right Bottom fork bridge to fixed fork tube, left and...
  • Page 41 appropriate chapter of the Repair Manual on CD-ROM.

  • Page 42: Threaded Fasteners, Front

    Threaded fasteners, Body-panel screws front wheel The body-panels crews listed below are locked by means of nylon thread and are hand- tightened. Check the locking effect of the nylon threads and the se- curity of the screws. Body-panel screws Five screws in each front body panel, left and right.

  • Page 43: Technical Data

    Technical data Tightening torques for internally mounted components ..40 Tightening torques for checking threading fasteners ... . 42...

  • Page 44: Tightening Torques For Internally Mounted Components

    Tightening torques for internally mounted components Activity Type of threaded connection Tightening torques Mirrors Clamping piece to clamping block M10 30 Nm Mirror to clamping piece 25 Nm Guard for final drive Guard, final-drive housing 8 Nm Cylinder guard Cylinder guard to engine M6 x 20, Mechanical thread lock 8 Nm Deflector, footbrake lever...
  • Page 45 Activity Type of threaded connection Tightening torques Hand protectors Handlebar fitting to handlebar M5 x 20 5 Nm Hand protector to holder for hand M5 x 14 3 Nm protector Holder for hand protector to mirror M5 x 14 3 Nm clamping block Hand protector to clamping block M8 x 16 3 Nm...

  • Page 46: Fasteners

    Tightening torques for checking threading fasteners Activity Type of threaded connection Tightening torques Frame Frame front section to rear frame M8 x 20 19 Nm section Frame front section to engine M12, Micro-encapsulated 66 Nm front / rear Rear frame to engine, bottom M12 x 50 55 Nm Rear frame to engine, top...
  • Page 47 Activity Type of threaded connection Tightening torques Rear wheel swinging arm Swinging arm to rear frame sec- M24 x 1.25 145 Nm tion, left, locknut Swinging arm to rear frame sec- M24 x 1.25 7 Nm tion, left, bearing stud Swinging arm to rear frame sec- 9 Nm tion, right...
  • Page 48 Activity Type of threaded connection Tightening torques Rear silencer Rear silencer to rear frame section M8 x 45 19 Nm Handlebars Handlebar clamping block to fork M10 x 100, grease thread, Optimoly TA 38 Nm bridge Handlebar to handlebar clamping M8 x 30, grease thread, Optimoly TA 19 Nm block...
  • Page 49 Activity Type of threaded connection Tightening torques Front wheel Front wheel, axle screw in axle M22 x 1.5 - Elox H, Optimoly TA 50 Nm holder Pinch bolt, axle holder M6 x 30 8 Nm...
  • Page 50 Flexible gaiter Abbreviations and symbols, 4 Number-plate carrier Test, 29 Installation, 11 Accessories Footbrake lever Installation, 6, 9 Removal, 10 Test, 23 Air filter Frame-protector strips Test, 21 Overview, 18 Paralever Alternator drive belt Checking bearing, 29 Test, 20 Hand protectors Installation, 15 Shift lever Brake discs...
  • Page 51 Swinging arm Checking bearing, 28 Telescopic fork Bleeding, 27 Changing oil, 29 Checking protector, 26 Threaded fasteners Body panels, 38 Engine and swinging arm, 33 Frame and mounted components, 34 General view, front, 36 General view, front wheel, 38 Test, 29 Torques, 40 Wheel bearing Test, 26...

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