BMW K 1100 LT/RS Repair Manual
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BMW K 1100 LT/RS Repair Manual

BMW K 1100 LT/RS Repair Manual

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Repair Manual
K 1100 LT/RS
BMW AG Motorcycle Division
After Sales

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Summary of Contents for BMW K 1100 LT/RS

  • Page 1 Repair Manual K 1100 LT/RS BMW AG Motorcycle Division After Sales...
  • Page 2 Published by BMW AG Motorcycle Division 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 5/99...

  • Page 3: Ux-Vs

    Service quality. All information in both text and illustrations refers to motorcycles in standard condition or with genuine BMW accessories installed, and not to motorcycles which have been modified in any way to depart from the manufacturer’s specification. The repair manual is structured in the logical sequence of the work to be performed: Removal, Disas- •...

  • Page 4: Maintenance And General Instructions

    Usage Each chapter starts with the list of contents. The list of contents is followed by the Technical Data table. Chapter 00 “Maintenance and general instructions” details the handover checklist and lists all tightening torques and operating fluids. Key to symbols In this Workshop Manual for the K 1200 LT model, the following symbols are used;...
  • Page 5 BMW AG Motorcycle Division Maintenance Schedule K 75 RT/K 1100 RS/LT (from 1993 onlys) Customer Registration No. Order No. Signature of mechanic Change oil when engine at regular operating temperature, renew oil filter element Change oil in gearbox, final drive and telescopic fork...
  • Page 6 BMW AG Motorcycle Division Pre-delivery Check K 75 RT/K 1100 RS/LT (from 1993 onlys) Customer Registration No. Pre-delivery check Order No. Signature of mechanic Inspect crates on receipt for signs of damage Motorcycle: – unpack – check scope of delivery –...

  • Page 7: Table Of Contents

    Contents Group / Chapter 00 Maintenance and general instructions ..........00.1 11 Motor ......................11.1 12 Engine electrics ..................12.1 13 Fuel preparation and control ..............13.1 16 Fuel tank and lines.................. 16.1 17 Radiator ....................17.1 18 Exhaust system ..................18.1 21 Clutch.......................
  • Page 8 Group / Chapter 33 Rear wheel drive ..................33.1 34 Brakes ...................... 34.1 36 Wheels and tyres..................36.1 46 Frame ....................... 46.1 51 Equipment....................51.1 61 General electrical equipment ..............61.1 62 Instruments....................62.1 63 Lights......................63.1...
  • Page 9 00 Maintenance and general instructions Contents Page Tightening torque .........................3 Table of operating fluids ......................10 Key to maintenance intervals ....................11 Changing engine oil ........................11 Inspections I, II, III, IV Changing oil in transmission (gearbox) ................11 Inspections I, III, IV Changing oil in rear wheel drive ..................12 Inspections I, III, IV Changing oil in telescopic fork...
  • Page 10 Contents Page Checking function of electric switch on side stand and adjusting if necessary ....................17 Inspections I, II, III Checking clutch clearance and adjusting if necessary ........18 Inspections I, III Reading out Motronic defect code memory ...............18 Inspections II, III Checking increased starting speed (choke) and adjusting if necessary ..19 Inspections I, III...
  • Page 11 Tightening torque Model K 1100 LT K 1100 RS Connection 11 Engine Freewheel Cover plate/freewheel cage at countershaft gear Oil – water pump Oil pressure switch Temperature sensor/screw plug Pressure relief valve Impeller Pump housing to crankcase Cover to pump housing 10 (3-Bond 1209) Intermediate flange Thrust plate at intermediate flange...
  • Page 12 Model K 1100 LT K 1100 RS Connection Timing chain Chain tensioner Slide rail at camshaft bearing cap Timing case cover Timing case cover 10 (3-Bond 1209) Cover for Hall-effect signal transmitter Screw plug Clutch Clutch housing to output shaft Tighten to Release and re-tighten to Wrench angle...
  • Page 13 Model K 1100 LT K 1100 RS Connection 13 Fuel preparation and control Injection rail Intake stub pipe Lower section of air cleaner housing Intake air line Motronic control unit 17 Radiator Connecting screw, temperature sensor Fastening, thermostat cover Radiator to frame Coolant stub pipe to cylinder head (with Loctite 243) Temperature sensor to coolant stub pipe...
  • Page 14 Model K 1100 LT K 1100 RS Connection 23 Transmission Transmission cover to transmission Machine screw for neutral stop Stud bolt, selector shaft 17 (Loctite 243) Transmission to intermediate flange Frame mounting to transmission Bearing mount to transmission 41 (Loctite 243) Starter motor to transmission Positive lead to starter motor Fixed bearing of swinging arm to transmission...

  • Page 15: Steering

    Model K 1100 LT K 1100 RS Connection 32 Steering Clamping screws for handlebar fitting Clamping screws Clamping block to fork bridge 33 Rear wheel drive Threaded ring 118 (clean thread + Hylomar SQ 32M) Hexagon nut, drive bevel gear 200 (clean thread + Loctite 273) Housing cover Swinging arm fixed bearing to transmission...

  • Page 16: Brakes

    Model K 1100 LT K 1100 RS Connection 34 Brakes ABS pulse wheel ABS sensor front/rear Brake caliperto sliding tube/rear wheel drive Brake line to brake caliper Bleed screws at brake caliper front Bleed screws at brake caliper rear Brake hose to distributor Brake hose to master brake cylinder Brake disc to front wheel Brake disc to rear wheel drive...

  • Page 17: Equipment

    Model K 1100 LT K 1100 RS Connection 46 Frame Frame to engine Fairing support bracket to frame Suspension strut to frame/rear wheel drive Handlebar to clamping block Clamping screws of fork bridge Locking tube Hexagon nut Centre stand to bearing block Side stand to bearing block Footrest plate Brake line to handbrake cylinder...

  • Page 18: Table Of Operating Fluids

    Table of operating fluids Item Order number Quantity Lubricant 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 Wheel, steering head and taper roller...

  • Page 19: Key To Maintenance Intervals

    Key to maintenance intervals • Replace O-ring in cover, if necessary. – Inspection at 1000 km (600 miles)I – BMW Service at 10,000 km (6000 miles))II Tightening torques: – BMW Inspection at 20,000 km (12,000 miles)III Oil drain plug..........18 Nm –...

  • Page 20: Changing Oil In Rear Wheel Drive

    Pump out oil by compressing forks several times. • Screw in oil filler plugs. • Lift vehicle with lifting gear, BMW No. 00 1 510, Inspections I, III, IV until the front wheel can move freely. Note: The load on the front wheel must be relieved to en-...

  • Page 21: Renewing Fuel Filter

    LT000070 Renewing fuel filter Cleaning inductive pulse generator at rear wheel drive Inspection III Inspections I, III, IV • If necessary, reduce fuel level with pump until fil- ter is clear. • Loosen hose clip (1) and shift towards filter. •...

  • Page 22: Checking Brake Pads, Brake Discs For Wear And Renewing If Necessary

    Mininum pad thickness on carrier plate..1.5 mm ..............(0.06 in) Wear limit of brake disc ....... 4.5 mm ..............(0.177 in) 34 1 500 LT000100 Note: Before installing the brake caliper, completely press back pistons with resetting tool (1), BMW No. 34 1 500. 00.14...

  • Page 23: Checking Brake System

    Checking brake fluid level and cor- Checking ABS sensor spacing and recting if necessary adjusting if necessary Inspections I, II, III Inspections I, II, III Checking brake fluid level Front sensor Max. Max. Min. Min. LT000310 LT000130 • Check sensor spacing with feeler gauge. Note: When checking front brake fluid level, the cover of Sensor spacing ......

  • Page 24: Renewing Brake Fluid

    LT000100 Do not release the brake pedal until the bleed screws have been closed. • Using piston resetting tool, BMW No. 34 1 500, press the pistons fully back into the brake cali- pers. • Take out the piston resetting tool and insert spacer, BMW No.
  • Page 25 LT000150 Checking function of electric switch Caution: on side stand and adjusting if nec- Bending the contact spring can result in malfunc- essary tioning of the switch. Therefore: Inspections I, II, III Never bend the contact spring! • • Place motorcycle on centre stand on even sur- Operate starter while slowly folding in the side face or lifting platform.

  • Page 26: And Adjusting If Necessary

    Slightly push back rubber sleeve (2). • With the aid of setting gauge, Caution: BMW No. 21 3 500,set dimension “b” with ad- Adjust to take up wear only at the adjusting screw justing screw at clutch hand lever. on the clutch release lever.

  • Page 27: Checking Increased Starting Speed (Choke) And Adjusting If Necessary

    LT130030 Checking increased starting speed (choke) and adjusting if necessary Inspections I, III Checking increased starting speed • Remove the left battery cover. • Move the increased starting speed device up to its limit stop (stage 2). Caution: Screw (2) is secured with lacquer and must not be reset.

  • Page 28: Checking Valve Clearance And Adjusting If Necessary

    • The setting device for the camshafts, Remove chain guide from stud bolt. • BMW No. 11 3 700, must fit in the slots at the First remove thrust bearing of camshafts to avoid ends of the shafts. misalignment. •...
  • Page 29 • The grooves at the front end must face the inside towards the crankshaft. • Fit setting device, BMW No. 11 3 700, and se- cure to the bearings of the camshaft. 00.21...
  • Page 30 Tightening torque: Cylinder head cover to cylinder head .... 9 Nm LT000230 • Screw fitted bolt, BMW No. 11 1 980, (arrow) into inner hole at the front. • Press centring pin, BMW No. 11 1 990, with gripper, BMW No. 00 5 500, into locating hole under the third camshaft bearing.

  • Page 31: Checking Steering Bearing Play And Adjusting If Necessary

    (2). Hexagon nut ..........65 Nm • Slide thrust ring (3), BMW No. 31 4 890, over the Clamping screws of fork bridge (6) ....15 Nm locking tube (4). Clamping block for handlebar ...... 22 Nm •...

  • Page 32: Lubricating Guide Pins, Adjustable Screen

    LT000260 Lubricating guide pins, adjustable screen Inspections III, IV • Release retaining screw (1) on both sides. • Slightly raise plate (2). • Spray guide pins (3) with silicone spray. 00.24...
  • Page 33 • Remove caps (1) at the vacuum connections. • Connect hoses of the synchrotester, BMW No. 13 0 800, in the specified order (note markings 1 - 4 on tester housing). • Connect tester to motocycle’s power socket with the corresponding adapter lead.
  • Page 34 If necessary, perform fault diagnosis, rectify the fault and cancel the memory entry. • Note: Using the BMW synchrotester, adjust idle speed Engine must be at operating temperature (85 °C). at the recirculating-air screws. The basic settings (ignition, valve clearance) must be correct.

  • Page 35: Motor

    11 Motor Contents Page Technical data ..........................5 Removing engine ........................11 Dismantling engine ........................12 Removing intermediate flange ....................13 Removing driver ..........................13 Removing clutch housing ........................14 Stripping down and re-assembling intermediate flange ..........15 Removing the driver bearing ......................15 Installing driver bearing ........................15 Removing and installing shaft sealing ring for driver ................16 Removing countershaft and layshaft with freewheel .............16...
  • Page 36 Contents Page Removing pistons with conrods, stripping down and re-assembling ....26 Removing piston with conrod ......................26 Dismantling piston ..........................26 Checking piston dimensions ......................26 Assembling pistons ...........................27 Checking cylinder dimensions ......................27 Removing and installing small-end bushing ..................27 Assembling pistons and conrods ......................28 Removing and installing crankshaft pinion and rotor flange ........28 Removing, dismantling and assembling combined oil-water pump...
  • Page 37 Contents Page Installing timing chain ........................44 Checking valve clearances .......................45 Installing intermediate flange ....................46 Installing freewheel ..........................46 Installing countershaft ........................46 Installing intermediate flange ......................46 Installing driver ..........................46 Installing alternator ........................46 Installing timing case cover ......................47 Installing hall-effect transmitter ....................47 Installing cover for Hall-effect transmitter ................48 Installing cylinder head cover ....................49...
  • Page 38 11.4...
  • Page 39 Technical data K 1100 LT K 1100 RS Engine, general Engine design Inline four-stroke engine installed longitudinally, with double overhead camshafts, liquid cooling and electronic fuel injection. Location of engine number At lower rear right of engine block Cylinder bore mm (in) 70.5 (2.77) Stroke mm (in) 70 (2.75)
  • Page 40 Technical data K 1100 LT K 1100 RS Valves Valve clearances with engine cold (max. 35 °C) Inlet valve mm (in) 0.15…0.20 (0.0059…0.0079) Exhaust valve mm (in) 0.25…0.30 (0.0098…0.0118) Valve timing at 5/100 mm (0.002 in) preload and 3 mm (0.118 in) lift Inlet opens 14°...
  • Page 41 Technical data K 1100 LT K 1100 RS Valves Valve guide dia. Extl. dia. mm (in) 11.533…11.544 (0.4541…0.4545) Intl. dia. mm (in) 6.0…6.012 (0.2362…0.2367) Wear limit mm (in) 6.1 (0.2402) Bore in cylinder head mm (in) 11.5…11.518 (0.4528…0.4535) Repair stage mm (in) 11.7…11.718 (0.4606…0.4613) Valve stem clearance Inlet...
  • Page 42 Technical data K 1100 LT K 1100 RS Crankshaft Main bearing and crankpin markings no colour spot Grinding stage 0 with colour spot Grinding stage 1 Width of guide bearing mm (in) 23.020…23.053 (0.9063…0.9076) Axial play mm (in) 0.080…0.183 (0.0031…0.0072) Wear limit mm (in) 0.250 (0.010) Main bearing dia.
  • Page 43 Technical data K 1100 LT K 1100 RS Piston rings 1st groove Rectangular-section Height mm (in) 1.175…1.190 (0.0462…0.0469) Wear limit mm (in) 1.100 (0.0433) Ring gap mm (in) 0.20…0.40 (0.0079…0.0157) Wear limit mm (in) 1.50 (0.059) Side clearance mm (in) 0.040…0.075 (0.0016…0.0030) Wear limit mm (in)
  • Page 44 11.10...

  • Page 45: Radiator

    (ABS II) Remove the ABS unit. • Detach the brake hose fastening at the battery Screw guide pins (1) und (2), BMW No. 23 1 820, • • carrier. into the holes with the reamed sleeve; the longer Remove the left footrest plate.
  • Page 46 Remove fuel injection rail. • Remove throttle rail. • 11 0 610 LT110060 Attach engine mount, BMW No. 11 0 610, to the • engine block. Lower the hoist and support the engine on as- • sembly stand, BMW No. 00 1 490.

  • Page 47: Removing Intermediate Flange

    LT110070 Removing intermediate flange Remove alternator. • Remove coils with holder. • Removing driver LT110080 To remove the screw, support the driver (arrow). • Pull the driver off by hand. • 11.13...
  • Page 48 Install the retaining device (arrow), Remove the intermediate flange. • • BMW No. 11 2 800, in the position illustrated. Unscrew hex nut (1) and take off thrust ring (2). • Push O-ring (3) forwards with the clutch housing •...

  • Page 49: Stripping Down And Re-Assembling Intermediate Flange

    • Cup spring (2) • Pull out ball bearing (3) with counter-support, • BMW No. 00 8 572, and internal puller 21/2, BMW No. 00 8 571. Seeger circlip (4) • Installing driver bearing Heat the intermediate flange at the bearing seat •...

  • Page 50: Removing Countershaft And Layshaft With Freewheel

    If the intermediate flange is installed, pull out the • sealing ring with an internal puller, BMW No. 00 5 010, and pressure head. Pre-shape the sealing ring, which must be dry, • with the thumb and drive it in with drift, BMW No.

  • Page 51: Dismantling And Assembling Freewheel

    Pull off freewheel cage (3). • Take out cup spring (4). • Pull needle roller bearing (6) out of the freewheel • gear with counter-holder, BMW No. 00 8 570, and internal puller 21/3, BMW No. 00 8 574. 11.17...
  • Page 52 Heat the bearing seat to 100 °C. • Pull out the bearing with counter-support, • BMW No. 00 8 570, and internal puller 21/3, BMW No. 00 8 574. If the bearing is defective and cannot be pulled • out, carefully cut through the needle roller sleeve with a grinder.

  • Page 53: Removing Timing Chain Cover

    Removing and installing sealing ring in timing case cover Drive the sealing ring out with a suitable drift. • Drive the sealing ring in from the inside using • handle, BMW No. 00 0 500, and drift, BMW No. 11 1 610. 11.19...

  • Page 54: Removing The Timing Chain

    • LT110790 tion of rotation (arrow). Pin (1) on the crankshaft must be aligned with the marking on the housing. Removing chain tensioner Secure chain tensioner (1) with clamp, • BMW No. 11 5 500, (arrow) and remove it. 11.20...
  • Page 55 LT110260 Removing camshaft chain sprockets Removing chain guide When taking out the retaining screws, hold the Remove keepers (2) and washers (3) at the pivot • • hexagon on the camshaft to prevent it from turn- pins. ing. Raise chain guide (4) slightly at the cylinder head •...
  • Page 56 Strike the cylinder head lightly with a plastic- • faced hammer to dislodge it. Removing bucket-type tappets Using special suction tool, BMW No. 11 3 251, • pull bucket tappets (5) out of the cylinder head. Make a note of which tappet belongs to which •...
  • Page 57 LT110280 Pull valve collets (1) out with a magnetic screw- • driver. Screw support plate, BMW No. 11 1 749, for the Release valve spring (3) and remove the various • • valve spring clamping tool on to the rear of the components.
  • Page 58 Insert the lower spring plate. • LT110320 Push assembly sleeve (arrow), • BMW No. 11 1 960, on to the valve stem. Drive in sealing ring (1) with drift, • BMW No. 11 5 601, until the drift reaches the cylinder head.

  • Page 59: Removing Crankshaft

    LT110330 Removing crankshaft Removing main bearings Take out all main bearing bolts except one (ar- • Removing big end bearings row). Move the piston in cylinders 1 and 4 to the bot- Take off the bearing caps. • • tom dead centre (BDC) position. Take out the last bolt.
  • Page 60 Dismantling piston Remove the circlip (1) at one side. • Press out piston pin (2) with drift, • BMW No. 11 2 930. Carefully remove piston rings (3). • Clean the piston. • LT110360 Measure piston diameter with a micrometer at •...
  • Page 61 Assembling pistons Removing and installing small-end bushing LT110370 LT110390 Install piston rings, using piston-ring pliers. Press out the small-end bushing. • • 1st groove: rectangular-section ring The gap in the new bushing, when pressed in, • 2nd groove: micro-chamfer ring (note pin must be at an angle of 60°...

  • Page 62: Removing And Installing Crankshaft Pinion And Rotor Flange

    Assembling pistons and conrods Note: [LT] Modified conrod length and pistons from 1993 model year on Comply with conrod weight tolerances. • Weight tolerance ..........± 4 g Assemble piston and conrod. • Note: The oil bore in the conrod eye is on top in the in- stalled position.
  • Page 63 LT110422 Removing, dismantling and assem- bling combined oil-water pump Removing pump Pull off the wires for the oil pressure and water • temperature display at the switch. Pull the wires out of the housing. • Remove housing cover (2) and loosen the gasket •...

  • Page 64: Oil Pressure Switch

    Using a 5 mm (0.2 in) wide screwdriver, carefully the open side downwards, using drift, • press out sealing ring (5). BMW No. 11 1 640, and handle, BMW No. 00 5 500. Removing pressure relief valve Press in slipring seal (6) with drift, •...

  • Page 65: Removing Output Shaft

    Oil the sealing face of the oil level sight glass • • light blows of a plastic-faced hammer. lightly and drive it in with a drift, BMW No. 00 5 550. Removing oil filter Unscrew oil filter (1) with the oil filter wrench, • BMW No. 11 4 650.

  • Page 66: Stripping And Assembling Output Shaft

    • Using two-arm puller, BMW No. 00 8 400, and • Stripping down output shaft thrust block, BMW No. 33 1 307, pull off ball Take off needle roller race (1) and circlip (2). bearing (8). • Pull output shaft (3) out of damper housing (4).
  • Page 67 Assembling tensioning gear Insert the tensioning spring. • Install tensioning gear with counter-holder, • BMW No. 12 4 600. Clamp the tensioning gear with damper housing • together into a vice with soft jaws. LT110490 Clamp the damper housing and the ball bearing •...

  • Page 68: Installing Output Shaft

    LT110510 Assembling engine Installing output shaft Push circlip (1) and needle roller sleeve (2) on to • the bearing point. Place the output shaft in the crankcase. • KR110521 Note: Gap of circlip (1) in crankcase (arrow). 11.34...
  • Page 69 LT110530 Assembling the crankcase Installing oil mesh strainer Note presence of O-ring (2). • Installing oil filter Coat the oil filter sealing ring with oil. • Do not tighten the oil filter more than half a turn • beyond the point where it makes contact. Installing oil sump Coat the sealing faces (which must be free from •...

  • Page 70: Measuring Crankshaft Bearing Play

    5 are not marked. LT110550 Measure bearing play with Plastigage Type Pg-1, • BMW No. 00 2 590. Place the Plastigage strip (arrow) over the entire • width of the bearing, 6…8 mm (0.24…0.32 in) from the centre.

  • Page 71: Checking Dimensions Of Crankshaft

    00 2 500 LT110570 Screw measuring fixture, • BMW No. 00 2 500, with dial gauge into the tapped hole for the timing case cover. Move the crankshaft from one limit to the other • and take the dial gauge reading.

  • Page 72: Installing Crankshaft

    LT110580 Installing crankshaft Oil the bearings lightly before inserting the crank- • shaft. Install the corresponding bearing caps with the • grooves aligned. Note: Bearing caps 1…3 are marked for identification; bearing caps 4 (thrust bearing) and 5 are not marked.

  • Page 73: Installing Piston With Conrod

    11 2 925 Oil the piston rings, piston skirt and cylinder wall • thoroughly. LT110600 Using tensioning strap, BMW No. 11 2 925, com- • press the piston rings. Insert the piston with conrod into the cylinder. • Drive the piston carefully into the cylinder with a •...

  • Page 74: Measuring Big End Bearing Play

    Place Plastigage strip (arrow), Type PG-1, Wear limit ......0.130 mm (0.0051 in) • BMW No. 00 2 590, over the entire width of the bearing, 6…8 mm (0.24…0.32 in) away from the If bearing shells are renewed, note paint marks •...

  • Page 75: Pump Housing To Crankcase

    Installing combined oil-water pump Apply a thin coat of 3-Bond 1209 to the sealing • faces, which must be free of oil and grease. Place O-ring on water passage. • Insert the input pinion into the output shaft with • an oiled O-ring.

  • Page 76: Installing Cylinder Head

    Tightening torque: Cylinder head bolts ........20 Nm Attach tighten angle measuring device, • BMW No. 11 2 500, using two T 50 Torx inserts, BMW No. 00 2 630. Tighten the cylinder head bolts, to the specified • torque and angle, as specified.

  • Page 77: Installing Camshafts

    Installing camshafts Note: Note correct identification of camshafts. Inlet side : three grooves after thrust bearing Exhaust side: two grooves after thrust bearing The camshaft bearing caps are also marked. • Inlet side: odd numbers Exhaust side: even numbers The numbers increase from the front (timing end) •...

  • Page 78: Installing Timing Chain

    (7) and secure. Tightening torque: Chain tensioner ..........9 Nm LT110670 Insert adjusting tool, BMW No. 11 3 700, and at- • tach it to the camshaft bearings. Place the timing chain in guide rail (1) and press •...

  • Page 79: Checking Valve Clearances

    LT110680 Press serrated washer (8) with eccentric shoul- • der into the chain guide rail spacing bushing by a small amount. Turn the serrated washer until the guide rail is • touching the outer edge of the cylinder head. Press the serrated washer in fully and allow it to •...

  • Page 80: Installing Intermediate Flange

    Attach the intermediate flange (with all collets in • position). Tighten screws with Torx insert, • BMW No. 00 2 600. Tightening torque: Intermediate flange......... 9 Nm Note: Note rubber filler in the starter motor area. 11.46...

  • Page 81: Lights

    LT110701 Installing timing case cover Installing hall-effect transmitter Apply a thin coat of 3-Bond 1209 to the sealing Screw adjusting disc (1) and gate rotor (2) to the • • faces, which must be free from oil and grease. crankshaft. Pass the wires for the telltale lights (oil pressure, •...
  • Page 82 LT110710 Installing cover for Hall-effect transmit- Install the wire for the Hall-effect transmitter with • rubber grommet (arrow) in the timing case cover. Secure the wire for the oil pressure telltale and • coolant temperature with clip (1). Install cover with cork gasket. •...

  • Page 83: Installing Cylinder Head Cover

    Take out the reamed and centering screw and in- • sert the remaining retaining screws. LT110720 Insert reamed bolt (arrow), BMW No. 11 1 980, • into inner front hole. Press centering pin, BMW No. 00 5 500, into •...

  • Page 84: Oil Sump

    • stated here: 1. Insert all 5 bolts loosely but do not screw them Attach hoist, BMW No. 00 1 510, to the oil sump. fully in. Insert a 1 mm thick spacing washer at the • Set the engine down on the hoist platform.
  • Page 85 Connect the engine wiring harness (coolant stub • pipe, throttle position sensor, CO detector, injec- tors, air cleaner housing). Attach cable straps (three) at fuel injection rail. • Attach wire cables for increased idle speed and • throttle operation. Throttle cable play....... 0.75 mm (0.03 in) Install the radiator.

  • Page 86: Cylinder Head Cover

    11 3 700 LT110800 The adjusting device for the camshafts, • BMW No. 11 3 700, must enter the slots at the end of the shafts. Remove the screw plug in the timing case cover. • 11.52...

  • Page 87: Engine Electrics

    12 Engine electrics Contents Page Technical data ..........................3 Removing and installing Hall generator ................5 Adjusting ignition timing ......................6 Removing and installing ignition coils ................8 Removing and installing ignition output stage ............9 Removing and installing alternator ..................10 Disassembling and assembling alternator ..............11 Alternator [only LT up to 1992 model year]...
  • Page 88 12.2...
  • Page 89 Technical data K 1100 LT K 1100 RS Starter Type Permanent magnet motor Gear ratio 27 : 1 Output kW 0,7 Alternator Type Three-phase alternator with integrated fully elec- tronic regulator Drive direct, gear ratio 1 : 1.5 Maximum output W/V 460/14 / –...
  • Page 90 12.4...
  • Page 91 LT120010 Removing and installing Hall gener- ator • Disconnect ground lead of battery and insulate. • Remove radiator cowling. • Remove fuel tank. • Disconnect Hall generator (1) plug connection. • Remove cover (2) together with gasket (3). • Remove base plate (4). •...

  • Page 92: Adjusting Ignition Timing

    Remove fuel tank. • Disconnect plug connection on Hall generator lead under the fuel tank. • Connect adapter lead (2), BMW No. 12 3 651, to Hall generator lead. • Connect ignition setting device (3), BMW No. 12 3 650,to adapter line.
  • Page 93 12 3 650 LT120040 • Loosen base plate (1) and turn to the left or right until diode (2) on ignition setting device goes out. Note: Ignition timing adjustment Turn to left Retard ignition Turn to right Advance ignition • Firmly tighten base plate.

  • Page 94: Removing And Installing Ignition Coils

    LT120050 Removing and installing ignition coils • Disconnect earth (ground) lead of battery and in- sulate. • Remove top (1) and bottom (2) ignition coil cover. • Disconnect plug connector (3) at the ignition coils. • Disconnect plug connector (4) for terminal “1” and “15”.

  • Page 95: Removing And Installing Ignition Output Stage

    LT120060 Removing and installing ignition output stage • Remove left battery bracket. • Disconnect earth (ground) lead of battery. • Remove ignition coils. • Remove ignition output stage (1). • Press retaining clip (2) and detach ignition output stage. • Install in the reverse order of removal.

  • Page 96: Removing And Installing Alternator

    LT120070 Removing and installing alternator • Remove right battery panel. • Remove Motronic control unit. • [ABS I] Remove ABS control unit. • Remove battery. • Remove cover (1). • Disconnect plug (2). • Remove alternator. • Install in the reverse order of removal. Tightening torque: Alternator ............

  • Page 97: Disassembling And Assembling Alternator

    LT120080 Disassembling and assembling • Remove coupling housing (2) with holding tool (3), BMW No. 12 4 600. alternator • Pull off fan wheel (4). • Remove key (5). Alternator • Release retaining screw (6) for bearing end plate. [only LT up to 1992 model year] •...
  • Page 98 Coat bearing seat in hous- ing with Molykote paste. LT120110 • Using the test probes of the BMW diagnosis test- , measure the resistance BMW No. 61 1 510 across the slip rings. Nominal resistance........7 ± 1...
  • Page 99 Checking armature for short to earth Checking stator winding for short to earth LT120120 LT120140 • • Check winding outputs individually with respect Measure resistance between slip rings and ar- to earth. mature. Note: Note: The resistance must be infinitely large. The resistance must be infinitely large.
  • Page 100 Release clips (2) and take off cover. • Remove voltage regulator (3) 12 4 600 LT120090 • Remove coupling housing (4), using counter- holder, BMW No. 12 4 600. • Assemble in the reverse order of work. Tightening torque: Coupling housing ......... 50 Nm 12.14...
  • Page 101 • Using BMW diagnostic tester, BMW No. 61 1 510, measure the resistance be- tween the sliprings. Measured result: ..... . .3...

  • Page 102: Removing And Installing Starter

    LT120150 Removing and installing starter • Remove control unit. • [ABS I] Remove control unit. • [ABS II] Drain front and rear brake systems. • [ABS II] Remove pressure modulator. • Remove battery. • Take off battery carrier. [ABS II] •...

  • Page 103: Disassembling And Assembling Starter

    LT120160 Disassembling and assembling starter • Clamp starter at retaining lugs in vice with jaw guards. • Release retaining bolts (1). • Detach bearing cap (2). • Check seal (3) and O-ring (4). • Pull out armature (5). • Note spacer washer (6) •...
  • Page 104 LT120170 Removing and installing brush holder Hexagon nut Outer insulator Carbon brush holder Brush retaining plate O-ring Inner insulator 12.18...
  • Page 105 LT120180 Renewing carbon brushes • With the aid of a small screwdriver, lift spring (1) and pull out carbon brush. Note: Fit carbon brush so that the chamfered side (arrow) faces towards the spring. 12.19...

  • Page 106: Checking Starter

    LT120190 Checking starter • Connect voltmeter between positive and nega- tive pole of battery. • Operate starter for 2...3 seconds. • Read off value. Note: If the read-off value is below 8 Volt, this indicates the battery does not have its full capacity. Note down value if measured value is above 8 Volt.

  • Page 107: Checking Starter Relay

    Checking starter relay LT120200 • Connect terminal 86 to positive battery terminal, terminal 85 to earth (ground). Note: The relay is defective if no switching noise can be heard. Check resistance if clear switching noise can be heard. Checking starter relay with ohmmeter LT120210 •...

  • Page 108: Troubleshooting On Alternator

    Troubleshooting Troubleshooting on alternator Alternator makes noises. Rework slip rings/replace carbon brushes. Do carbon brushes whistle? Battery produces excessive gas (vapour) Check contact between regulator/alternator and between alternator/diode carrier. Repair cable connections. Is contact poor? Check regulator. Renew regulator. Is regulator defective? Check battery.
  • Page 109 Indicator lamp lights at only half brightness intensity when engine running. Check contacts of cable connections. Repair cable connections/plug contacts. Do cable connections have poor contact. Check regulator. Renew regulator. Is regulator defective? Check carbon brushes. Renew carbon brushes. Are carbon brushes defective? Check rectifier.
  • Page 110 Indicator lamp lights at half or full brightness with engine running. Check regulator. Renew regulator. Is regulator defective? Check supply line. Repair break; Does supply line have break/short circuit? renew cable/connection elements. Check carbon brushes. Renew carbon brushes. Are carbon brushes defective? Check rotor winding.
  • Page 111 Indicator lamp does not light when engine is stationary and ignition switched on. Check indicator lamp. Replace indicator lamp. Is lamp defective? Check battery. Charge/renew battery. Is battery discharged/defective? Check alternator. Immediately disconnect charge line (discharge Has generator short at positive diode? when stationary).

  • Page 112: Troubleshooting On Starter

    Troubleshooting on starter Starter does not turn when start switch is operated. Switch on light. Does light operate? Check battery. Charge or renew battery. Is battery discharged, defective? Check power circuit. Repair break. Does power circuit have a break? 12.26...
  • Page 113 Starter does not turn when start switch is operated. Connect jumper at connection between termi- Switch on light. Does light operate? nal 50 and 30. Does starter turn? Check ignition switch and supply line. Is ignition switch defective? Replace ignition switch. Is there a break in supply line? Repair break.
  • Page 114 Starter turns too slowly, does not crank en- gine. Check battery voltage. Charge battery, replace if necessary. Is battery voltage too low? Check battery terminals. Clean poles and terminals, firmly tighten. Are terminals loose or oxidised? Check connections. Secure connections. Are connections loose? Check collector.

  • Page 115: Troubleshooting On Battery

    Troubleshooting on battery Battery produces excessive gas. Check battery. Renew battery. Is battery defective? Check contact between regulator/alternator and between alternator/diode carrier. Repair cable connections. Is contact poor? Check regulator. Renew regulator. Is regulator defective? Acid level too low. Check level. Top up with distilled water.
  • Page 116 Acid density too low. nein Check charge status of battery. Charge battery. Is battery discharged? Check acid concentration. Adjust acid concentration. Is acid concentration too low? Check line network. Is there short-circuit in line Check electrical system. network? Check alternator. Alternator does not charge Check generator/regulator;...
  • Page 117 Insufficient power output Check connection terminals. Clean/tighten terminals. Are terminals loose/oxidated? Check acid level. Top up with distilled water. Is level below top edge of plates? Check charge status. Charge battery/replace defective battery. Is charge too low? Battery constantly overcharged. Check charging system.
  • Page 118 12.32...

  • Page 119: Fuel Preparation And Control

    13 Fuel preparation and control Contents Page Technical data ..........................3 Adjusting idle speed ........................5 Checking start speed increase (choke), adjusting if necessary ......6 Checking start speed increase ....................6 Adjusting start speed increase ....................6 Adjusting CO value ........................7 Removing/installing and checking/adjusting throttle position sensor ...8 Removing and installing throttle position sensor ..............8...
  • Page 120 13.2...
  • Page 121 Technical data K 1100 LS K 1100 RS mm (in) 35 (1.37795) Inside ø of throttle stub pipe CO value % by vol. 1,5 ± 0,5 Idle speed rpm 950 ± 50 13.3...
  • Page 122 13.4...

  • Page 123: Adjusting Idle Speed

    Remove protective caps (1) at the vacuum con- nections. • Connect connection hoses of the Synchrotester, BMW No. 13 0 800, one after the other (note hose markings 1-4 on tester housing). • Connect tester to vehicle with the corresponding adapter lead.

  • Page 124: Checking Start Speed Increase (Choke), Adjusting If Necessary

    LT130030 Checking start speed increase (choke), adjusting if necessary Checking start speed increase • Remove left battery cover. • Set speed increase to limit stop (stage 2). Caution: Screw (2) is sealed with lacquer and must not be turned. Note: Stop face (1) must be in contact with screw (2) and the cable must have no play;...

  • Page 125: Adjusting Co Value

    Run the engine at idle speed. unit. • If necessary, carry out fault diagnosis, rectify the fault and cancel the memory entry. • Using the BMW Synchrotester, adust idle speed at the recirculating-air screws. CO value % by vol........1,5 ± 0,5 Idle speed ..........950 ±...

  • Page 126: Checking Trottle Position Sensor

    Adjusting throttle position sensor necessary after installing it again. Note: Note: See the booklet “BMW Diagnosis, Motronic MA 2.1 Only adjust if the throttle position sensor was re- with oxygen sensing” or “without oxygen sensing”, moved or renewed. or the booklet “BMW Diagnosis MA 2.2”.

  • Page 127: Removing And Installing Air Cleaner Insert

    LT130070 Removing and installing air cleaner insert • Remove both knee pads. • Remove fuel tank. • Remove left and right heat-insulating bulkhead. • Release front clip (1) and both rear clips (2). • Slightly raise top section of air cleaner housing and remove air cleaner element.

  • Page 128: Removing And Installing Air Cleaner Housing

    LT130080 Removing and installing air cleaner housing • Remove both knee pads. • Remove fuel tank. • Remove left and right side fairings. • Remove intake air guide. • Remove fairing retaining bracket on right. • Remove air cleaner. • Loosen wire retainer (1), disconnect multiplug (2) at air temperature sensor.
  • Page 129 LT130090 • Loosen and pull off oil return pipe (5). • Loosen and pull off air return pipe (6). • Pull top section of air cleaner housing (7) out to the right. • Remove bottom section of air cleaner housing. •...

  • Page 130: Removing And Installing Throttle Rail

    Install in the reverse order of removal. Note: Do not change the location of the hose clips on the throttle coupling unions. Firmly tighten hose clips at the air intake lines with special tool, BMW No. 31 1 500. 13.12...

  • Page 131: Removing And Installing Injectors

    LT130120 Removing and installing injectors Removing and installing intake stub pipe • Release wire retainer (1) and detach plug (2). • Release clip (3) at the injector and pull it out. • Install in the reverse order of removal. Note: Ensure that the O-ring on the injector is in good con- dition! LT130130...
  • Page 132 LT130140 Removing and installing Motronic control unit Caution: Disconnect earth (ground) lead at battery! • Release multiplug (1) and disconnect. • Detach Motronic control unit (2). Note: Take particular care when connecting the multiplug to ensure the lock engages. Tightening torque: Control unit ............

  • Page 133: Fuel Tank And Lines

    16 Fuel tank and lines Contents Page Technical data ..........................3 Removing and installing fuel tank ..................5 Removing and installing fuel filter ..................6 Removing and installing fuel level sensor ..............7 Removing and installing fuel pump ..................8 Checking fuel pump pressure ....................9 16.1...
  • Page 134 16.2...
  • Page 135 Technical data K 1100 LT K 1100 RS Fuel tank Tank capacity l (Imp.gal) 22 (4.84) incl. reserve capacity l (Imp.gal) 5 (1.1) Fuel pump Type Roller-cell pump Make Bosch Operating voltage V 12 Fuel pressure bar (psi) 2.5 (36.26) Delivery rate l/h (gal/h) 45 (9.9) 16.3...
  • Page 136 16.4...

  • Page 137: Removing And Installing Fuel Tank

    LT160010 Removing and installing fuel tank • Open seat. • Remove left/right knee pads. • Remove retaining clips (1). • Release fuel line (2) at fuel tank. • Release fuel line (3) at injector rail. • Disconnect plug (4). • Lift out fuel tank.

  • Page 138: Removing And Installing Fuel Filter

    LT160020 Removing and installing fuel filter • If necessary reduce fuel level with pump until fil- ter is accessible. • Loosen hose clip (1) and slide towards filter. • Disconnect line and pull filter with line out of the fuel tank. •...

  • Page 139: Removing And Installing Fuel Level Sensor

    LT160030 Removing and installing fuel level sensor • Removing and installing fuel level sensor • Remove and empty fuel tank. • Remove filler neck. • Release electrical connections (1/2) at the fuel pump. • Pull back insulation a little and remove fuel level pickup (3) from the outside.

  • Page 140: Removing And Installing Fuel Pump

    LT160040 Removing and installing fuel pump • Remove and empty fuel tank. • Remove filler neck. • Release electrical connections (1/2) at the fuel pump. • Release hose clips (3/4) and detach lines. • Compress clips (arrows) on retaining ring and pull out pump.

  • Page 141: Checking Fuel Pump Pressure

    16 1 500 LT160050 Checking fuel pump pressure • Connect test pressure gauge, BMW No. 16 1 500, on the delivery side. • Run engine at idle speed. Fuel pressure: Nominal value ......2.5 bar (36.26 psi) • If the fuel pressure is lower, check pump, fuel fil- ter and line.
  • Page 142 16.10...
  • Page 143 17 Radiator Contents Page Technical data ..........................3 Changing coolant .........................5 Draining coolant ..........................5 Filling with coolant ..........................5 Removing and installing thermostat ..................6 Checking thermostat ........................6 Removing and installing radiator ..................7 Removing and installing fan ....................8 Removing and installing coolant hoses ................9 Checking cooling system .......................10...
  • Page 144 17.2...
  • Page 145 Technical data K 1100 LT K 1100 RS Cooling system capacity l(Imp.gal) 3.0 (0.66) in expansion tank + 0.4 (0.088) Coolant Concentration down to - 28 °C) Antifreeze Water Only use nitride-free long-term frost and corro- sion protection agents Thermostat opens at °C 85 Cut-in temperature for fan °C 105...
  • Page 146 17.4...

  • Page 147: Changing Coolant

    LT170010 Changing coolant Filling with coolant Draining coolant • Remove fuel tank. • Release cap (1) on filler neck. • [RS] Remove lower section of fairing • Release screw plug (2) on water pump , or [RS] water temperature sensor [LT].

  • Page 148: Removing And Installing Thermostat

    LT170030 Removing and installing thermostat • Remove fuel tank. • Remove right side section of fairing. • Remove radiator cowling. • Remove cover (1). • Pull out thermostat (2). Checking thermostat • Heat up thermostat in water bath. • Check start of opening and fully open setting. Opening temperature: Start of opening ..........85 °C...

  • Page 149: Removing And Installing Radiator

    LT170040 Removing and installing radiator • Release connections (2,3,4) of the coolant hos- • Disconnect plug connection (5) for fan motor. • Remove fuel tank. • [RS] Remove bottom section of fairing • Remove left/right side fairing. • Remove radiator cowling. LT170060 •...

  • Page 150: Removing And Installing Fan

    LT170070 Removing and installing fan • Remove radiator. • Remove rubber ring (1) and spacer bush (2). • Release retaining bolts (3, 4). • Install in the reverse order of removal. 17.8...

  • Page 151: Removing And Installing Coolant Hoses

    LT170080 Removing and installing coolant hoses • Remove fuel tank. • [RS] Remove bottom section of fairing • Remove left/right side fairings. • Remove corresponding coolant hose. • Remove radiator in order to release connections on coolant filler neck (1). Note: Before screwing back in, clean the thread of micro- encapsulated screw (2) and secure it with...

  • Page 152: Checking Cooling System

    Checking cap for filler neck • Remove fuel tank. • Connect adapter (1), BMW No. 17 0 003, to pump, BMW No. 17 0 500. • Screw cap onto screw coupling (2), BMW No. 17 0 004, and connect to pump.

  • Page 153: Troubleshooting

    Troubleshooting Coolant temperature warning lamp lights Check coolant in expansion tank. Top up coolant. Is coolant level too low? Check thermostat. Replace thermostat. Is thermostat defective? Check water pump. Repair/renew water pump. Is water pump defective? Fan motor does not switch on. Check fuse F7.
  • Page 154 Übermäßiger Kühlmittelverlust. Check coolant circuit. Repair break. Has coolant circuit a break? 17.12...

  • Page 155: Exhaust System

    18 Exhaust system Contents Page Removing and installing exhaust system ................3 Removing and installing oxygen sensor ................4 18.1...
  • Page 156 18.2...

  • Page 157: Removing And Installing Exhaust System

    LT180010 Removing and installing exhaust system • Release mounting (1) on cylinder head. • Release mounting (2) on transmission. • Release mounting (3) on footrest plate. • - Detach plug connection for oxygen [CAT] sensor. Note: Use new sealing rings (4) during installation. Tightening torques : Exhaust system to cylinder head ....

  • Page 158: Removing And Installing Oxygen Sensor

    Removing and installing oxygen sensor LT180030 • Separate plug connection for oxygen sensor. LT180020 • Remove left footrest plate. • Unscrew oxygen sensor at hexagon. Note: Before installing, coat thread of oxygen sensor with Optimoly TA. Caution: Read out Motronic defect code memory after test run! Tightening torque: Oxygen sensor ........
  • Page 159 21 Clutch Contents Page Technical Data ..........................3 Removing clutch ...........................5 Removing clutch housing ......................7 Installing clutch housing ......................8 Installing clutch ..........................9 Adjusting clutch clearance ....................11 Removing and installing clutch thrust bearing ............12 Removing and installing clutch control rod ..............13 Removing and installing clutch release lever .............14 Troubleshooting...
  • Page 160 21.2...
  • Page 161 Technical Data K 1100 LT K 1100 RS Type of clutch Single dry plate clutch with diaphragm spring Outside -ø mm (in) 180 (7.0866) ± 1 (0.039379) diaphragm spring Total thickness of driving disc mm (in) 5.3 (0.20866) ± 0.25 (0.00984) (disc and lining) Minimum thickness of driving disc mm (in) 4.5 (0.177165)
  • Page 162 21.4...

  • Page 163: Removing Clutch

    00 1 510 LT210130 Removing clutch • Remove transmission together with the com- plete rear wheel drive and rear wheel. • Secure lifting gear, BMW No. 00 1 510, to the oil sump. • Remove main stand. • Remove rear mudguard. •...

  • Page 164: Housing Cover

    LT210060 • Release housing cover (2). • Remove clutch disc (3), pressure plate (4), diaphragm ring (5) and wire ring (6). 21.6...

  • Page 165: Removing Clutch Housing

    LT210030 Removing clutch housing Caution: If clutch housing is difficult to move, use three-point • Secure retaining fixture?(1), BMW No. 11 2 800, puller, BMW No. 33 1 830 , and pressure tool. as shown. Do not damage bushing for thrust bearing! •...

  • Page 166: Installing Clutch Housing

    LT210050 Installing clutch housing • Coat tapers in clutch housing with Optimoly MP 3 or similar. • Fit thrust washer (1) on the clutch housing. • Using retaining device, fit clutch housing in the correct position. • Install thrust ring (4) with new O-ring (3). •...

  • Page 167: Installing Clutch

    LT210010 Installing clutch • Grease all lubrication points with Optimoly MP 3. Lubrication points: Contact surfaces of pressure plate/diaphragm spring, wire ring, cone/tip of control rod. Note: Install diaphragm spring (2) with the convex curve facing towards the pressure plate (3). •...
  • Page 168 21 2 670 LT210020 • Release lower retaining bolt (1) of the ignition coil mounting. • Secure centring fixture (2), BMW No. 21 2 670, to intermediate flange. • Centre driving disc with corresponding centring pin (3). • Evenly tighten retaining bolts (4) crosswise.

  • Page 169: Adjusting Clutch Clearance

    • Re-attach clutch cable at clutch release lever. LT210090 • With the aid of box wrench, BMW No. 21 3 610, release locknut (6) of adjusting screw (7) on clutch release lever. • Unscrew adjusting screw by one to two turns, then screw in until pressure point can be felt.

  • Page 170: Removing And Installing Clutch Thrust Bearing

    LT210100 Removing and installing clutch thrust bearing • Remove rear wheel. • Remove exhaust system. • Detach clutch cable at clutch release lever (1). • Loosen retaining clip (2) at sealing gaiter. • Remove gaiter (3) with spring (4). • Remove thrust bearing (5) with pointed-nose pliers.
  • Page 171 LT210110 Removing and installing clutch con- trol rod • Remove rear wheel. • Remove exhaust system. • Remove clutch thrust bearing. • Remove clutch control rod (1) by pulling to the rear. • Install in the reverse order of removal. 21.13...

  • Page 172: Removing And Installing Clutch Release Lever

    LT210120 Removing and installing clutch release lever • Remove exhaust system. • Detach clutch cable at clutch release lever. • Remove retaining ring (4) and washer (3) on right-hand side. • Remove mounting pin (1) by pulling out to left. •...
  • Page 173 Troubleshooting Clutch slips. Check clutch clearance. Adjust clutch clearance. Replace clutch disc if Is clutch clearance incorrect? necessary. Check clutch lining. Replace thrust ring on transmission input shaft. Is clutch lining oiled? Renew clutch disc. Is clutch lining worn? Renew clutch disc. Clutch slips.
  • Page 174 Clutch operation difficult. Clutch too harsh? Check output shaft lubrication. Lubricate with Optimoly MP 3. Is output shaft not lubricated? 21.16...
  • Page 175 23 Gearbox Contents Page Technical Data ..........................3 Removing transmission (gearbox) ..................5 Preparatory work ..........................5 Removing starter ..........................6 Removing bearing mount with main stand ................7 Removing transmission (gearbox) ...................8 Disassembling transmission (gearbox) ................9 Removing transmission cover....................9 Disassembling/assembling transmission cover ..............10 Removing and installing bearing shell ....................10 Removing and installing shaft sealing ring on input shaft ..............10...
  • Page 176 Contents Page Disassembling and assembling output shaft ..............17 Removing ball bearing ........................17 Removing spur gears ........................18 Installing spur gears ..........................19 Installing transmission shafts ....................20 Installing gearshift forks ......................20 Measuring distances between transmission shafts ............21 Measuring bearing distance of shafts ....................21 Measuring transmission cover ......................22 Installing transmission cover ....................24...
  • Page 177 Technical Data K 1100 LT K 1100 RS Type of gearshift 5-speed transmission with dog-clutch engage- ment and integrated damper for all gears Type of gearshift With adjustable gearshift pedal and gear selector drum with overshoot protection Transmission ratio 1st gear 4.50 2nd gear 2.96...
  • Page 178 23.4...
  • Page 179 LT230430 Removing transmission (gearbox) • [ABS I] Remove holder for pressure modulators. • Remove ABS unit. [ABS II] • Remove battery carrier. Preparatory work • Remove starter motor. • Remove left fairing side section [RS] • Remove exhaust system. • Disconnect CAT plug connection for oxygen Note: sensor.

  • Page 180: Removing Starter

    LT230410 Removing starter • Release positive and negative lead at starter. • Release mounting. • Pull out starter. 23.6...

  • Page 181: Removing Bearing Mount With Main Stand

    Removing bearing mount with main stand 00 1 510 LT230500 • Secure lifting gear, BMW No. 00 1 510, to the oil sump and slightly raise engine. • Release mounting for main stand. Caution: The retaining bolts are micro-encapsulated and can therefore not be reused.
  • Page 182 LT230450 Removing transmission (gearbox) • Release retaining bolts. • Screw guide pins, BMW No. 23 1 820, in holes with fitted sleeve, long pin on right-hand side. • Slowly pull off gearbox. Caution: Hold gearbox at installation height until the control rod can be seen completely, otherwise it can easily bend.

  • Page 183: Removing Transmission Cover

    100°C LT230010 Disassembling transmission (gear- box) Removing transmission cover. • Secure gearbox with holder (arrow “A”), BMW No. 23 1 600, to assembly stand. • Engage neutral. • Release idle lock (1). • Remove coil (2) and ball (4). •...
  • Page 184 • Drive out shaft sealing ring with drift from the in- LT230020 side. • Fit new sealing ring with drift, BMW No. 23 1 770 • Heat bearing cover to 100 °C. and handle, BMW No. 00 5 500. •...

  • Page 185: Removing Gear Selector Drum

    Remove shafts (1) of gearshift forks. • Press pawl (2) towards the outside and secure with clamping fixture (arrow), BMW No. 11 5 500. • Tilt back input shaft by approx. 45° • Turn gearshift forks towards the outside until guide pins are free.

  • Page 186: Removing Transmission Shafts

    100°C LT230090 Removing transmission shafts Removing pawl • Heat bearing seat of input shaft (1) and the inter- mediate shaft (2) to 100 °C. • Pull out both shafts together. • Remove input shaft (3). LT230100 • Using drift, drive out vent (arrow) from the inside. •...

  • Page 187: Removing Selector Shaft

    Release setscrew (arrow) (secured with Loctite). • Pull out selector shaft together with gearshift le- • ver. Fit shaft sealing ring using drift, and handle, BMW No. 23 1 760 Removing segment BMW No. 00 5 500 LT230120 • Remove retaining ring (arrow). •...

  • Page 188: Removing And Installing Shaft Sealing Ring For Gear Selector Drum

    • Heat transmission housing to 100 °C. • Remove bearing shell with the aid of support, BMW No. 00 8 560, and internal extractor, BMW No. 00 8 563. • Fit new bearing shell in transmission housing while still hot.

  • Page 189: Disassembling And Assembling Input Shaft

    Remove retaining ring (1). sition. • • Using universal puller, BMW No. 00 7 500, and Fit retaining ring (1) in front of the taper roller pressure tool (arrow), remove spur gear (3) to- bearing. gether with taper roller bearing (2).
  • Page 190 00 7 500 LT230200 • Fit universal puller under the spur gear and pull down taper roller bearing as far as it will go on the retaining ring. Note: There must be no clearance between the bearing and retaining ring in order to precisely determine the thickness of the spacer! 23.16...
  • Page 191 As part of the overall dimension, the spacer ring is fitted between the spur gear for 1st and 4th gear. LT230220 • Clamp output shaft in vice with jaw guards. • Remove ball bearing with universal puller, BMW No. 00 7 500. 23.17...
  • Page 192 80°C LT230230 Removing spur gears • Remove spur gear for 1st (1) and 5th gear (2) with spacer shim rings. • Heat bearing bush (4) to 80 °C. LT230250 • Remove retaining ring (9). • Remove serrated washer (10). • Remove spur gear for 2nd gear (11).
  • Page 193 • Installing spur gears Turn output shaft in vice, splines facing down- ward. • Fit spur gear for 4th gear (1), claws facing down- ward. • Fit spacer shim ring. LT230260 • Slide serrated washer (10) over smooth end (ar- 125.8 -0.1 row) onto output shaft up to the bearing seat.
  • Page 194 80°C LT230290 Installing transmission shafts • Fit gearshift forks for 1st and 2nd gear (2) with short guide end facing downward in the upper • Heat bearing points for intermediate shaft and section of the output shaft. • output shaft in the housing to 80°C. Fit gearshift fork for 3rd and 4th gear (3) with •...
  • Page 195 LT230310 Measuring distances between trans- mission shafts Measuring bearing distance of shafts • Place transmission measuring plate, BMW No. 23 3 660 (arrow), on the transmission housing. • Measuring procedure for intermediate shaft and output shaft: Using depth gauge, , meas- BMW No.
  • Page 196 00 2 550 LT230330 Measuring transmission cover • Measure from the parting surface of the trans- mission cover to the base of the bearing seat. • Only applies to intermediate shaft and output shaft 00 2 550 LT230350 Cover dimension output shaft Dab = Cover dimension intermediate shaft Dzw =...
  • Page 197 Measuring distances between transmission shafts Example Output shaft Intermediate Input shaft Maße in mm (in) ”ab” shaft ”an” 30.00 30.00 30.00 (1.1811 in) (1.1811 in) (1.1811 in) measure! + M ( 5.45 6.05 -20.10 (0.2146 in) (0.2382 in) (-0.7913 in) 35.45 36.05 9.90...
  • Page 198 Installing transmission cover LT230380 • Thinly coat end cap (arrow) with LT230420 Three-Bond 1209 and knock in with drift by 8 mm (0.31496 in). • • Knock out cap (arrow) from the inside using a Fit idle lock (ball and spring) in idle position. •...
  • Page 199 Optimoly MP 3. 23 1 820 23 1 820 LT230470 • Screw guide pins, BMW No. 23 1 820, in the holes with centring sleeve in the intermediate flange. • Screw in long pin on right-hand side. 23 1 800 LT230530 •...
  • Page 200 LT230440 Installing bearing mount with main stand LT230520 • Note line arrangement for electrical side stand. LT230490 Note: Clean threaded holes in transmission and retaining bolts (recut thread). • Place switch (1) for electric side support on bear- ing mount, secure lead with cable clip (2). •...

  • Page 201: Starter To Transmission

    LT230410 Installing starter • [ABS I] Install support bracket for pressure mod- ulators. • Connect positive and negative leads. Note: Tightening torque: Note arrangement of wiring loom. Positive lead ..........5 Nm Starter to transmission ........9 Nm LT230510 23.27...

  • Page 202: Motronic Control Unit

    Re-assembling motorcycle • Install battery. • Intall Motronic control unit. • [ABS II] Install ABS unit. • Install battery. • Intall Motronic control unit. • [ABS I] Install control unit. • Install swinging arm. • Install footrest plates. • [ABS I] Install pressure modulators. •...

  • Page 203: Front Fork

    31 Front fork Inhalt Seite Technical Data ..........................3 Removing telescopic fork ......................5 Removing fork stabilisor ......................5 Removing telescopic fork without fork bridge ..............5 Removing telescopic fork with fork bridge ................5 Removing upper fork bridge ........................5 Removing and installing lower taper roller bearing ............6 Removing taper roller bearing ......................6 Installing taper roller bearing .......................6...
  • Page 204 31.2...
  • Page 205 Technical Data K 1100 LT K 1100 RS Front wheel castor mm (in) 95 (3.74) Steering angle ° 34 Spring travel (normal position, 75 kg load) mm (in) 135 (5.315) Test installation length of fixed tubes mm (in) ca. 210 (approx. 8.268) Fixed tube surface hart verchromt Fixed tube outside ø...
  • Page 206 31.4...

  • Page 207: Removing Telescopic Fork

    LT310010 Removing telescopic fork Removing telescopic fork without fork bridge • • Secure lifting gear, BMW No. 00 1 510, to oil Release clamping screws (1,2), pull down sump. telescopic fork and remove. • Remove fuel tank. • Remove front mudguard.

  • Page 208: Removing And Installing Lower Taper Roller Bearing

    Removing and installing lower taper Removing and installing upper taper roller bearing roller bearing Removing taper roller bearing Removing taper roller bearing LT310030 LT310040 • • Press down steering tube (1) by approx. 5 mm Using a drift, knock out taper roller bearing to- and press back again.

  • Page 209: Removing And Installing Bearing Outer Race In Steering Head

    With the aid of the spindle of the frame test gauge, BMW No. 46 5 604/605, in conjunction with the thrust piece, BMW No. 31 4 820, install bearing outer race (4) together with hexagon nut and washer to the limit stop.

  • Page 210: Measuring Telescopic Fork

    31 4 620 LT310070 Measuring telescopic fork • Place two test straight edges, BMW No. 31 4 620, over the upper and lower ends of the fixed tubes. • Note: Determine any distortion by visual alignment (ar- After a collision, the telescopic fork must be exam- rows).
  • Page 211 LT310090 Checking parallel alignment of fixed tubes • Clamp fork bridge at steering tube in vice with jaw guards. • Install upper fork bridge. Note: Fork bridge must slide smoothly on to fixed tubes. • Check parallel alignment of fixed tubes using slide gauge.
  • Page 212 LT310100 Checking runout of fixed tube • Place both ends of stanchion in V-blocks. • Slowly turn fixed tube while checking dial gauge. Caution: Distorted fixed tubes must not be straightened out! Permissible runout ....0.15 mm (0.0059 in) 31.10...

  • Page 213: Disassembling Telescopic Fork

    Using a small screwdriver, lever out retaining ring (2) for sealing ring. • Fit support ring (3), BMW No. 31 3 610, on slider tube. • Lever out shaft sealing ring (4) using a slightly rounded off screwdriver.

  • Page 214: Disassembling Fixed Tube

    Screw base screw fitting (arrow) loosely into Remove damper cartridge (5) with support spring damper cartridge. (6) and guide sleeve (7). • Lightly press damper cartridge into fixed tube using clamping fixture, BMW No. 31 5 550, and clamping insert, BMW No. 31 5 553. 31.12...
  • Page 215 LT310160 • Press apart plain bush (8) on the fixed tube (arrows) and remove. LT310170 • Slightly preform new plain bush in order to achieve an optimum fit on the fixed tube. 31.13...

  • Page 216: Assembling Telescopic Fork

    LT310140 • Loosely screw base screw fitting (arrow) into damper cartridge. • With the aid of clamping fixture, BMW No. 31 5 550, and clamping insert, BMW No. 31 5 553, lightly press damper car- tridge into fixed tube. 31.14...
  • Page 217 LT310150 • Fit spacer sleeve (4). • Fit perforated disc (3), smooth side facing down- ward. • Fit retainers (2) and relieve clamping fixture. • Screw in screw plug, renew seal if necessary. Tightening torque: Base screw fitting......... 20 Nm 31.15...

  • Page 218: Assembling Slider Tube

    ....0,40 - 0,01 l (0.704 - 0.0176 Imp. pt) New filling: left, right..0,40 - 0,01 l (0.704 - 0.0176 Imp. pt) 31 3 620 Tightening torque: Oil filler plug ..........10 Nm LT310220 • Fit drift, BMW No. 31 3 620, on to fixed tube and release. 31.16...

  • Page 219: Installing Telescopic Fork

    80°C LT310260 Installing telescopic fork • Grease taper roller bearing with Shell “Retinax A” or similar. • Fit telescopic fork from below into steering head. • Install setting ring (1), heat bearing 80 °C • Install upper fork bridge (2). •...
  • Page 220 (2). Locking tube ..........65 Nm • Fit thrust ring (3), BMW No. 31 4 890, over the Hexagon nut ..........65 Nm locking tube (4). Clamping screw of fork bridge (6)....15 Nm •...

  • Page 221: Installing Fork Stabilisor

    Installing fork stabilisor LT310020 • Install fork stabilisor, handtighten screws. • Install brake distributor (1). • Lay ABS sensor line (2) and connect. • Install fuel tank. • Install front wheel. • Install brake caliper. Note: Compress telescopic fork several times then firmly tighten fork stabiliser crosswise.
  • Page 222 31.20...
  • Page 223 32 Steering Contents Page Technical Data ..........................3 Removing and installing left and right handlebar fittings ........5 Removing and installing left handlebar fitting ..............5 Removing and installing handlebar weight ...................5 Removing and installing right handlebar fitting ..............7 Removing and installing handlebar ..................8 Removing and installing handlebar clamping blocks ............9...
  • Page 224 32.2...
  • Page 225 Technical Data K 1100 LT K 1100 RS Steering angle ° 2 x 34 Steering tube -ø mm (in) 22 (0.86614) Handlebar width with weights mm (in) 765 (30.11805) 700 (27.559) 32.3...
  • Page 226 32.4...
  • Page 227 LT320010 Removing and installing left and Removing and installing handlebar weight right handlebar fittings Removing and installing left handlebar fitting • Remove fuel tank. • Cut through cable clip (1) [LT] • Disconnect plug connection for clutch switch (2). • Detach cold start operating cable at lever (3).
  • Page 228 LT320030 • Cut open rubber grip (1) and remove. • Release multifunction switch (2). • Loosen clamping screw (3) of handlebar fitting. • Remove fitting from handlebar. • Install in the reverse order of removal. Note: Bond rubber grip with Loctite 454 on handlebar. Tightening torque: Clamping screw, handlebar fitting ....
  • Page 229 LT320040 Removing and installing right handle- • Remove fitting. • Cut through rubber grip and remove. bar fitting • Install in the reverse order of removal. • Remove fuel tank. • [LT] Cut through cable clip (1). • Disconnect plug connection (2) for brake light Caution: switch.
  • Page 230 LT320060 Removing and installing handlebar • Remove fuel tank. • Remove handlebar cover (1). • Disconnect plug connections for switches. • Remove left and right handlebar fittings. • Release top sections of clamping block (2). • Install in the reverse order of removal. Tightening torque: Clamping screws ..........
  • Page 231 LT320070 Removing and installing handlebar clamping blocks • Remove stop plate (3). • Remove clamping blocks (4). • Drive out handlebar mounting with drift. • Install in the reverse order of removal. Tightening torque: Clamping block ..........16 Nm 32.9...
  • Page 232 LT320080 Removing and installing accelera- tor cable • Remove fuel tank. • Remove cable cover (1) on handlebar fitting. • Detach cable. • Turn in cam disc on throttle stub pipe (2) and de- tach cable. • Install in the reverse order of removal. Note: When installing, first attach cable at cam disc.
  • Page 233 LT320090 Removing and installing clutch cable • Remove fuel tank. • Detach clutch cable (1) at clutch release lever. • Pull clutch hand lever and press out nipple (2). • Unscrew set screw (3) from fitting housing. • Cut through cable clip and pull out operating cable.
  • Page 234 LT320100 Removing and installing operating cable for increasing starting speed • Remove fuel tank. • Remove operating lever (1). • Detach cable (2). • On throttle rail, release locknut (3) from adjusting screw (4) and unscrew adjusting screw. • Detach nipple (5). •...
  • Page 235 Mark current position of setting ring (1) on adhe- Tightening torque: sive tape and on setting ring (2). • Slide thrust ring (3), BMW No. 31 4 890, over the Locking tube ..........65 Nm locking tube (4). Hexagon nut ..........65 Nm •...
  • Page 236 32.14...

  • Page 237: Housing Cover

    33 Rear wheel drive Contents Page Technical data ..........................3 Removing, disassembling, assembling and installing rear wheel drive ..5 Removing rear wheel drive ......................5 Removing, disassembling and assembling drive bevel gear ........5 Removing retaining ring ........................5 Disassembling drive bevel gear ......................7 Removing needle bearing for drive bevel gear ..................8 Installing needle bearing for drive bevel gear ..................8 Assembling drive bevel gear ........................9...
  • Page 238 33.2...
  • Page 239 SAE 80 W 90 Drive shaft Encapsulated in the one-arm swinging fork Arrangement (BMW PARALEVER), 2-piece double drive shaft with integrated torsion damper, universal joints on both ends, slide piece on axle drive end. Rear wheel suspension Spring strut...
  • Page 240 33.4...

  • Page 241: Removing Rear Wheel Drive

    120°C 120°C LT330350 Removing, disassembling, assem- Removing, disassembling and assem- bling and installing rear wheel drive bling drive bevel gear • Remove licence plate bracket. • Remove rear wheel. • Remove brake disc, mark position with ABS. Removing rear wheel drive •...
  • Page 242 Remove thrust ring (7). • Heat housing to 120 °C and release threaded ring (8) with pin wrench (2), BMW No. 33 1 700. • Heat bearing seat to 120 °C in order to remove the drive bevel gear (9).
  • Page 243 Clamp drive bevel gear (1) in vice with jaw guards (splines facing upward). 00 7 500 LT33040 • Using puller, BMW No. 00 7 500, remove both bearings at the same time. • Remove thrust bearing (4), inner race (5), bearing cage (6) and outer race (7).
  • Page 244 00 8 573 RT330060 • Remove outer race of needle bearing with the aid of inner extractor, BMW No. 00 8 573, and sup- port, BMW No. 00 8 570. Installing needle bearing for drive bevel gear • Heat bearing seat of needle bearing to 100 °C.
  • Page 245 100°C LT330070 Assembling drive bevel gear • Heat inner race (4) to 100 °C and slide onto drive bevel gear (1) as far as it will go. • Slide outer bearing race (2) together with cylin- der roller cage (3) onto inner race (4). •...

  • Page 246: Installing Drive Bevel Gear

    Nut for drive bevel gear • Drive sealing ring (2) into threaded rim (3) with (clean thread + Loctide 273)....... 200 Nm the aid of drift, BMW No. 33 1 760, and retainer, BMW No. 00 5 550. • Heat housing to 120 °C.

  • Page 247: Removing And Installing Taper Needle Bearing In Rear Wheel Drive

    00 8 573 00 8 572 RT33090 • Remove needle bearing using inner extractor 21/4, BMW No. 00 8 573, and support 22/1, BMW No. 00 8 572. • Heat housing neck to 120 °C. • Press in needle bearing with inner race on drift, BMW No.

  • Page 248: Removing Crown Wheel

    LT330130 RT330120 • Clamp ring gear in vice with jaw guards. • Fit pressure piece (arrow), BMW No. 33 1 307. • • Remove housing cover (1) with crown wheel (2) Using puller, BMW No. 33 1 830, remove deep- and bearing (3).

  • Page 249: Installing Crown Wheel

    • Heat housing to 80 °C. • Press outer race into bearing seat with drift, BMW No. 23 4 670, and handle, 00 8 560 BMW No. 00 5 500. Note: Check that outer race is correctly seated by light blows.

  • Page 250: Checking/Adjusting Tooth Backlash

    (1). (1.4173 in) insert, BMW No. 33 1 720. • Fit measuring ring, BMW No. 33 2 600, with dial Gear backlash: gauge on crown wheel and secure to housing (adjust without oil) ......0.07...0.16 mm with knurled screw (1).

  • Page 251: Checking Contact Pattern

    Checking contact pattern • The contact pattern must be checked when the set of gears, the housing or the bearing of the drive bevel gear has been replaced. LT330240 • If this contact pattern is obtained, a thinner spac- er ring must be installed. LT330220 Note: The contact pattern is set with the spacer ring?(1) on...

  • Page 252: Shimming Housing Cover

    Engage the retaining ring with light hammer blows (plastic-headed hammer). LT330270 • Fit measuring ring (arrow), BMW No. 33 2 601 • Measure from the outer race of the ball bearing to the parting surface of the housing through the cutout in the measuring ring.

  • Page 253: Installing Rear Wheel Drive

    LT330320 Installing rear wheel drive • Screw in the bearing pin of the loose bearing (3) with Loctite 2701. • Coat spline on sliding piece (arrow), for example with Optimoly MP3. • Fit inner race (5) of right-hand needle bearing Tightening torques: with a little grease, e.g.

  • Page 254: Brake Caliper

    LT330320 • • Apply a load of approx. 85 Kg (1887.43 lb)to the Install the rear wheel, insert the wheel studs and motorcycle and tighten loose strut (4) with the tighten them in the specified order. nut on the wheel side. Tightening torques: Tightening torques: wheel studs:...

  • Page 255: Removing, Disassembling And Assembling Rear Swinging Arm

    00 8 563 LT330370 • Remove taper roller bearing with support, 26 1 660 BMW No. 00 8 572, and internal extractor 21/2, BMW No. 00 8 571. • Remove outer bearing race with support, LT330310 BMW No. 00 8 572 and inner extractor 21/5, BMW No.

  • Page 256: Removing And Installing Gaiter

    Removing and installing gaiter Removing drive shaft LT330300 LT330380 • • Remove inner retaining ring, pull gaiter out of Press off drive shaft with screwdriver. swinging arm. • Install in the reverse order of removal. • Coat inside and outside (arrows) of sealing lip Caution: with, for example, Optimoly MP3.

  • Page 257: Installing Swinging Arm

    LT330310 • Coat bearing pin of fixed bearing with Optimoly TA and install and firmly tighten with special tool BMW No. 26 1 660 LT330390 • Install bracket (1) for line of electric side stand switch. Tightening torque: Swinging arm fixed bearing ......9 Nm •...
  • Page 258 33.22...
  • Page 259 34 Brakes Contents Page Technical Data ..........................3 Removing and installing front brake caliper ..............5 Dismantling and assembling front brake caliper ............6 Dismantling front brake caliper ....................6 Assembling front brake caliper ....................7 Removing and installing brake pads ..................8 Removing and installing front brake disc ...............9 Removing and installing ABS pulse wheel ................9...
  • Page 260 Contents Page [ABS II] Installing ABS unit ......................19 [ABS II] Removing and installing relay and relay base ..........20 [ABS II] Removing relay ......................20 [ABS II] Installing relay ........................20 [ABS II] Removing relay base ....................21 [ABS II] Installing relay base .....................21 Removing and installing rear brake caliper ..............22 Removing and installing rear brake pads...
  • Page 261 Technical Data K 1100 LT K 1100 RS Brake fluid DOT 4 Minimum brake pad thickness mm (in) 1.5 (0.059) Front wheel Brake disc Ø mm (in) 305 (12.01) ± 0.1 ± 0.0039 Brake disc thickness mm (in) 5 (0.197 Minimum thickness mm (in) 4.5 (0.177) Brake pad surface...
  • Page 262 34.4...

  • Page 263: Removing And Installing Front Brake Caliper

    LT340010 Removing and installing front brake • Release brake line at brake caliper and close off. caliper Caution: • Mask off brake caliper at top of wheel side with Ensure brake fluid does not come in contact with tape (rim guard). painted vehicle parts;...

  • Page 264: Dismantling And Assembling Front Brake Caliper

    34 1 500 LT340280 Dismantling and assembling front brake caliper • Hold a cloth over the brake caliper. • Caution: Carefully press out brake pistons (2), using a The brake caliper halves must not be unscrewed! compressed air gun at the brake line connection. Dismantling front brake caliper Caution: Do not allow your fingers to become trapped...

  • Page 265: Assembling Front Brake Caliper

    Coat brake caliper pistons (2) with brake fluid and insert. Caution: Do not tilt the brake pistons when installing. • Using piston resetting tool (5), BMW No. 34 1 500, press the pistons fully back. • Insert brake pads and secure with retainers. 34.7...

  • Page 266: Removing And Installing Brake Pads

    Minimum brake pad thickness: Thickness on carrier plate ......1.5 mm Note: Before installing the brake pad, completely press • Install in the reverse order of removal. back the pistons with the aid of the resetting tool (1), BMW No. 34 1 500. 34.8...

  • Page 267: Removing And Installing Front Brake Disc

    LT340050 Removing and installing front brake Removing and installing ABS pulse disc wheel • Remove front wheel. • Release retaining screws (1) for brake disc carri- • Detach brake disc carrier (2) with brake disc. LT340060 • Release pulse wheel on brake disc carrier. Tightening torque: Pulse wheel............

  • Page 268: Removing And Installing Front Abs Sensor

    Remove rear section of mudguard. • Detach cable clips. • Release sensor (2) with Torx socket, BMW No. 34 2 500. • Install in the reverse order of removal. Note: Carefully install the sensor line (arrow), note position and number of cable clips and ensure tyre can turn smoothly.

  • Page 269: Adjusting Front Abs Sensor Gap

    Raise front wheel with front wheel stand, BMW No. 36 3 950. • Secure dial gauge holder (1), BMW No. 34 2 520 Note: with dial gauge to fork sliding tube. If the pulse wheel has been replaced, its maximum •...

  • Page 270: Removing And Installing Front Brake Line

    LT340090 Removing and installing front brake Removing lower brake line line • Remove rear section of mudguard. Removing upper brake line • Drain brake system. • Remove fuel tank. • Release brake line (1) at handbrake cylinder. • Remove cover for brake distributor on mud- guard.

  • Page 271: Removing And Installing Abs Brake Line From Front Pressure Modulator

    LT340110 Removing and installing ABS brake line from front pressure modulator • Remove knee pads. • Remove fuel tank. • Release screw connections (1,2). • Release connections at pressure modulator (3). • Remove both lines together. • Release spacer (4) and replace defective line. •...

  • Page 272: Removing And Installing Handbrake Cylinder

    LT340120 Removing and installing handbrake cylinder • • Drain brake system. Check brake cylinder, piston and sealing rings. • Install in the reverse order of removal. Caution: Ensure brake fluid does not come in contact with Note: painted parts of the vehicle; brake fluid destroys the The sealing lips of the piston must face inwarde.

  • Page 273: Bleeding Brake

    • Take out the piston resetting tool, insert spacer, • Detach the cover from the brake fluid reservoir BMW No. 34 1 520, and move it up to the brake and remove it together with the diaphragm. disc. • •...

  • Page 274: Bleeding Rear Brake

    Bleeding rear brake [ABS II] Bleeding pressure modulator • Remove the left battery cover. • Connect a vessel to the brake caliper bleed Bleeding brake caliper screws to trap escaping brake fluid, then open • the bleed screw by half a turn. The rear brake caliper does not have to be remo •...

  • Page 275: Removing And Installing Pressure Modulator

    • Work on the ABS unit is only to be carried out by an Note earth (ground) wire (6). • authorised BMW workshop. Install in the reverse order of work. • Restore the correct brake fluide level and bleed the brake system.

  • Page 276: Abs Ii] Removing Abs Unit

    LT340250 [ABS II] Removing ABS unit • • Remove the dualseat. Secure the front brake lever to the handlebar • Remove the left and right battery trim panels. with a rubber band (so that the fluid replenishing • Remove the Motronic control unit. bore is close).

  • Page 277: [Abs Ii] Installing Abs Unit

    [ABS II] Installing ABS unit • Install ABS unit (6). • Reconnect central plug (5). Caution: Do not tilt the cables or the insulation may be dam- aged. • Push 2-pin plug (4) on correvtly and as far as it will do, then press the two wires into the centre (smal ler) cable entries.

  • Page 278: [Abs Ii] Removing And Installing Relay And Relay Base

    LT340270 [ABS II] Removing and installing [ABS II] Installing relay relay and relay base • Insert ABS relay with FAG logo in the direction of the retaining hook. • Tighten the screws at the relay base. [ABS II] Removing relay •...

  • Page 279: [Abs Ii] Removing Relay Base

    • Install a new cover (1). Caution: Caution: When pushing on, make sur that all cables are cor- The same Torx screws must be used because of rectly located in their guides. their self-locking acition. When inserting, make sure Scrap the old cover. that the thread already present in the sheet metal is entered again.

  • Page 280: Removing And Installing Rear Brake Caliper

    ..........(0.0236...0.0256 in) pinion in brake caliper with the aid of the piston re- From 1997 MY on ......0.45 - 0.55 mm setting tool (4), BMW No. 34 1 500..........(0.0177...0.0216 in) Removing and installing rear brake Caution:...

  • Page 281: Dismantling And Assembling Rear Brake Caliper

    LT340290 Dismantling and assembling rear Assembling rear brake caliper brake caliper • Coat the new sealing rings with brake fluid and insert them into the left/right brake caliper cylin- Dismantling rear brake caliper ders. • Remove keepers (1). • Drive out spring (2) and retaining pin (3). Caution: •...

  • Page 282: Removing And Installing Rear Brake Disc

    LT340150 Removing and installing rear brake disc • Remove brake caliper. • Remove rear wheel. • Remove brake disc. Note: Mark installation position of the brake disc so that the vertical runout of the pulse wheel is not changed. • Install in the reverse order of removal.

  • Page 283: Removing And Installing Rear Abs Sensor

    • Remove brake caliper but do not loosen brake line. • Release sensor with socket wrench, BMW No. 00 2 640. • Disconnect plug connection (1) for sensor line. • Install in the reverse order of removal. Caution: Check sensor spacing where the gap is greatest; if necessary, adjust with spacer plates (3).

  • Page 284: Measuring Vertical Runout At Rear Pulse Wheel

    Secure dial gauge with retaining fixture to bottom of spring strut mounting. • Position dial gauge with measuring shoe (1), BMW No. 34 2 510, on pulse wheel. • Set dial gauge to zero. • Measure vertical runout over the entire circum- ference.

  • Page 285: Removing And Installing Rear Master Brake Cylinder

    LT340180 Removing and installing rear master brake cylinder • Drain brake system. • Note spacer sleeve (3); spring is under pressure. • Open clip (4) on the supply line, detach line. • Caution: Install in the reverse order of removal. Ensure brake fluid does not come in contact with painted parts of the vehicle;...

  • Page 286: Disassembling Rear Master Brake Cylinder

    LT340200 Disassembling rear master brake cyl- inder Caution: Piston is under spring loading. • Using thrust piece (1), push piston (2) a little way inwards. • Press out stop screw (3). • Pull out piston with spring (4). • Loosen spring from ring groove. •...

  • Page 287: Removing And Installing Brake Pedal

    LT340210 Removing and installing brake pedal • Remove footrest plate. • Detach sealing gaiter (1) at master brake cylin- der. • Release mounting (2) for brake pedal. Caution: Spring is under tension. • Remove bearing bush (3). • Install in the reverse order of removal. Note: Grease bearing bush with „Shell Retinax A“...

  • Page 288: Adjusting Foot Brake Pedal

    LT340220 Adjusting foot brake pedal • Loosen locknut (1). • Perform basic setting with adjusting screw (2). • Adjust distance „A“ with feeler gauge. Basic setting: Distance „A“ ......0.2 mm (0.00787 in) • Turn adjusting screw (3) on master brake cylinder until slight resistance is felt when the foot brake pedal is operated.

  • Page 289: Troubleshooting: Front Wheel/Rear Wheel Brake

    Troubleshooting: Front wheel/rear wheel brake Brake rubs/vibrates. Check brake pads. Renew brake pads. Are brake pads worn/damaged? Brake pedal soft/spongy. Check brake fluid. Top up brake fluid to MAX level. Is brake fluid too low? Check brake system. Bleed brake system. Is there air in brake system? Check brake system.
  • Page 290 Reduced brake effect when applied hard? Check brake fluid. Renew brake fluid. Has brake fluid aged? Only mederate brake effect? Check brake pads. Renew brake pads. Are brake pads worn/damaged? Check brake system. Bleed brake system. Is there air in brake system? Brakes squeak.
  • Page 291 Brakes rubbing. Check hydraulic system. Rectify defect. Is there a defect in hydraulic system operation? Check brake piston. Change break piston/master brake cylinder. Are brake pistons jammed? Check brake discs/wheels. Replace brake discs/wheels. Is lateral runout too large? 34.33...
  • Page 292 34.34...
  • Page 293 36 Wheels and tyres Contents Page Technical Data ..........................3 Removing and installing front wheel .................5 Removing and instaling wheel bearings ................6 Removing left bearing .........................6 Removing right bearing ........................6 Installing left and right bearings ......................6 Removing and installing rear wheel ...................7 Removing rear wheel ........................7...
  • Page 294 36.2...

  • Page 295: Technical Data

    Technical Data K 1100 LT K 1100 RS Rim size front 2.50 x 18 MT H 2 3.50 x 17 MT H 2 rear 3.00 x 17 MT H 2 4.50 x 18 MT H 2 Vertical runout mm (in) 0.3 (0.012) Lateral runout mm (in) 0.3 (0.012) Tyre size...
  • Page 296 36.4...

  • Page 297: Removing And Installing Front Wheel

    BMW No. 36 3 950. [LT] Raise the front wheel with the front wheel Tightening torques: • stand and adapter, BMW No. 36 3 954. Quick-release axle ........33 Nm [LT] Remove the rear mudguard. Quick-release axle clamp screws ....14 Nm •...

  • Page 298: Removing And Instaling Wheel Bearings

    Install the circlip at the left bearing. • Take out circlip (1) with Seeger circlip pliers. • Place the protective ring (2), BMW No. 31 3 610, • in position with the open side upwards. Pull out wheel bearing (3) with internal puller, •...

  • Page 299: Removing And Installing Rear Wheel

    LT360040 Removing and installing rear wheel Tighten the outer wheel studs in a crosswise pat- • tern to the preload torque. Tighten the central stud to the specified torque. Removing rear wheel • Tighten the outer wheel studs in a crosswise pat- •...

  • Page 300: Static Balancing Of Front And Rear Wheels

    Raise the wheel on the balancing device, shaft with spacing washers, e.g. Part No. • BMW No. 36 3 600, and allow it to find its own 36 31 1 451 791. equilibrium. Raise the wheel on the balancing device, •...

  • Page 301: Checking Wheel For Runout

    Centre the wheel on the balancing shaft with spac- • BMW No. 36 3 615, at left and right on the bal- ing washers, e.g. Part No. 36 31 1 451 791. ancing shaft so that the shaft cannot wander to and fro.
  • Page 302 36.10...
  • Page 303 46 Frame Contents Page Technical Data ..........................3 Removing and installing front mudguard ................5 Removing and installing rear section ................6 Removing and installing rear mudguard .................7 Removing and installing fairing [LT] ..................8 Removing side sections of fairing ....................8 Removing radiator cowling ......................8 Removing and installing windshield ..................9...
  • Page 304 Contents Page Checking frame with gauge ......................18 Removing and installing frame ...................20 Removing frame ..........................20 Disassembling and assembling frame .................20 Removing outer bearing race in steering head ..................20 Installing outer bearing race in steering head ..................20 Removing and installing seat lock .....................21 Removing and installing handle ......................21 Installing frame ..........................22...

  • Page 305: Technical Data

    Technical Data K 1100 LT K 1100 RS Location of type identification plate Rear right frame tube Location of chassis number Rear right frame tube Maximum width (over mirrors) mm (in) 915 (36.02) 802 (31.57) Seat height, without load mm (in) 810 (31.89) 800 (31.5) Wheelbase, without load mm (in) 1565 (61.6)
  • Page 306 46.4...

  • Page 307: Removing And Installing Front Mudguard

    LT460010 Removing and installing front mudguard • Loosen clamping screws (1,2). • Detach cover (3). • Remove rear section of mudguard (4). • [LT] Detach Velcro connections (5). • Remove front section of mudguard (6). • Install in the reverse order of removal. LT460020 Note: [LT] Position of Velcro connection (6).

  • Page 308: Removing And Installing Rear Section

    LT460030 Removing and installing rear sec- tion • Remove dualseat. • Remove combined tail light unit. • Release securing screw (1). • Install in the reverse order of removal. 46.6...

  • Page 309: Removing And Installing Rear Mudguard

    LT490040 Removing and installing rear mudguard 1. Rubber sleeves on gearbox 2. Bracket 3. Sheet-metal nuts 4. Licence plate support bracket 46.7...

  • Page 310: Removing And Installing Fairing [Lt]

    LT460050 Removing and installing fairing [LT] Removing side sections of fairing • Remove knee pad (1). • Remove storage box (2). • Remove cover (3). • Remove side section (4). • Install in the reverse order of removal. Removing radiator cowling •...

  • Page 311: Removing And Installing Windshield

    LT460070 Removing and installing windshield • Release securing screws (1) on left and right and detach screen. Removing and installing windshield complete with motor • Remove inner cover. • Release securing screws (2). • Detach water ducts (3) at the top nipple. •...

  • Page 312: Disassembling And Assembling Adjustable Windshield

    LT460080 Disassembling and assembling adjust- Note: able windshield The retaining screws are micro-encapsulated and therefore cannot be re-used. Clean the threads and Removing and installing actuator motor the holes. Coat screws with Loctite 243 before in- serting. • Release securing elements (1) for actuator motor and remove motor.

  • Page 313: Removing Lever

    Removing lever Removing guide bush in lever • • Remove actuator motor. Remove lever. • Remove plate. • Detach spring. LT460110 LT460100 • Loosen locknut (1), unscrew pressure screw (2). • Release securing element (3) of guide rod (4), while holding with pin (5). Note: •...

  • Page 314: Removing And Installing Upper Section Of Fairing

    LT460130 Removing and installing upper section of fairing • Remove side sections of fairing and radiator cowling. • Remove cover (1). • Remove complete windshield (2). • Disconnect plug connections for headlight and turn indicators. • Remove upper section of fairing (3). •...

  • Page 315: Removing And Installing Fairing [Rs]

    LT460140 Removing and installing fairing [RS] Removing and installing radiator cowling Removing and installing lower section of fairing – Lower section of fairing (1) • Release securing element on side section (2). • Release securing screw at oil sump. • Install in the reverse order of removal.

  • Page 316: Removing And Installing Upper Section Of Fairing

    LT460160 Removing and installing upper Removing and installing windshield, section of fairing spoiler and headlamp • Remove lower section of fairing, side sections and radiator cowling. • Remove cover (1). • Remove support bracket (2). • Remove cover at right/left (3) and centre (4). •...

  • Page 317: Removing And Installing Fairing Support Bracket

    LT460200 Removing and installing fairing Arrangement of cable clips [RS] support bracket • Remove fairing. • [LT] Remove instrument cluster. • Remove horns (1). • Disconnect cable clips for wiring loom. • Release securing screw (2). • Install in the reverse order of removal. Arrangement of cable clips [LT] LT460200 Tightening torque:...

  • Page 318: Checking Running Gear

    • Mount motorcycle on centre stand on even base. • Position track offset gauge (1), BMW No. 36 3 920, on left or right side of motor- cycle. Note: In order to measure with the track offset gauge from the left or right side, the supports need only be screwed in from the other side.
  • Page 319 LT460220 • • Calculate track offset ”S”: The track offset ”S” represents the amount by which the longitudinal axis of the front wheel is EXAMPLE: offset to the left or right with respect to the rear wheel. Formula: - - - - - –...

  • Page 320: Checking Frame With Gauge

    If this is not possible, the frame is in all probability distorted. • Fit adapter, BMW No. 46 5 606, instead of se- curing screws. • Screw measuring discs, BMW No. 46 5 603, at the same level on the adapter.
  • Page 321 46 5 602 46 5 602 LT460250 • Fit measuring pins (1), BMW No. 46 5 602, lightly greased, in the outer holes. • Slightly loosen nut on steering head and align gauge so that the same distance is obtained on the left and right with respect to the measuring discs.

  • Page 322: Removing And Installing Frame

    00 8 560 00 1 510 31 4 800 LT460320 LT460270 • Support with lifting gear, BMW No. 00 1 510, un- • der oil sump. Remove outer bearing race (1) at top and bottom • Remove seat. with inner extractor, BMW No. 00 5 560 in con- •...

  • Page 323: Removing And Installing Seat Lock

    LT510040 Removing and installing seat lock 1. Saucer-head screw 2. Phillips-head screw 3. Stop nut Removing and installing handle • Lever out spring using screwdriver, remove spring seat. • Detach handle. • Remove spring with second spring seat. • Install in the reverse order of removal. Note: Grease the pivot point a little before installing han- dle.

  • Page 324: Installing Frame

    LT460300 Installing frame Tightening torques: • Installation basically takes place in the reverse Locking tube ..........65 Nm order of removal. Hexagon nut ..........65 Nm • Place frame on drive train and firmly tighten Clamping screws of fork bridge....15 Nm screws and bolts in the specified order.

  • Page 325: Removing And Installing Main Centre Stand

    Line arrangement for side stand 00 1 510 LT460320 • Raise motorcycle with lifting gear, BMW No. 00 1 510, under the oil sump until stand is free to move. • Disconnect cable clips for side stand line. LT460330 Tightening torque: Main stand to bearing block ......

  • Page 326: Disassembling And Assembling Side Stand

    LT460340 Disassembling and assembling side stand isassembling side stand • Detach switch (1). • Detach tension springs (2). • Remove bracket (3) with spring. • Remove operating hook (4). • Remove leg spring (5). • Release securing screw (6) of side stand. 46.24...

  • Page 327: Assembling Side Stand

    LT460350 Assembling side stand Note: The securing screw of the side support is micro-en- capsulated and cannot be reused. Clean thread and holes. Coat screws with Loctite 243 before insert- ing. • Fit securing screw (6) with Loctite 243. • Fit leg spring (1) as illustrated.

  • Page 328: Disassembling And Assembling Main Centre Stand

    LT460370 Disassembling and assembling main centre stand • Detach tension springs (1). • Release screws (2) on left/right. • Release retaining ring (3). • Press out sleeve (4) on left/right. • Remove bearing block (5). • Loosen grease nipple (6). •...

  • Page 329: Checking Switching Function Of Side Stand

    LT460380 Checking switching function of side • Operate starter while slowly folding in side stand, the engine must start up in area ”b”. stand • If the engine does not start up, or if the side stand is difficult to move, check the switch or disas- •...
  • Page 330 46.28...
  • Page 331 51 Equipment Contents Page Removing and installing ignition switch/steering lock ...........3 Removing and installing lock cylinder for fuel tank ..........4 Removing lock cylinder ........................4 Installing locking cylinder ......................4 Removing lock cylinder with broken key ................4 Removing and installing dualseat lock ................5 51.1...
  • Page 332 51.2...

  • Page 333: Removing And Installing Ignition Switch/Steering Lock

    Secure shear bolts with Loctite 270. • Remove screw plugs (2). Tightening torques: Handlebar clamping blocks......22 Nm Shear bolts......to shear point (~ 20 Nm) 51 0 500 LT510020 • Fit drilling bushing (1), BMW No. 51 0 500, in hole. 51.3...

  • Page 334: Removing And Installing Lock Cylinder For Fuel Tank

    LT510030 Removing and installing lock cylin- Removing lock cylinder with broken der for fuel tank • With the aid of 4-5 mm drill, drill out lock cylin- Removing lock cylinder der over its entire length. • Increase drill until the lock cylinder can be •...

  • Page 335: Removing And Installing Dualseat Lock

    LT510040 Removing and installing dualseat lock 5. Saucer-head screw 6. Phillip-head screw 7. Stop nut 51.5...
  • Page 336 51.6...
  • Page 337 61 General electrical equipment Contents Page Technical Data ..........................3 Removing and installing Motronic control unit ............5 [ABS I] Removing and installing control unit ..............6 [ABS II] Removing and installing control unit ...............6 Removing and installing battery ..................7 Relay locations (central electrical unit) ................8 Locations and connections, ABS wiring loom .............9...
  • Page 338 61.2...

  • Page 339: Technical Data

    Technical Data K 1100 LT K 1100 RS Battery Ah 19 61.3...
  • Page 340 61.4...

  • Page 341: Removing And Installing Motronic Control Unit

    LT610010 Removing and installing Motronic control unit Caution: Switch off ignition, disconnect and insulate earth (ground) lead! • Open dualseat. • Press catch (1) for multi-pin plug and detach plug. • Loosen screws (2) and remove control unit. Tightening torque: Motronic control unit ........

  • Page 342: [Abs I] Removing And Installing Control Unit

    LT610020 [ABS I] Removing and installing [ABS II] Removing and installing control unit control unit Caution: Note: Switch off ignition, disconnect and insulate earth [ABS II] The control unit is on the pressure modula- (ground) lead! tor. For removal, see Group 34 “Removing and installing •...

  • Page 343: Removing And Installing Battery

    LT610030 Removing and installing battery Caution: Switch off ignition, disconnect and insulate ground lead! • Remove Motronic control unit. • [ABS I] Remove ABS control unit. • Disconnect positive lead. • Detach vent hose (1). • Install in the reverse order of removal. Note: First connect positive pole, followed by negative pole.

  • Page 344: Relay Locations (Central Electrical Unit)

    LT610040 Relay locations (central electrical unit) • First remove the fuel tank in order to remove a relay. 1. Lamp control unit 2. Start relay 3. Turn indicator relay 4. [ABS I] ABS relay Note: With ABS II the relay is on the ABS unit. See Group 34 “Removing and installing ABS relay base”.

  • Page 345: Locations And Connections, Abs Wiring Loom

    LT610050 Locations and connections, ABS wiring loom Note: All ABS plug connections are blue. 1. [ABS I] Multi-pin plug, ABS control unit 2. [ABS I] Plug connection, front pressure modulator 3. [ABS I] Plug connection, rear pressure modulator 4. Plug connection, front sensor 5.

  • Page 346: Locations, Frame Wiring Loom

    LT610060 Locations, frame wiring loom Wiring arrangement, fairing bracket, [LT] View from left Note: When removing the wiring loom, also remove the central electrical box together with the wiring loom. 1. Central earth (ground) at frame 2. Plug connection for tail light 3.

  • Page 347: View From Right

    LT610080 View from right Wiring arrangement fairing bracket, [RS] 1. Right multi-function switch connection 2. Ignition lock connection 3. Handbrake light switch plug connection 4. Hall generator plug connection 5. Hall generator line 6. Oil pressure switch line 7. Brake light switch plug connection 8.
  • Page 348 61.12...

  • Page 349: Instruments

    62 Instruments Contents Page Technical Data ..........................3 Removing and installing instrument cluster ..............5 [LT] .................................5 [RS] ................................6 Disassembling and assembling instrument cluster ............7 Removing and installing indicator lamp ....................7 Removing and installing p.c. board .....................8 Removing and installing quartz clock ....................8 Removing and installing frame for indicator lamps ................8 Removing and installing p.c.
  • Page 350 62.2...

  • Page 351: Technical Data

    Technical Data K 1100 LT K 1100 RS Instrument cluster Turn signal indicator lamps 12 V/4 W T 8/4 Other indicator lamps, instrument lights 12 V/3 W 10/3 62.3...
  • Page 352 62.4...

  • Page 353: Removing And Installing Instrument Cluster

    LT620010 Removing and installing instrument cluster [LT] • Remove upper section of fairing. • Release screw (1) and disconnect central plug connector. • Release screws (2), remove instrument cluster and counterweight (3). • Rubber buffers (4) remain in instrument support bracket.
  • Page 354 LT620020 [RS] • Remove upper section of fairing. • Release screw (1) and disconnect central plug connector. • Release screws (2) and remove instrument clus- ter. • Housing base (3) and cable cover (4) remain on the frame. • Install in the reverse order of removal. 62.6...

  • Page 355: Disassembling And Assembling Instrument Cluster

    Note: Ensure gasket is fitted in correct position. 61 1 250 LT620040 • Grip indicator lamp (1) diagonally with relay pli- ers, BMW No. 61 1 250, and pull out or press in. Note: Do not damage conductor tracks. 62.7...

  • Page 356: Removing And Installing P.c. Board

    Removing and installing p.c. board Removing and installing frame for indicator lamps LT620050 LT620070 • Release securing screws and carefully lift out • p.c. board (1). Carefully press hooks (arrows) towards the out- side. • Carefully lift out frame (7,8). Note: Do not damage p.c.

  • Page 357: Removing And Installing Revolution Counter

    Removing and installing revolution counter LT620090 • Release screws (1). • Lift out revolution counter (2). Removing and installing speedometer LT620100 • Release screws (3). • Completely pull out reset button (4) to the right. • Lift out speedometer (5). 62.9...

  • Page 358: Removing And Installing P.c. Board For Gear Indicator

    LT620110 Removing and installing p.c. board for gear indi- cator • Remove tachometer. • Carefully pull pointer (1) off the spindle. • Release screws (2). • Remove dial face (3). • Release screws (4). • Lift out p.c. board (5). Note: Note position of spacer (6).
  • Page 359 63 Lights Contents Page Technical Data ..........................3 Disassembling and assembling headlights ..............5 Adjusting headlights ........................6 63.1...
  • Page 360 63.2...
  • Page 361 Technical Data K 1100 LT K 1100 RS Lights Headlight Halogen rectangular headlight with two-stage manual range adjustment Bulbs High beam/low beam H 4 halogen bulb 55/60 W, asymmetric Parking light 12 V/4 W Rear light 12 V/10 W Brake light 12 V/21 W Turn signal light 12 V/21 W...
  • Page 362 63.4...
  • Page 363 LT630010 Disassembling and assembling headlights • Remove upper section of fairing. • Remove headlight. • Release retaining spring (5). Note: Do not touch the inside of the reflector or bulbs with bare hands. Individual parts: 1. Glass 2. Gasket 3. Reflector 4.
  • Page 364 LT630020 Adjusting headlights • Engage swivel lever (1) in top position. • Correct headlight range with adjusting screw (2). • Turning counterclockwise: shorter • Turning clockwise: further • Adjust side angle with knurled screw (3). 63.6...

This manual is also suitable for:

K1100 ltK1100 rs

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