Table Of Contents - BMW K75 Repair Manual

Table of Contents

Table Of Contents3
Maintenance And General Instructions5
Introduction6
Tightening Torques7
Conversion And Comparison Table For Statutory Measurement Units8
Conversion Table9
Removing Motorcycle From Crate11
Front Wheel- Installing13
Checking Motorcycle For Missing Items14
Completing The Motorcycle15
Battery Trims - Installing15
Engine Spoiler - Assembling And Mounting16
Windshield - Fitting19
Cleaning The Motorcycle20
Pre-Delivery Check21
Battery - Removing And Installing21
Battery - Filling With Acid22
Battery - Charging22
Battery Brake Fluid Level22
Tightening Torque For Rear-Wheel Studs - Checking With Torque Wrench23
Tyre Pressure (Front And Rear) - Checking23
Lights And Indicators - Checking23
Final Functional Check23
Maintenance And Inspection Chart - Driveline24
Maintenance And Inspection Chart - Frame25
Servicing Materials, K Models26
Service Data27
Engine Oil Viscosity Chart In Relation To Ambient Temperature28
Determining Engine Oil Consumption28
Engine Oil - Changing29
Gear Oil - Changing29
Final Drive Oil - Changing30
Final-Drive Inductive Transmitter - Cleaning30
Spark Plug Electrolyte Gap - Checking30
Determining State Of Engine From Spark Plug Appearance31
Spark Plugs - Renewing32
Clutch Cable Nipple - Greasing32
Clutch Play - Checking, Adjusting32
Valve Clearance - Checking, Adjusting33
Air Cleaner Element - Removing And Installing34
Throttle Actuator39
Increased Starting Speed39
Idle Speed - Checking, Adjusting If Necessary39
Oil In Telescopic Fork - Changing40
Steering Head Bearing Play - Checking, Adjusting41
Fuel Filter - Renewing43
Brakes - Checking44
Brake Fluid - Changing44
Battery Acid Level - Checking47
Coolant Concentration - Checking47
Free Travel At Brake Pedal (Drum Brake) - Checking, Adjusting49
Footbrake Lever - Adjusting49
Screws And Nuts - Taking Up Slack49
Final Check, Including For Road And Functional Safety50
Check Tyre Pressures At Front And Rear50
Engine52
Engine Specifications55
Engine Tightening Torques63
Engine: General Layout64
Engine: Valve Gear65
Engine: Oil Circuit66
Engine: Shaft Arrangement67
Crankshaft With Connecting Rod And Piston69
Output Shaft70
Intermediate Flange72
Auxiliary Shaft With Freewheel73
Combined Water And Oil Pump74
Engine - Removing75
Battery - Removing75
Coolant - Draining76
Radiator - Removing76
Throttle Cable On Throttle Butterfly Stub Pipe Assembly - Detaching77
Clutch Cable - Detaching77
Cable For Increased Starting Speed - Detaching77
Ignition Cables - Removing78
Plug Connections - Uncoupling78
Driveline - Removing81
Engine - Stripping Down84
Injector Rail - Removing84
Ignition Coils - Removing84
Intake Pipe/Coolant Pipe - Removing84
Alternator And Starter - Removing85
Driver - Removing85
Clutch - Removing85
Clutch Housing - Removing85
Intermediate Flange - Removing86
Countershaft - Removing86
Auxiliary Shaft - Removing86
Lid For Water Pump - Removing87
Combined Water/Oil Pump - Removing87
Oil Sump - Removing87
Oil Mesh Strainer And Oil Filter Cartridge - Removing88
Crankcase Lower Section - Removing88
Output Shaft - Removing88
Rocker Cover - Removing89
Crankcase End Cover - Removing89
Hall-Effect Transmitter - Removing89
Gate Rotor - Removing90
Timing Case Cover - Removing90
Control Case/Sliding Rail - Removing90
Chain Tensioner - Removing90
Spark Plugs - Removing91
Chain Sprockets - Removing91
Chain Guide Rail - Removing91
Camshaft - Removing91
Cylinder Head - Removing92
Cylinder Head - Detaching92
Pistons - Removing93
Crankshaft - Removing93
Big End Bearing Cap - Removing94
Cylinder Head - Stripping Down95
Valve Stem Seals - Removing95
Valve And Valve Seat - Regrinding96
Valve Stem Seal - Installing97
Cylinder Head - Assembling97
Combined Water/Oil Pump98
Combined Water/Oil Pump - Stripping Down99
Oil Pressure Switch - Removing And Installing100
Pressure Relief Valve - Removing100
Combined Water/Oil Pump - Assembling100
Pump Shaft - Installing101
Intermediate Flange - Stripping Down And Assembling103
Shaft Sealing Ring - Removing103
Freewheel - Stripping Down105
Freewheel - Assembling106
Needle Roller Bearing For Auxiliary Shaft In Crankcase - Removing106
Chain Tensioner - Stripping Down And Assembling107
Tensioning Rail - Removing107
Oil Level Sight Glass - Removing And Installing108
Shaft Sealing Ring In Chaincase Cover - Removing And Installing108
Piston - Stripping Down109
Piston - Measuring109
Cylinder - Measuring110
Piston - Assembling110
Small End Bushing - Removing And Installing111
Piston And Connecting Rod - Assembling111
Crankshaft Pinion And Rotor Flange - Removing And Installing112
Big End Bearing Play - Measuring112
Crankshaft - Measuring113
Crankshaft - Installing113
Output Shaft - Stripping Down117
Tensioner Gear - Stripping Down117
Tensioner Gear - Assembling118
Output Shaft - Assembling120
Tensioning Gear - Shimming121
Ball Bearing With Shoulder - Installing121
Assembling The Engine122
Piston - Installing122
Output Shaft - Installing123
Bottom Section Of Crankcase - Installing124
Oil Sump - Installing124
Cylinder Head - Installing126
Camshafts - Installing126
Timing Chain - Installing127
Camshaft Gears - Installing127
Slide Rail - Installing127
Chain Tensioner - Installing127
Valve Clearance - Adjusting128
Timing Chain Cover - Installing129
Combined Water/Oil Pump - Installing130
Cover For Water Pump - Installing130
Rotor Blade - Installing130
Hall-Effect Transmitter - Installing130
Hall-Effect Transmitter Cover - Installing131
Freewheel And Auxiliary Shaft - Installing131
Intermediate Flange - Installing131
Output Shaft Sealing Ring - Installing132
Clutch Housing - Installing132
Driver - Installing133
Alternator - Installing133
Crankcase Cover - Installing133
Spark Plugs - Installing134
Cylinder Head Cover - Installing134
Throttle Butterfly Stub Pipe Assembly - Installing134
Ignition Coils - Installing135
Injectors - Installing135
Driveline - Assembling136
Mounting The Centre Stand - Removing And Installing136
Air Cleaner Housing - Installing137
Throttle Cable - Installing138
Clutch Cable - Installing138
Engine Wiring Harness - Installing138
Ignition Coils - Connecting Up138
Cable For Increased Starting Speed - Installing139
Radiator - Installing139
Connections On Frame Wiring Harness140
Battery - Installing141
Coolant - Adding141
Rear Mudguard And License Plate Holder - Installing142
Exhaust System - Installing143
Frame Fixation On Driving Device144
Engine - Electrical System145
Engine-Electrical System146
Ignition System: Diagram150
Ignition System: Hall-Effect Transmitter151
Starter Motor152
Alternator153
Magnetic Gate - Removing And Installing154
Ignition - Timing155
Ignition Control Unit - Removing And Installing158
Ignition Coils - Removing And Installing158
Alternator - Removing And Installing159
Alternator Driver - Removing And Installing159
Ignition Coils-Connecting Up159
Starter Motor - Removing And Installing160
Starter Motor - Stripping Down160
Carbon Brushes - Renewing160
Starter Motor - Assembling161
Fuel Supply And Mixture Control162
Fuel Supply And Mixture Contra I163
Fuel Injection System: Diagram164
Intake Air System165
Engine Idle Speed - Adjusting166
Increased Starting Speed - Adjusting167
Co-Value - Adjusting167
Throttle Butterfly Switch - Removing And Installing168
Throttle Butterfly Assembly - Removing And Installing169
Air Cleaner Element - Checking, Removing And Installing171
Pressure Regulator - Removing And Installing172
Fuel Injection Control Unit - Removing And Installing173
Air Flowmeter - Removing And Installing175
Fuel Tank And Lines176
Fueltank And Lines177
Fuel Tank And Lines Specifications178
Fuel System179
Fuel Tank Layout180
Fuel Tank On Frame181
Fuel Tank - Removing And Installing182
Fuel Pump - Removing And Installing186
Fuel Pump Pressure - Testing188
Fuel Filter - Removing And Installing189
Fuel Level Sensor (Lever Sensor) - Removing And Installing190
Radiator191
Radiator Specifications193
Radiator Tightening Torques194
Coolant Circuit195
Radiator - Removing And Installing197
Fan Motor - Renewing198
Filler Cap - Checking198
Coolant - Renewing199
Thermostat - Removing And Installing200
Exhaust System201
Complete Exhaust System - Removing And Installing203
Silencer - Removing And Installing203
Shield Panel On Silencer - Removing And Installing204
Clutch205
Clutch Specifications207
Clutch Tightening Torques208
Lubricating Points210
Clutch Housing Installing212
Clutch - Installing212
Clutch Operating Clearance - Adjusting213
Clutch Thrust Rod - Removing/Installing216
Output Shaft Sealing Ring - Removing And Installing216
Clutch Thrust Bearing - Installing216
Gearbox217
Gearbox Specifications219
Gearbox Tightening Torques220
Input Shaft222
Selector Drum224
Foot Shift Mechanism225
Gearbox - Removing226
Exhaust System - Removing226
Rear Wheel - Removing227
Left Footrest Plate - Removing227
Right Footrest Plate - Removing227
Rear Mudguard - Removing229
Fuel Injection Control Unit - Removing230
Spring Strut - Removing232
Final Drive - Removing232
Rear Swinging Arm - Removing232
Gearbox - Installing234
Rear Swinging Arm - Installing236
Final Drive - Installing237
Fuel Injection Control Unit - Installing238
Rear Mudguard - Installing238
Right Footrest Plate - Installing238
Rear Wheel - Installing239
Left Footrest Plate - Installing239
Gearbox - Stripping Down241
Gearbox Cover - Removing241
Selector Drum - Removing242
Selector Forks - Removing242
Gearbox Shafts - Removing242
Selector Pawl - Removing243
Selector Shaft - Removing243
Shift Segment - Removing243
Stop Lever - Removing And Installing243
Selector Pawl - Stripping Down244
Selector Pawl - Assembling244
Shift Segment - Stripping Down244
Shift Segment - Assembling244
Shaft Sealing Ring For Output Shaft - Removing245
Bearing Shell For Input Shaft Taper Roller Bearings - Removing245
Bearing Shell For Input Shaft Taper Roller Bearings - Installing245
Intermediate Shall Ball Bearings - Removing And Installing245
Input Shaft - Stripping Down246
Input Shaft - Assembling246
Before Stripping Down Output Shaft247
Measure End Play With Feeler Gauge247
Gearbox - Assembling250
Selector Shaft - Installing250
Selector Pawl - Installing250
Gearbox Shafts - Installing250
Selector Forks - Installing251
Selector Drum - Installing251
Gearbox Shafts - Spacing Out252
Gearbox Cover - Installing254
Shaft Seal Ring In Gearbox Cover - Installing254
Shaft Sealing Ring For Output Shaft - Installing255
Pedal Switch - Removing And Installing255
Front Fork256
Frontfork257
Telescopic Fork Specifications258
Telescopic Fork Tightening Torques259
Telescopic Fork260
Front Fork Showa Type265
Telescopic Fork - Removing266
Telescopic Fork - Stripping Down269
Fluidbloc - Removing And Installing274
Taper Roller Bearing In Steering Head - Removing And Installing275
Telescopic Fork - Measuring276
Telescopic Forks - Installing277
Models With Fork Stabiliser278
Steering Head Tube - Installing279
Steering281
Steering Specifications283
Steering Tightening Torques283
Left Handlebar Grip284
Right Handlebar Grip285
Handlebar - Removing And Installing286
Right Handlebar Fitting - Removing286
Left Handlebar Fitting - Removing287
Throttle Cable - Removing290
Increased Starting Speed Cable - Removing And Installing292
Clutch Cable - Removing And Installing294
Clutch Play - Adjusting295
Rear Wheel Drive297
Rear Wheel Drive Specifications299
Rear Wheel Drive Tightening Torques300
Bevel Pinion Bearings301
Crown Wheel Bearings302
Spring Strut And Swinging Arm With Drive Shaft303
Rear Wheel Drive - Removing304
Rear Wheel Drive - Stripping Down306
Measure And Assembly The Rear Wheel Drive310
Drive Shaft - Removing318
Universal Joint - Checking For Wear318
Drive Shaft Snap Ring - Removing And Installing318
Rear Swinging Arm Taper Roller Bearing - Removing And Installing318
Sealing Sleeve Between Swinging Arm And Gearbox - Removing And Installing319
Drive Shaft - Installing320
Rear Wheel Drive - Installing321
Brakes323
Front Brake Lines326
Right Handlebar, Brake Cylinder327
Rear Brake Master Cylinder328
Rear Drum Brake329
Brake Fluid - Changing (Front And Rear)330
Front Brake Pads - Removing And Installing332
Front Brake Caliper - Removing And Installing332
Rear Brake Pads - Removing And Installing333
Rear Brake Caliper - Removing And Installing333
Rear Brake Master Cylinder - Removing And Installing334
Brake Shoes - Removing335
Brake Shoes - Installing335
Rear Drum Brake - Adjusting336
Rear Brake Disc - Removing And Installing336
Front Brake Discs - Removing And Installing337
Footbrake Pedal - Removing And Installing338
Footbrake Light Switch - Removing And Installing339
Handbrake Light Switch - Removing And Installing340
Wheels And Tyres341
Wheels And Tyres Specifications343
Wheels And Tyres Tightening Torques344
Front Wheel Bearings345
Front Wheel - Removing And Installing346
Front Wheel Bearings - Removing And Installing346
Rear Wheel - Removing And Installing347
Frame, Fairing348
Frame Technical Data351
Frame, Fairing Sections Tightening Torques352
K 75S Fairing Sections353
Rear Section355
Footrest Plate356
Centre Stand And Side Stand357
Front Mudguard358
K 75 Headlight Fairing - Removing And Installing359
Cockpit Fairing - Removing And Installing361
K 100 Headlight Fairing - Removing And Installing363
K 75, K 75C Radiator Trim - Removing And Installing365
K 100 Radiator Trim - Removing And Installing366
K75S Fairing - Removing And Installing367
Windshield - Removing And Installing367
Radiator Trim - Removing And Installing367
Side Fairings - Removing And Installing368
Centre Fairing - Removing And Installing370
Instrument Cluster - Removing And Installing371
Fairing Mounting - Removing And Installing372
Engine Spoiler - Removing And Installing374
K 100 Rs Fairing - Removing And Installing376
Knee Pads - Removing And Installing376
Side Farings On Left Or Right - Removing And Installing377
Mirror With Integral Turn Indicator - Removing And Installing379
Inner Fairing - Removing And Installing379
Upper Fairing - Removing And Installing381
K 100 Rt, Lt Fairing - Removing And Installing383
Storage Compartment And Knee Pads On Either Side - Removing And Installing383
Lower Fairing - Removing And Installing384
Radiator Fairing - Removing And Installing386
Windshield And Inner Fairing - Removing And Installing386
Frame - Removing390
Dualseat - Removing395
Rear Section With Rear Mudguard - Removing396
Electrical Connections - Disconnecting398
Frame - Disconnecting From Driveline399
Steering Lock - Removing399
Ignition Control Unit - Removing400
Frame Wiring Harness - Removing400
Dualseat Lock - Removing400
Grab Handle - Removing401
Bearing Shells For Steering Head Bearing - Removing401
Rubber Bearing On Frame - Removing401
Frame - Installing402
Bearing Shells - For Steering Head Bearing - Installing402
Front Silentblocs - Pressing In402
Dualseat Lock - Installing403
Steering Lock - Installing403
Lift Handle - Installing403
Frame Wiring Harness - Installing403
Frame - Fitting To Driveline408
Telescopic Fork - Installing409
Handlebar410
Steering Head Bearing - Adjusting410
Wire Cables - Adjusting411
Distributor Pipe - Installing412
Divider - Installing413
Rear Section - Installing414
Coolant - Topping Up415
Dualseat - Installing416
Centre Stand - Removing And Installing417
Bearing Bushings For Centre Stand - Removing And Installing417
Pivot Block - Removing And Installing417
Lift Hande - Removing/Installing418
Wheel Offset - Measuring419
Calculation Of Wheel Offset "S"420
Frame - Checking421
Equipment423
Dualseat Lock - Removing And Installing425
Dualseat427
Dualseat On Frame429
General Electrical System432
General Electrical System Specifications433
Cable Connector Arrangement On Frame434
Electrical Equipment Box435
Left Or Right Horn, L 75 C, K 100 - Removing And Installing438
Headlight Fairing - Removing438
Cockpit Fairing - Removing438
K 75 Horn - Removing And Installing439
K 75 S Horn - Removing And Installing439
K 100 Rt, Lt Right Or Left Horn - Removing And Installing439
K 100 Rs Right Or Left Horn - Removing And Installing440
Instruments441
Instrument Cluster443
K 75 C, K100 Instrument Cluster - Removing And Installing445
Instrument Cluster - Stripping Down And Assembling449
Printed Circuit Board - Removing And Installing449
Quartz Clock - Removing And Installing450
Telltale Light Frame - Removing And Installing450
Fuel Gauge Board - Removing And Installing451
Revolution Counter - Removing And Installing451
Revolution Counter Dial - Removing And Installing451
Gear Indicator Board - Removing And Installing451
Speedometer Board - Removing And Installing452
Telltale Light - Renewing452
Lights453
Lights Specifications455
Headlight Setting - Adjusting456
K 75 Headlight - Adjusting456
K 75C, K 100 Headlight - Adjusting456
K 75 S Headlight - Adjusting457
K 100 Rs, Rt, Lt Headlight - Adjusting457
K 75 Headlight - Removing And Installing458
K 75 C, K 100 Headlight - Removing And Installing459
Rear Light Cluster - Removing And Installing461