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BMW R 1200 C Manuals
Manuals and User Guides for BMW R 1200 C. We have
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BMW R 1200 C manuals available for free PDF download: Repair Manual
BMW R 1200 C Repair Manual (311 pages)
Brand:
BMW
| Category:
Motorcycle
| Size: 53.42 MB
Table of Contents
Pre-Delivery Check Contents - Pre-Delivery Check
10
Table of Contents
10
Tightening Torques
13
Table of Operating Fluids
20
Pre-Delivery Check
21
General View of Crated Motorcycle
21
Check the Shipping Crate for Damage
22
In Case of Damage in Germany
22
In Case of Damage in Importer Markets
22
Unpacking the Motorcycle
22
Inspecting Motorcycle for Damage
23
Checking that Delivery Is Complete
23
Installing Remaining Items on Motorcycle
24
Install the Windscreen
24
Installing Sump Guard
25
Filling and Charging the Battery
26
Disengaging and Raising the Fuel Tank
26
Checking Engine Oil When Engine Is Cold, Topping up if Necessary
27
Checking Headlight Beam Angle, Adjusting if Necessary
28
Checking Tightness of Rear Wheel Studs
28
Checking Tyre Pressures
28
Attaching Adhesive Label
28
Final Inspection and Function Check
29
Final Cleaning
29
Handing over the Motorcycle
29
Maintenance
30
Key to Maintenance Intervals
30
Reading out Moditec Fault Memory
30
(Inspections I, II, III and IV)
30
Changing Engine Oil, Replacing Oil Filter Element
30
Changing Oil in Gearbox
31
(Inspections III and IV) or at the Latest Every 2 Years
31
Changing the Oil in the Rear Wheel Drive
31
(Inspections I, III and IV)
31
Replacing Fuel Filter
32
(Inspection III)
32
Km (12,000 Miles)
32
Checking Battery Fluid Level and Topping up if Necessary; Cleaning and Greasing the Battery Posts
34
(Inspections III and IV)
34
Replacing Intake Air Filter Element
34
(Inspection III)
34
More Frequently if Necessary
34
Replacing Poly-V Belt
35
(Inspection III) (Every 60,000 Km/36,000 Miles)
35
Checking Brake System for Correct Operation and Freedom from Leaks; Repairing/Replacing if Necessary
36
(Inspection III)
36
Checking Brake Fluid Level
36
(Inspections II and III)
36
Front Brake
36
Rear Brake
36
Checking Brake Pads and Discs for Wear/Replacing
37
(Inspections II and III)
37
Checking Front Brake Pad Wear
37
Checking Rear Brake Pad Wear
37
Checking Brake Disc Wear
37
Replacing Brake Pads, Front Brake
38
Replacing Brake Pads, Rear Brake
38
Changing Brake Fluid and Bleeding Brake System
39
Change the Brake Fluid Annually
39
(Inspection IV)
39
Bleeding Front Brake Circuit/Changing Brake Fluid
39
Additional Information for [ABS]
40
Bleeding Rear Brake Circuit/Changing Brake Fluid
41
Checking Clutch Operating Fluid Level
42
(Inspections II and III)
42
Changing the Clutch Fluid
42
(Inspections IV) at the Latest Every 2 Years
42
Checking Tightness of Rear Wheel Studs
43
Checking Rear Wheel Bearing Play by Tilting Wheel
43
(Inspection III)
43
Checking Swinging Arm Bearings, Adjusting if Necessary
43
(Inspections I and III)
43
Greasing the Side Stand Pivot
44
(Inspections I, II and III)
44
Checking Function of Side Stand Contact Switch
44
(Inspections I, II, III and IV)
44
Checking/Replacing Spark Plugs
44
(Inspection II) Check/(Inspection III) Replace
44
Tightening Cylinder Heads
45
Checking/Adjusting Valve Clearances
45
(Inspections I, II and III)
45
Replacing if Necessary
46
Checking Throttle-Cable Play
46
Checking and Adjusting Idle Speed and Throttle-Valve Synchronisation
46
(Inspections I, II and III)
46
Final Inspection with Road Safety and Functional Check
47
(Inspections I, II, III and IV)
47
Road Safety Check
47
Roadworthiness Check
47
11 Engine
48
Technical Data
52
Cutaway Drawing of Engine
59
Lubricating-Oil Circuit
60
Cooling-Oil Circuit
61
Removing Engine
62
Installing Auxiliary Frame (Raising Frame Unit Clear of Engine)
64
Removing Auxiliary Frame (Lowering Frame Unit Onto Engine)
65
Disassembling Engine
66
Removing Cylinder Head Cover
67
Locking the Engine at TDC
68
Firing TDC
68
Removing and Installing Chain Tensioner
69
Work Instructions, Timing-Chain Tensioner
69
Remove Valve Gear Carrier
70
Disassembling/Assembling Valve Gear Carrier
71
Removing Cylinder Head
73
Disassembling, Checking, Repairing and Reassembling Cylinder Head
74
Removing and Installing Valves
74
Removing Valve Stem Seals
74
Checking Valves for Wear
75
Remachining Valve Seat
75
Checking and Repairing Cylinder Head
75
Checking Valve Guide for Wear
75
Replacing Valve Guides
76
Installing Valve and Valve Stem Seal
77
Removing Cylinder
78
Removing and Disassembling Piston
78
Checking Pistons and Cylinders
79
Assembling Pistons
79
Removing and Installing Conrod
80
Removing and Installing Alternator Mount Cover with Engine Installed
81
Removing Alternator Mount Cover
81
Replacing Radial Shaft Seal in Alternator Mount Cover
81
Removing Auxiliary Shaft Drive
82
Removing Oil Pump
83
Removing Radial Shaft Seal from Crankshaft with Engine Installed
84
Disassembling Crankcase
85
Removing Crankshaft, Auxiliary Shaft and Timing Chain Tensioning and Slide
87
Rails
87
Removing and Installing Oil Intake Strainers
88
Replacing Oil Level Sight Glass
88
Removing and Installing Oil Thermostat
88
Removing Conrods
88
Checking Conrods
88
Measuring Crankshaft Bearing Play
89
Measuring Radial Bearing Play
89
Installing Main Bearings
90
Measuring Axial Bearing Play
90
Measuring Big End Bearing Play
91
Assembling Engine
92
Installing Conrods
92
Installing Crankshaft
93
Installing Timing Chain Tensioning and Slide Rails
93
Installing Auxiliary Shaft/Timing Chains
93
Assembling Engine Block
94
Installing Radial Shaft Seals on Crankshaft
97
Installing the Crankshaft-End Radial Shaft Seal
97
Installing the Clutch-End Radial Shaft Seal
97
Installing Clutch Housing
98
Installing Oil Pump
99
Installing Auxiliary Shaft Drive
100
Installing Piston
101
Installing Cylinder
102
Installing Cylinder Head
103
Adjusting Valve Clearances
104
Installing Right Cylinder Head
105
Installing Left Cylinder Head
106
Installing Alternator
110
12 Engine Electrics
112
Technical Data
114
Removing and Installing Coil and Ignition Lead
116
Checking Ignition Coil Resistance
116
Removing and Installing Alternator
117
Poly-V Belt Adjusting Procedure
117
Disassembling/Assembling Alternator
118
Checking Alternator
118
Checking Armature for Short to Ground (Earth)
118
Disassembling/Assembling Alternator (Option 50 A)
118
Checking Alternator
119
Checking Armature for Short to Ground (Earth)
119
Option 50 a
119
Removing and Installing Starter Motor
120
Disassembling/Assembling Starter Motor
121
Replacing Carbon Brushes
121
Checking Starter Motor
121
Checking Starter Relay
121
Removing and Installing Magnetic Gate
122
Timing the Ignition
123
13 Fuel Preparation and Control
124
Technical Data
126
Removing and Installing Air Filter Housing
128
Removing and Installing Trottle-Valve Stub Pipe
129
Removing and Installing Motronic Control Unit
130
Removing and Installing Throttle-Valve Potentiometer
130
16 Fuel Tank and Lines
131
Technical Data
133
Removing and Installing Fuel Tank
135
Removing and Installing Roll-Over Valve
136
Checking Fuel Pump Pressure
137
Removing and Installing Fuel Filter
137
Removing and Installing Fuel Filter, Fuel Pump and Fuel Level Sensor
137
Removing and Installing Fuel Pump and Fuel Level Sensor
137
Removing and Installing Fuel Distributor and Pressure Regulator
138
Exhaust System
139
Removing and Installing Exhaust System
141
Removing and Installing Silencer and Front Silencer
141
Removing and Installing Exhaust Manifolds
142
21 Clutch
143
Technical Data
145
Removing and Installing Clutch
147
Removing Clutch
147
Removing Clutch from Vehicle
147
Removing Clutch from Engine
149
Installing Clutch
149
Installing Clutch in Engine
149
Installing Clutch in Vehicle
149
Removing and Installing Clutch Slave Cylinder
150
Removing and Installing Clutch Hydraulic Line
150
Filling/Bleeding Clutch Line
151
23 Transmission
152
Technical Data
154
Gearbox - Sectional Drawing
156
Removing and Installing Gear-Shift Lever
158
Removing/Installing Gearbox
158
Replacing the Shaft Sealing Rings in the Gearbox Housing and Gearbox Cover
160
Replacing the Input Shaft Sealing Ring at Input End
160
Replacing Output Shaft Sealing Ring
160
Replacing Input Shaft Sealing Ring at Output End
161
Replacing Shaft Sealing Ring for Selector Drum
161
Replacing Sealing Ring for Selector Shaft
161
Disassembling Gearbox
162
Removing Gearbox Housing
162
Removing Selector Drum
163
Disassembling/Assembling Selector Shaft
163
Removing Gearbox Shafts
164
Replacing Grooved Ball Bearings of Intermediate Shaft
164
Disassembling/Assembling Input Shaft
165
Disassembling Input Shaft
165
Assembling Input Shaft/Checking and Adjusting Axial Play of Spring Cluster
166
Disassembling/Reassembling Output Shaft
167
Disassembling Output Shaft
167
Assembling Output Shaft
168
Checking Endplay
169
Checking/Adjusting Fully Assembled Length of Gearbox Shafts and Selector
170
Drum
170
Checking/Adjusting Fully-Assembled Length of Intermediate Shaft
170
Checking/Adjusting Fully-Assembled Length of Output Shaft
171
Checking/Adjusting Fully-Assembled Length of Input Shaft
172
Checking/Adjusting Fully Assembled Length of Selector Drum
173
Shimming Selector Shaft
174
Assembling Gearbox
175
Installing Input, Output and Intermediate Shafts
175
Installing Selector Shaft
176
Installing Selector Drum
176
Installing Gearbox Housing
177
31 Front Forks
179
Technical Data
181
Removing and Installing Telescopic Fork
183
Removing and Installing Telescopic Fork Without Fork Bridge
183
Removing and Installing Fork Bridge
184
Removing and Installing Pot-Type Joints
185
Removing and Installing Angular-Contact Ball Bearing
185
Removing and Installing Slider Tube Bridge
186
Removing and Installing Ball Joint in Slider Tube Bridge
186
Checking Friction at Ball Joint/Angular-Contact Ball Bearing
186
Disassembling/Assembling Telescopic Fork
187
Disassembling Telescopic Fork
187
Assembling Telescopic Fork
187
Measuring Telescopic Fork
188
Examining Slider Tube Bridge and Fork Bridge
188
Checking Runout of Fixed Tube
188
Checking Runout of Slider Tube
188
Disassembling/Assembling Leading Link
189
Removing and Installing Front Spring Strut
189
Removing and Installing Leading Link
189
32 Steering
190
Technical Data
192
Removing and Installing Left Handlebar Fitting
194
Removing and Installing Right Handlebar Fitting
195
Removing and Installing Brake Piston in Handlebar Fitting
196
Removing and Installing Clutch Piston in Handlebar Fitting
197
Checking and Adjusting Operating Clearance at Front Brake/Clutch Levers
198
Front Brake
198
Clutch
198
Removing and Installing Handlebar
199
Removing and Installing Bowden-Cable Divider, Bowden Cable for Throttle Actuation and Starting-Speed Increase
200
Disassembling Bowden-Cable Divider
201
33 Rear Wheel Drive
202
Technical Data
204
Removing, Disassembling, Reassembling and Installing Rear Wheel Drive
206
Removing Rear Wheel Drive
206
Removing and Installing Taper Roller Bearing in Rear Wheel Drive
206
Removing Input Bevel Pinion
207
Disassembling Input Bevel Pinion
208
Removing Needle Roller Bearing for Input Bevel Pinion
209
Installing Needle Roller Bearing for Input Bevel Pinion
209
Assembling Input Bevel Pinion
209
Installing Input Bevel Pinion
210
Removing and Disassembling Crown Wheel
212
Assembling and Installing Crown Wheel
213
Shimming Input Bevel Pinion and Crown Wheel
214
Checking Tooth Contact Pattern
215
Checking and Adjusting Backlash
216
Shimming Housing Cover
217
Installing Housing Cover
217
Installing Sliding Element
217
Installing Rear Wheel Drive
218
Removing and Installing Spring Strut
219
Removing and Installing Rear Swinging Arm
220
Removing Rear Swinging Arm
220
Removing and Installing Taper Roller Bearing
221
Removing and Installing Flexible Gaiter
221
Removing Drive Shaft
221
Checking Universal Joint for Wear
221
Installing Drive Shaft
221
Installing Rear Swinging Arm
222
34 Brakes
223
Technical Data
225
Removing and Installing Front Brake Caliper
226
Disassembling and Assembling Front Brake Caliper
227
Removing and Installing Filler Adapter
228
Removing and Installing Rear Brake Caliper
229
Disassembling and Assembling Rear Brake Caliper
230
Removing and Installing Front Brake Disc
231
Removing and Installing Rear Brake Disc (Mounted on Rear-Wheel Hub)
232
Removing and Installing Front ABS Sensor
233
ABS Sensor Gap, Front: Adjusting
234
Checking and Adjusting Sensor Gap
234
Marking Sensor Ring
234
Removing and Installing Rear ABS Sensor
235
Adjusting Rear ABS Sensor Gap
236
Checking and Adjusting Sensor Gap
236
Marking Sensor Wheel
236
Removing and Installing Rear Brake Master Cylinder
237
Checking and Adjusting Play of Piston Rod
238
Removing and Installing Footbrake Lever
238
Removing and Installing ABS Unit
239
Removing the ABS Unit
239
Installing the ABS Unit
240
Removing ABS Relay
240
Removing and Installing ABS Relay and Relay Socket
240
Installing the ABS Relay
241
Removing ABS Relay Socket
241
Installing the ABS Relay Base
242
Removing and Installing Brake Line (with ABS)
243
Removing and Installing Front Brake Line
243
Removing and Installing Rear Brake Line
244
36 Wheels and Tyres
245
Removing and Installing Front Wheel
249
Removing Front Wheel
249
Installing the Front Wheel
249
Removing and Installing Wheel Bearings
250
Removing/Installing Rear Wheel
252
Removing Rear Wheel
252
Installing Rear Wheel
252
Static Balancing of Front Wheel/Rear Wheel
253
Checking Front/Rear Wheel Rim for Runout
254
Removing/Installing Spokes
255
Centering the Wheel Rim
255
Centering Lateral Runout
255
46 Frame
256
Overall View, Frame
260
Removing and Installing Main (Centre) Stand
261
Removing and Installing Side Stand
262
Removing and Installing Bottom Section of Mudguard
263
Removing and Installing Front Mudguard
263
Removing and Installing Top Section of Mudguard
264
Removing and Installing Windscreen
265
Removing and Installing Fairing Bracket
266
Removing and Installing Luggage Rack
267
Removing and Installing Number-Plate Carrier
268
Removing/Installing Rear Mudguard
269
Removing and Installing Rear Footrest Plate
270
Removing and Installing Front Footrest Plate
271
Removing and Installing Right Footrest Plate
271
Removing and Installing Left Footrest Plate
272
Removing/Installing Frame
273
Removing and Installing Frame Tail Section
274
Checking Running Gear
275
Measuring Wheel Track Offset
275
Measuring the Leading Link
277
51 Equipment
278
Removing and Installing Ignition Switch/Steering Lock
280
Removing and Installing Ignition/Light Switch
280
Removing and Installing Lock Barrel
281
Drilling out Lock Barrel
281
Removing and Installing Lock Barrel for Fuel Tank Filler Cap
281
Removing and Installing Seat Lock
282
Removing and Installing Lock Barrel
282
Removing and Installing Helmet Lock
282
Technical Data
288
Removing and Installing Central Electrical Equipment Box
290
Disassembling/Assembling Central Electrical Equipment Box
290
Relay Positions/Fuse Assignments (Central Electrical Equipment Box)
291
Fuse Assignments
291
Wiring-Harness Routing, Frame [ABS]
292
Wiring-Harness Routing/Connection in Central Electrical Equipment Box
295
Wiring-Harness Routing/Central Electrical Equipment Box/Output
298
Wiring-Harness Routing View from Right
298
Removing and Installing Battery Holder
302
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BMW R 1200 C Repair Manual (288 pages)
Brand:
BMW
| Category:
Motorcycle
| Size: 23.13 MB
Table of Contents
00 Maintenance and General Instructions
9
Table of Contents
9
Maintenance and General Instructions
9
Tightening Torques
11
Table of Operating Fluids
17
Key to Maintenance Intervals
19
Reading out Moditec Fault Memory
19
(Inspections I, II, III and IV)
19
Checking Throttle Cable Play, Adjusting if Necessary
19
(Inspections I and III)
19
Changing Engine Oil, Renew Oil Filter Element
20
(Inspections I, II, III and IV)
20
Changing Oil in Gearbox
21
(Inspections III and IV) or at Least Every 2 Years
21
Changing Oil in Rear Wheel Drive; Cleaning Inductive Signal Transmitter at Rear Wheel
21
(Inspections I, III and IV)
21
Years
21
Renewing Fuel Filter
22
(Inspection III)
22
000 Km (12 000 Miles)
22
Checking Battery Acid Level/Topping up if Necessary, Cleaning/Greasing Battery Posts
24
(Inspections III and IV)
24
Renewing Intake Air Cleaner Element
24
(Inspection III)
24
Renewing Poly-V Belt
25
(Every 60 000 Km/36 000 Miles)
25
(Inspection III)
25
Poly-V Belt Adjusting Procedure
25
Checking Brake Fluid Level
26
Front Brake
26
Rear Brake
26
Checking Brake Pads and Discs for Wear/Renewing
27
(Inspections II and III)
27
Checking Front Brake Pad Wear
27
Checking Rear Brake Pad Wear
27
Checking Brake Disc Wear
27
Renewing Brake Pads Front Brake
28
Renewing Brake Padsrear Brake
28
Renewing Brake Fluid and Bleeding Brake System
29
Renew the Brake Fluid Annually
29
(Inspection IV)
29
[ABS Inspection II and III]
29
Bleeding Front Brake Circuit/Renewing Brake Fluid
29
Additionally with [ABS]
30
Bleeding Rear Brake Circuit/Renewing Brake Fluid
31
Additionally with [ABS]
32
Checking Clutch Operating Fluid Level
32
(Inspections I, II and III)
32
Checking Tightness of Rear Wheel Studs
33
Checking Rear Wheel Bearing Play by Tilting Wheel
33
(Inspection III)
33
Checking Swinging Arm Bearings, Adjusting if Necessary
33
(Inspections I and III)
33
Greasing the Side (Prop) Stand Pivot
33
(Inspections I, II and III)
33
Checking Function of Side (Prop) Stand Contact Switch
33
(Inspections I, II, III and IV)
33
Tightening Cylinder Heads
34
Checking/Adjusting Valve Operating Clearances
34
(Inspections I, II and III)
34
Checking/Renewing Spark Plugs
35
(Inspection II)/Renewing (Inspection III)
35
Check Synchronising
35
(Inspections I, II and III)
35
Final Inspection with Road Safety and Functional Check
36
(Inspections I, II, III and IV)
36
Road Safety Check
36
Roadworthiness Check
36
11 Motor
37
Technical Data
41
Sectioned Drawing of Engine
47
Lubricating Oil Circuit
48
Coolant Circuit
49
Removing Engine
51
Dismantling Engine
54
Removing Cylinder Head Cover
55
Locking the Engine in the TDC Position
56
Top Dead Centre on Ignition Stroke
56
Removing and Installing Chain Tensioner
57
Assembly Specification for Timing Chain Tensioner
57
Removing Valve Gear Holder
58
Dismantling/Reassembling Valve Gear Holder
59
Removing Cylinder Head
61
Dismantling, Checking, Repairing and Re-Assembling Cylinder Head
62
Removing and Installing Valves
62
Removing Valve Stem Seals
62
Checking Valves for Wear
63
Remachining Valve Seat
63
Checking and Repairing Cylinder Head
63
Checking Valve Guide for Wear
63
Replacing Valve Guides
64
Installing Valve and Valve Stem Seal
65
Removing Cylinder Barrel
66
Removing/Dismantling Piston
66
Checking Pistons and Cylinders
67
Assembling Pistons
67
Removing/Installing Conrod
68
Removing and Installing Alternator Cover with Engine Installed
69
Removing Alternator Mount Cover
69
Renewing Radial Shaft Seal in Alternator Mount Cover
70
Renewing Radial Shaft Seal for Rotary Breather
70
Removing Auxiliary Shaft Drive
71
Removing Oil Pump
72
Removing Radial Shaft Seal on Crankshaft with Engine Installed
73
Dismantling Crankcase
74
Removing Crankshaft, Auxiliary Shaft and Timing Chain Tensioning and Slide Rails
76
Removing and Installing Oil Pick-Up Basket
77
Replacing Oil Level Sight Glass
77
Removing Conrods
77
Checking Conrods
77
Measuring Main and Big End Bearing Play
78
Measuring Radial Bearing Play
78
Installing Main Bearing
79
Measuring Axial Bearing Play
79
Measuring Big End Bearing Play
80
Assembling Engine
81
Installing Conrod
81
Installing Crankshaft
82
Installing Timing Chain Tensioning and Slide Rails
82
Installing Auxiliary Shaft/Timing Chains
82
Assembling Engine Block
83
Installing the Crankshaft Radial Seal
85
Installing Clutch Housing
86
Installing Oil Pump
87
Installing Auxiliary Shaft Drive
88
Installing Piston
89
Installing Cylinder
90
Installing Cylinder Head
91
Adjusting Valve Clearances
92
Installing Right Cylinder Head
93
Adjustment Specification
93
Installing Left Cylinder Head
94
Adjustment Specification
94
Installing Alternator Mount Cover
96
Installing Magnetic Gate/Belt Pulley
96
Timing the Ignition
97
Installing Alternator
98
Installing Engine
99
12 Engine Electrics
101
Technical Data
103
Removing and Installing Coil and Ignition Lead
105
Check Ignition Coil Resistance
105
Removing and Installing Alternator
106
Poly-V Belt Adjusting Procedure
106
Dismantling/Reassembling Alternator
107
Checking Alternator
107
Checking Armature for Short to Ground (Earth)
107
Removing and Installing Starter Motor
108
Dismantling/Reassembling Starter Motor
109
Renewing Carbon Brushes
109
Checking Starter Motor
109
Checking Starter Relay
109
Removing and Installing Magnetic Gate
110
Timing the Ignition
111
13 Fuel Preparation and Control
113
Technical Data
115
Removing and Installing Air Cleaner
117
Removing and Installing Throttle Potentiometer
117
Removing and Installing Throttle Stub Pipe
117
Removing and Installing Injectors
118
Removing and Installing Throttle Positioner
118
Removing and Installing Throttle Potentiometer
118
Removing and Installing Motronic Control Unit
119
16 Fuel Tank and Lines
121
Technical Data
123
Removing and Installing Fuel Tank
125
Removing and Installing Fuel Filter
126
Removing and Installing Fuel Filter, Fuel Pump and Fuel Level Sensor
126
Removing and Installing Fuel Distributor and Pressure Regulator
127
Exhaust System
129
Removing and Installing Fuel Pump and Fuel Level Sensor
127
Checking Fuel Pump Pressure
127
21 Clutch
133
Technical Data
135
Installing Clutch
137
Removing and Installing Clutch
137
Removing Clutch
137
Removing and Installing Clutch Hydraulic Line
138
Removing and Installing Clutch Slave Cylinder
138
Filling/Bleeding Clutch Line
139
23 Gearbox
141
Technical Data
143
Removing Gearbox
145
Renewing the Shaft Sealing Rings in the Gearbox Housing and Gearbox Cover
147
Renew the Input Shaft Sealing Ring at the Input End
147
Renewing Output Shaft Sealing Ring
147
Renewing Input Shaft Sealing Ring at Output Side
148
Renewing Shaft Sealing Ring for Selector Drum
148
Renewing Sealing Ring for Selector Shaft
148
Removing and Installing Gear Pedal
145
Dismantling Gearbox
149
Removing Gearbox Housing
149
Removing Selector Drum
150
Dismantling/Assembling Selector Shaft
150
Removing Gearbox Shafts
151
Renewing Deep-Groove Ball Bearing on Intermediate Shaft
151
Dismantling/Assembling Input Shaft
152
Dismantling Input Shaft
152
Assembling Input Shaft
153
Dismantling/Reassembling Output Shaft
154
Stripping down Output Shaft
154
Assembling Output Shaft
155
Checking Endplay
156
Checking/Adjusting Fully Compressed Length of Gearbox Shafts, Selector Drum
157
Checking/Adjusting Fully-Compressed Length of Intermediate Shaft
157
Checking/Adjusting Fully-Compressed Length of Output Shaft
158
Checking/Adjusting Fully-Compressed Length of Input Shaft
159
Checking/Adjusting Fully-Compressed Length of Selector Drum
160
Shimming Selector Shaft
161
Assembling Gearbox
162
Installing Input, Output and Intermediate Shaft
162
Installing Selector Shaft
163
Installing Selector Drum
163
Assembling Gearbox Housing
164
31 Front Fork
167
Technical Data
169
Removing and Installing Telescopic Fork
171
Removing and Installing Fork Bridge
171
Removing and Installing Pot-Type Joints
172
Removing and Installing Ball Thrust Bearing
173
Removing and Installing Slider Tube Bridge
174
Removing and Installing Ball Joint
174
Checking Friction at Ball Joint/Ball Thrust Bearing
174
Assembly Specification for Telescopic Fork
175
Dismantling/Reassembling Telescopic Fork
176
Assembling Telescopic Fork
176
Dismantling Telescopic Fork
176
Measuring Telescopic Fork
177
Check Slider Tube Bridge
177
Checking Runout of Fixed Tube
177
Removing and Installing Leading Link
178
Removing and Installing Front Suspension Strut
178
Dismantling/Reassembling Leading Link
178
32 Steering
179
Technical Data
181
Removing and Installing Left Handlebar Fitting
183
Removing and Installing Right Handlebar Fitting
184
Removing and Installing Handlebar
185
Removing/Installing Throttle Cable
186
33 Rear Wheel Drive
187
Technical Data
189
Removing, Dismantling, Reassembling and Installing Rear Wheel Drive
191
Removing Rear Wheel Drive
191
Removing Input Bevel Pinion
191
Disassembling Input Bevel Pinion
193
Removing Needle Roller Bearing for Input Bevel Pinion
193
Installing Needle Roller Bearing for Input Bevel Pinion
193
Assembling Input Bevel Pinion
194
Installing Input Bevel Pinion
195
Removing and Dismantling the Crown Wheel
196
Assembling/Installing Crown Wheel
197
Checking/Adjusting Backlash
198
Checking Tooth Contact Pattern
199
Shimming Housing Cover
200
Installing Housing Cover
200
Installing Splined Element
200
Removing/Installing Rear Swinging Fork
201
Removing Rear Swinging Arm
201
Removing and Installing Taper Roller Bearing
202
Removing and Installing Flexible Gaiter
202
Removing Drive Shaft
202
Checking Universal Joint for Wear
202
Installing Drive Shaft
202
Installing Rear Swinging Arm
203
Installing Rear Wheel Drive
204
Removing and Installing Suspension Strut
205
34 Brakes
207
Technical Data
209
Removing and Installing Front Brake Caliper
211
Dismantling and Assembling Front Brake Caliper
212
Dismantling Front Brake Caliper
212
Assembling Front Brake Caliper
212
Removing and Installing Rear Brake Caliper
213
Dismantling and Assembling Rear Brake Caliper
214
Dismantling Rear Brake Caliper
214
Assembling Rear Brake Caliper
214
Removing and Installing Front Brake Disc
215
Removing/Installing Rear Brake Disc
216
Removing and Installing Front ABS Sensor
217
Adjusting Front ABS Sensor Gap
218
Marking Sensor Wheel
218
Checking and Adjusting Sensor Gap
218
Removing and Installing Rear ABS Sensor
219
Adjusting Rear ABS Sensor Gap
220
Marking Sensor Wheel
220
Checking and Adjusting Sensor Gap
220
Removing and Installing Rear Brake Master Cylinder
221
Checking and Adjusting Reliefclearance of Piston Rod
221
Removing and Installing Brake Pedal
221
Removing and Installing ABS Unit
222
Removing the ABS Unit
222
Installing the Abs Unit
223
Removing and Installing ABS Relay and Relay Base
224
Removing ABS Relay
224
Installing the ABS Relay
224
Removing ABS Relay Base
224
Installing the ABS Relay Base
225
Removing and Installing Brake Lines
226
Removing and Installing Front Brake Line
226
Removing and Installing Rear Brake Line
227
36 Wheels and Tyres
229
Technical Data
231
Installing Front Wheel
233
Removing and Installing Front Wheel
233
Removing Front Wheel
233
Removing and Installing Wheel Bearings
234
Removing/Installing Rear Wheel
236
Static Balancing of Front Wheel/Rear Wheel
237
Checking Front/Rear Wheel Rim for Runout
238
Centering Lateral Runout
239
Centering the Wheel Rim
239
Removing/Installing Spokes
239
46 Frame
241
Technical Data
243
Removing and Installing Rear Mudguard
245
Removing/Installing Front Mudguard
245
Removing and Installing Front Frame
246
Removing and Installing Rear Frame
248
Removing and Installing Side (Prop) Stand
250
Removing/Installing Footrest Supports
250
Checking Running Gear
251
Measuring Wheel Track Offset
251
Technical Data
263
Removing and Installing Central Electrical Equipment Box
265
Frame Wiring Harness
267
Wiring Harness
268
View from Left
268
Wiring Harness
272
View from Right
272
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