1993-1999 BMW K1100LT & K1100RS Service Repair Manual (Highly Detailed FSM, Preview)

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

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

Introduction This repair manual will help you to perform all the main maintenance and repair work correctly and efficient- ly. If it is consulted regularly by workshop personnel it will form a useful addition to the theoretical and prac- tical knowledge acquired at the BMW Training Centre. It is a contribution towards achieving even higher 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- sembly, Repair, Assembly, Installation. • The entire contents are divided into individual chapters, corresponding to the Construction Groups. 11 . 10 Chapter Page number within chapter • Work to be performed during an Inspection is described in Group “00”. The various inspection routines are numbered I, II, III and IV. This numbering is repeated in the work descriptions which follow, so that work can take place without interruption. • Use of the BMW special tools needed for certain tasks is described in the work instructions. If the need arises, repair instructions are also issued in the form of Service Information. This information is of course incorporated into the next issue of the repair manual. We also recommend, as an additional source of information, the Electronic Parts Catalogue (ETC), which contains clear and easy-to-follow illustrations. If the work described here is restricted to a particular equipment specification, for instance if a specific optional extra (OE) is fitted, this is stated in square brackets at the start of the item concerned, e.g. [LT]. Please refer to the following pages as well for a description of other symbols used and how to work with it. BMW AG Motorcycle Division After Sales Published by: BMW AG Motorcycle Division After Sales UX-VS-2 D - 80788 München 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

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; their meanings are ex- plained in the table. Special instructions aimed at improving the work procedures L Note: Specific information on operating, inspecting and adjusting work for the motorcycle as well as maintenance procedures. e Caution: Instructions and precautions specifically intended to prevent damage to the motorcycle. Failure to comply with them could invalidate the warranty. d Caution: This symbol stands for precautions and measures which are essential in order to protect the rider or other persons from possibly severe or fatal injury. Contents Headlines for the work described in the chapter........................................... with the relevant page number X Tightening torques: Values are stated if they differ from DIN EN 24 014 or DIN 912 ISO industrial standards.

Order No. 01 71 9 799 131 UX-VS-2, 12/98 Printed in Germany Customer Registration No. Order No. Signature of mechanic BMW Inspection 1000km/600mls BMW Service 10000 km/ 6000 miles BMW Inspection 20 000 km/ 12 000 miles BMW Annual Service Change oil when engine at regular operating temperature, renew oil filter element 1) Change oil in gearbox, final drive and telescopic fork 2) Clean inductive sensor at rear wheel 2) Grease upper/lower clutch cable nipples and side/centre stand pivots Renew intake air cleaner element 3) Renew fuel filter element 4) Check hose clips on fuel and cooling system for leaks and take up slack if necessary Check coolant level and concentration, and top up if necessary Renew coolant after at least every 2 years * ) Check brake pads and discs for wear, renew if necessary * ) Check front/rear brake fluid level, top up if necessary * ) [b SI 00 027 95 (716)] Check brake system with regard to function, leaks; repair/renew as required * ) Renew brake fluid at least once a year Check sensor gap for ABS at front and rear, adjust if necessary 6) Check sensor/pulse wheel for ABS at front and rear for contamination, clean if necessary 6) 5) Check operation of electric side stand switch (angle) Check clutch operating clearance, adjust if necessary Check free travel at throttle and cold-start (choke) cables, adjust if necessary Renew spark plugs Read out MOTRONIC fault memory 7) Check valve clearences, adjust if necessary 8) 5) Check steering head bearing play, adjust if necessary * ) Check battery acid level, top up with distilled water if necessary Clean and grease the battery posts, if necessary Take up slack at bolts and nuts: – power unit to frame – suspension strut mounts – side/center stand pivot – rear wheel studs Apply silicone spray to guide rods of adjustable windshield (only K 1100 LT, K 75 RT) Check idle speed, throttle synchronisation and CO value, adjust if necessary Final inspection with safety/operating check: – condition of tyres and wheels, tyre pressures – lights and signal systems – telltale and warning lights – clutch and gear shift – handbrake and footbrake, ABS – steering – instruments – test ride, if necessary Recommendation: In severe operating conditions, grease the throttle twistgrip and steering head bearings at least every 30,000 km (18,000 miles) * ) 1) at least every 6 months; if motorcycle is used only for short journeys or at outside temperatures below 0°C, every 3 months, and at least every 3,000 km (1,800 miles) 2) at least once a year 3) in very dirty or dusty conditions, renew the intake air cleaner element every 10,000 km (6,000 miles), or even more frequently if necessary 4) normally every 40,000 km (24,000 miles), but if fuel is of poor quality every 20,000 km (12,000 miles) 5) K 75 models only 6) only motorcycles with ABS 7) only motorcycles with catalytic converter 8) on all K models, renew the lining on the chain tensioner rail every 60,000 km (36,000 miles) * ) invoiced as a separate item BMW AG Motorcycle Division Maintenance Schedule K 75 RT/K 1100 RS/LT (from 1993 onlys)

Order No. 01 71 9 799 131 UX-VS-2, 12/98 Printed in Germany Customer Registration No. Order No. Signature of mechanic BMW Pre-delivery check Inspect crates on receipt for signs of damage Motorcycle: – unpack – check scope of delivery – install front wheel – complete – clean Battery: – remove – add battery acid – charge – grease the terminal posts – re-install (mark date) Check complete specification delivery: – tools – handbooks and documents – keys – optional extras Check front and rear wheel brake fluid levels (only disc brake) Check switch function of electrically-operated side stand (angle) Check torque setting of the rear wheel retaining studs Check tyre pressure Fuel the motorcycle Safety/operating check as final inspection: – idle speed – clutch, gear shifting – steering – front and rear brakes, ABS – telltale and warning lights, instruments, lighting and signalling equipment – adjust the headlight – test ride, if necessary BMW AG Motorcycle Division Pre-delivery Check K 75 RT/K 1100 RS/LT (from 1993 onlys)

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 ....................................................................................................... 21.1 23 Gearbox.................................................................................................... 23.1 31 Front fork ................................................................................................. 31.1 32 Steering.................................................................................................... 32.1 Contents 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 Group / Chapter

00.1 Contents Page 00 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 ........................................................................................... 12 Inspection I, III, IV Renewing intake air cleaner ................................................................................................ 12 Inspection III Renewing fuel filter ................................................................................................................... 13 Inspection III Cleaning inductive pulse generator at rear wheel drive ....................................... 13 Inspections I, III, IV Checking brake pads, brake discs for wear and renewing if necessary .... 14 Inspection II, III Front wheel brake Rear wheel brake Checking brake fluid level and correcting if necessary ....................................... 15 Inspections I, II, III Checking brake fluid level Adding brake fluid Checking brake system .......................................................................................................... 15 Inspection III Checking ABS sensor spacing and adjusting if necessary ................................ 15 Inspections I, II, III Front sensor Rear sensor Renewing brake fluid ............................................................................................................... 16 Renewing front brake fluid Renewing rear brake fluid 00 Maintenance and general instructions

00.2 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 Checking increased starting speed Checking valve clearance and adjusting if necessary .......................................... 20 Inspections I, III Adjusting valve clearance ..................................................................................................... 20 Removing sprockets Removing camshafts Installing camshafts Installing sprockets Installing cylinder head cover Checking steering bearing play and adjusting if necessary .............................. 23 Inspection III Lubricating guide pins, adjustable screen ................................................................... 24 Inspections III, IV Checking idle speed, synchronising and CO value and adjusting if necessary ...................................................................... 25 Inspections I, II, III, IV Adjusting idle speed Adjusting CO value without catalytic converter

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1993-1999 BMW K1100LT & K1100RS Service Repair Manual (Highly Detailed FSM, Preview)

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