Bmw K1100Lt Repair Manual-21215B300081.pdf -Bookmark created by https://wimanual.com Repair Manual Introduction U sage Key to symbols Contents Maintenance Schedule K 75 RT Pre-delivery Check K 75 RT Contents 00 Maintenance and general instructions Tightening torque Table of operating fluids Key to maintenance intervals Changing engine oil Inspections I, II, III, IV Changing oil in transmission (gearbox) Inspections I, III, IV Changing oil in rear wheel drive Inspections I, III, IV Changing oil in telescopic fork Inspection I, III, IV Renewing intake air cleaner Inspection III Renewing fuel filter Inspection III Cleaning inductive pulse generator at rear wheel d... Inspections I, III, IV Checking brake pads, brake discs for wear and rene... Inspection II, III Front wheel brake Rear wheel brake Checking brake fluid level and correcting if neces... Inspections I, II, III Checking brake fluid level Adding brake fluid Checking brake system Inspection III Checking ABSsensor spacing and adjusting if neces... Inspections I, II, III Front sensor Rear sensor Renewing brake fluid Renewing front brake fluid Renewing rear brake fluid Checking function of electric switch on side stand... Inspections I, II, III Checking clutch clearance and adjusting if necessa... Inspections I, III Reading out Motronic defect code memory Inspections II, III Checking increased starting speed (choke) and adju... Inspections I, III Checking increased starting speed Checking valve clearance and adjusting if necessar... Inspections I, III Adjusting valve clearance Removing sprockets Removing camshafts Installing camshafts Installing sprockets Installing cylinder head cover Checking steering bearing play and adjusting if ne... Inspection III Lubricating guide pins, adjustable screen Inspections III, IV Checking idle speed, synchronising and CO value an... Inspections I, II, III, IV Adjusting idle speed Adjusting CO value without catalytic converter 11 Motor Removing engine Dismantling engine Removing intermediate flange Removing driver Removing clutch housing Stripping down and re-assembling intermediate flan... Removing the driver bearing Installing driver bearing Removing and installing shaft sealing ring for dri... Removing countershaft and layshaft with freewheel Dismantling and assembling freewheel Stripping down freewheel Assembling freewheel Removing and installing layshaft needle roller bea... Removing bearing Installing bearing Removing timing chain cover Removing the Hall-effect signal transmitter Remove the crankshaft cover Removing cylinder head cover Removing and installing sealing ring in timing cas... Removing the timing chain Removing chain tensioner Removing chain tensioner rail Renewing chain tensioner rail facing Removing camshaft chain sprockets Removing chain guide Removing, stripping down and assembling cylinder h... Removing camshafts Removing cylinder head Removing bucket-type tappets Removing valves Remachining valve seat Installing valve and valve stem seal Removing crankshaft Removing big end bearings Removing main bearings Removing pistons with conrods, stripping down and ... Removing piston with conrod Dismantling piston Checking piston dimensions Assembling pistons Checking cylinder dimensions Removing and installing small-end bushing Assembling pistons and conrods Removing and installing crankshaft pinion and roto... Removing, dismantling and assembling combined oil-... Removing pump Dismantling pump Removing slipring seal and shaft sealing ring Removing pressure relief valve Installing pressure relief valve Install the shaft sealing ring and slipring seal Installing pump shaft and impeller Removing output shaft Removing oil sump Removing oil filter Removing lower section of crankcase Removing and installing oil level sight glass Stripping and assembling output shaft Stripping down output shaft Stripping down tensioning gear Assembling tensioning gear Installing damper Assembling engine Installing output shaft Assembling the crankcase Installing oil mesh strainer Installing oil filter Installing oil sump Measuring crankshaft bearing play Measuring radial play Measuring endplay Checking dimensions of crankshaft Installing crankshaft Installing piston with conrod Measuring big end bearing play Installing big end bearing Installing combined oil-water pump Installing cylinder head Installing camshafts Installing timing chain Checking valve clearances Installing intermediate flange Installing freewheel Installing countershaft Installing intermediate flange Installing driver Installing alternator Installing timing case cover Installing hall-effect transmitter Installing cover for Hall-effect transmitter Installing cylinder head cover Installing engine Checking Adjusting valve clearances 12 Engine electrics Removing and installing Hall generator Adjusting ignition timing Removing and installing ignition coils Removing and installing ignition output stage Removing and installing alternator Disassembling and assembling alternator Alternator [only LT up to 1992 model year] Checking exciter winding Checking armature for short to earth Checking resistance between phase outputs Checking stator winding for short to earth Alternator [LT from 1992 model year on, RS] Checking alternator Checking armature for short to earth Removing and installing starter Disassembling and assembling starter Removing and installing brush holder Renewing carbon brushes Checking starter Checking starter relay Checking starter relay with ohmmeter Troubleshooting Troubleshooting on alternator Troubleshooting on starter Troubleshooting on battery 13 Fuel preparation and control Adjusting idle speed Checking start speed increase (choke), adjusting i... Checking start speed increase Adjusting start speed increase Adjusting CO value Removing Removing and installing throttle position sensor Checking trottle position sensor Adjusting throttle position sensor Removing and installing air cleaner insert Removing and installing air cleaner housing Removing and installing throttle rail Removing and installing injectors Removing and installing intake stub pipe Removing and installing Motronic control unit 16 Fuel tank and lines Removing and installing fuel tank Removing and installing fuel filter Removing and installing fuel level sensor Removing and installing fuel pump Checking fuel pump pressure 17 Radiator Changing coolant Draining coolant Filling with coolant Removing and installing thermostat Checking thermostat Removing and installing radiator Removing and installing fan Removing and installing coolant hoses Checking cooling system Checking cap for filler neck Checking coolant system for leaks Troubleshooting 18 Exhaust system Removing and installing exhaust system Removing and installing oxygen sensor 21 Clutch Removing clutch Removing clutch housing Installing clutch housing Installing clutch Adjusting clutch clearance Removing and installing clutch thrust bearing Removing and installing clutch control rod Removing and installing clutch release lever Troubleshooting 23 Gearbox Removing transmission (gearbox) Preparatory work Removing starter Removing bearing mount with main stand Removing transmission (gearbox) Disassembling transmission (gearbox) Removing transmission cover. Disassembling Removing and installing bearing shell Removing and installing shaft sealing ring on inpu... Removing and installing locking lever Removing gear selector drum Removing gearshift forks Removing transmission shafts Removing pawl Removing selector shaft Removing segment Removing and installing shaft sealing ring on inpu... Removing and installing shaft sealing ring for gea... Removing and installing bearing shell for taper ro... Removing and installing ball bearing on intermedia... Disassembling and assembling input shaft Disassembling input shaft Assembling input shaft Disassembling and assembling output shaft Removing ball bearing Removing spur gears Installing spur gears Installing transmission shafts Installing gearshift forks Measuring distances between transmission shafts Measuring bearing distance of shafts Measuring transmission cover Installing transmission cover Installing transmission (gearbox) Installing bearing mount with main stand Installing starter Re-assembling motorcycle 31 Front fork Removing telescopic fork Removing fork stabilisor Removing telescopic fork without fork bridge Removing telescopic fork with fork bridge Removing upper fork bridge Removing and installing lower taper roller bearing... Removing taper roller bearing Installing taper roller bearing Removing and installing upper taper roller bearing... Removing taper roller bearing Installing taper roller bearing Removing and installing bearing outer race in stee... Removing bearing outer race Installing bearing outer race Measuring telescopic fork Checking lower fork bridge Checking parallel alignment of fixed tubes Checking runout of fixed tube Disassembling telescopic fork Removing fixed tube Disassembling slider tube Disassembling fixed tube Assembling telescopic fork Assembling fixed tube Assembling slider tube Installing telescopic fork Adjusting steering bearing play Installing fork stabilisor 32 Steering Removing and installing left and right handlebar f... Removing and installing left handlebar fitting Removing and installing handlebar weight Removing and installing right handlebar fitting Removing and installing handlebar Removing and installing handlebar clamping blocks Removing and installing accelerator cable Removing and installing clutch cable Removing and installing operating cable for increa... Adjusting steering bearing play 33 Rear wheel drive Removing, disassembling, assembling and installing... Removing rear wheel drive Removing, disassembling and assembling drive bevel... Removing retaining ring Disassembling drive bevel gear Removing needle bearing for drive bevel gear Installing needle bearing for drive bevel gear Assembling drive bevel gear Installing drive bevel gear Removing and installing taper needle bearing in re... Removing crown wheel Installing crown wheel Checking Checking contact pattern Shimming housing cover Installing housing cover Installing slider Installing rear wheel drive Removing, disassembling and assembling rear swingi... Removing and installing taper roller bearing Removing and installing gaiter Removing drive shaft Checking universal joint for wear Removing retaining ring Installing drive shaft Installing swinging arm Installing footrest plates 34 Brakes Removing and installing front brake caliper Dismantling and assembling front brake caliper Dismantling front brake caliper Assembling front brake caliper Removing and installing brake pads Removing and installing front brake disc Removing and installing ABS pulse wheel Removing and installing front ABS sensor Adjusting front ABS sensor gap Removing and installing front brake line Removing upper brake line Removing lower brake line Removing and installing ABS brake line from front ... Removing and installing handbrake cylinder Bleeding brake Bleeding front brake Bleeding brake caliper [ABS II] Bleeding pressure modulator Bleeding the handlebar fitting Bleeding rear brake Bleeding brake caliper [ABS II] Bleeding pressure modulator Removing and installing pressure modulator [ABS I] Removing and installing front or rear pres... [ABS II] Removing ABS unit [ABS II] Installing ABS unit [ABS II] Removing and installing relay and relay b... [ABS II] Removing relay [ABS II] Installing relay [ABS II] Removing relay base [ABS II] Installing relay base Removing and installing rear brake caliper Removing and installing rear brake pads Dismantling and assembling rear brake caliper Dismantling rear brake caliper Assembling rear brake caliper Removing and installing rear brake disc Removing and installing rear ABS sensor Measuring vertical runout at rear pulse wheel Removing and installing rear master brake cylinder... Disassembling rear master brake cylinder Removing and installing brake pedal Adjusting foot brake pedal Troubleshooting: Front wheel 36 Wheels and tyres Removing and installing front wheel Removing and instaling wheel bearings Removing left bearing Removing right bearing Installing left and right bearings Removing and installing rear wheel Removing rear wheel Installing rear wheel Static balancing of front and rear wheels Static balancing of front wheel Static balancing of rear wheel Checking wheel for runout Checking front wheel for runout Checking rear wheel for runout 46 Frame Removing and installing front mudguard Removing and installing rear section Removing and installing rear mudguard Removing and installing fairing [LT] Removing side sections of fairing Removing radiator cowling Removing and installing windshield Removing and installing windshield complete with m... Disassembling and assembling adjustable windshield... Removing and installing actuator motor Removing plate Removing lever Removing guide bush in lever Removing sliding piece Removing and installing upper section of fairing Removing and installing fairing [RS] Removing and installing lower section of fairing Removing and installing side section of fairing Removing and installing radiator cowling Removing and installing upper section of fairing Removing and installing windshield, spoiler and he... Removing and installing fairing support bracket Arrangement of cable clips [LT] Arrangement of cable clips [RS] Checking running gear Measuring track offset Checking frame with gauge Removing and installing frame Removing frame Disassembling and assembling frame Removing outer bearing race in steering head Installing outer bearing race in steering head Removing and installing seat lock Removing and installing handle Installing frame Removing and installing main centre stand Line arrangement for side stand Disassembling and assembling side stand Disassembling side stand Assembling side stand Disassembling and assembling main centre stand Checking switching function of side stand 51 Equipment Removing and installing ignition switch Removing and installing lock cylinder for fuel tan... Removing lock cylinder Installing locking cylinder Removing lock cylinder with broken key Removing and installing dualseat lock 61 General electrical equipment Removing and installing Motronic control unit [ABS I] Removing and installing control unit [ABS II] Removing and installing control unit Removing and installing battery Relay locations (central electrical unit) Locations and connections, ABS wiring loom Locations, frame wiring loom View from left Wiring arrangement, fairing bracket, [LT] View from right Wiring arrangement fairing bracket, [RS] 62 Instruments Removing and installing instrument cluster [LT] [RS] Disassembling and assembling instrument cluster Removing and installing indicator lamp Removing and installing p.c. board Removing and installing quartz clock Removing and installing frame for indicator lamps Removing and installing p.c. board for fuel gauge Removing and installing revolution counter Removing and installing speedometer Removing and installing p.c. board for gear indica... 63 Lights Disassembling and assembling headlights Adjusting headlights . 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