User manual BMW R 1100 S REPAIR MANUAL

[. . . ] Repair Manual R 1100 S BMW AG Motorcycle Division After Sales 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. Produced in Germany 06/99 Introduction This repair manual will help you to perform all the main maintenance and repair work correctly and efficiently. It should be consulted regularly by workshop personnel as an addition to the practical and theoretical knowledge obtained in Training School courses. [. . . ] Remove the nut securing the metal tab of the pipe clamp securing the rear silencer and bend back the metal tab. Remove rear silencer XatTightening torque: Clip silencer (muffler) (coat clip contact face with Never Seez). . . . . . . 55 Nm Oxygen sensor (coat thread with Never Seez). . . . . . . . . . . . . . . . . . . . . . . 45 Nm Removing and installing exhaust manifolds · · · · L gently with a plastic-headed hammer and pull Note: Tap the silencer down and to the rear to remove. Remove screws securing manifold to front silencer. Remove manifold. · · · · · Disconnect manifolds from front silencer. Installation is the reverse of the removal procedure. X Tightening to cylinder head. . . . . . . . . . . . . . . . 21 Nm torque: Exhaust manifold Clamp at connecting pipe (coat clamp contact face with Never Seez). . . 12 Nm 18. 3 18. 4 21 Clutch 21 Contents Technical Data Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Removing and installing clutch Removing clutch Installing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Removing and installing clutch hydraulic line Removing and installing clutch slave cylinder Filling/bleeding clutch line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 21. 1 21. 2 21 Technical Data Type of clutch Operation Master cylinder piston dia. Wear dimension R 1100 S Single dry plate with increased-leverage diaphragm spring Hydraulic, with master and slave cylinders mm (in) 13 (0. 5) mm (in) 24 (0. 9) DOT 4 brake fluid mm (in) 165 (6. 5) mm (in) 4. 8 (0. 19) (measured with tips of calipers pressed by hand against rivets of clutch plate) 21. 3 21. 4 2 1 11 5 640 S210010 Removing and installing clutch Removing clutch a · · · Secure the clutch with the retaining screws. Tighten retaining screws in diagonally opposite sequence. · · · · Preparatory work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Group 23 (removal of transmission) Lock the clutch housing with special tool, BMW No. Remove the clutch. Installing clutch Install clutch housing with crankshaft pin (2) located in bore (1). 11 5 640, to lock clutch housing. Lubrication points: Splines on clutch plate and gearbox input shaft. Optimoly MP3 paste X Tightening torque: Housing cover to flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Nm e Caution: · Always use new screws for housing and cover. Insert all screws by hand and tighten down. Tightening torque: Clutch housing to crankshaft (oil screw threads lightly) Initial tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm Wrench angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32° X · Install clutch. e Caution: colour marks on clutch housing, Make sure that thrust plate and housing cover are offset 120°. 21. 5 S210020 Removing and installing clutch hydraulic line Removing and installing clutch slave cylinder · · · · · Remove fuel tank. Drain the clutch operating system. · · · · · · e Caution:brake fluid to come into contact with Do not allow painted parts of the motorcycle, because brake fluid attacks paint. Secure stand, BMW No. 5 mm (0. 20 in) to the rear. · · · · Disconnect line from master cylinder. Use a shortened cranked hex screwdriver or similar to disconnect the lines from the clutch slave cylinder. Fill the clutch operating system. Caution: Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid attacks paint. e · · · · · L Note: When installing, fit new sealing rings. Detach the clutch slave cylinder and pull it to the rear with the line. [. . . ] 51 0 531. · · · · · · Key in ON position/press in keeper (1) with a stiff wire or similar. Press lock barrel down until keeper engages. Tightening torques: Non-removable screws (microencapsulated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm X Drilling out lock barrel Use a 4-5 mm (0. 16-0. 20 in) dia. · Repeat with a drill bit of larger diameter until the lock barrel can be removed. Removing and installing ignition/light switch Removing and installing dualseat lock S510030 2 S510010 · Remove socket head cap screw (2). · · · · · · Remove seat. [. . . ]