BMW R1100S (1999) [149/302] Gearbox

Содержание

• Repair manual 1
• Introduction 3
• Contents 5
• 12 000 miles 7
• 6 000 miles 7
• 600 miles 7
• Annual service 7
• At 1 000 km 7
• Bmw ag motorcycle division maintenance schedule r1100 s 7
• Bmw inspection 7
• Bmw service 7
• Change clutch fluid 7
• Change the oil in the gearbox while at regular operating temperature 7
• Change the oil in the rear wheel drive while at regular operating temperature clean the inductive sensor at the rear wheel 7
• Change the oil while at regular operating temperature and renew the oil filter element 7
• Check adjust valve operating clearances 7
• Check battery acid level if necessary add distilled water clean grease battery poles if necessary 7
• Check clutch operating fluid level 7
• Check condition of spark plugs 7
• Check function of side prop stand contact switch 7
• Check rear wheel bearing play by tilting wheel 7
• Check tightness of rear wheel studs 7
• Every 10 000 km 7
• Every 20 000 km 7
• Final inspection with road safety and functional check condition of tyres and wheels tyre pressures lights and signalling equipment telltale and warning lights clutch gear shift handbrake and foot brake steering instruments trial run if necessary 7
• Grease the side prop stand pivot 7
• Maintenance schedule 7
• Read out the fault memory with the bmw moditec unit 7
• Renew the brake fluid annually 7
• Renewing intake air cleaner element 7
• Take up slack at cylinder head nuts 7
• Bmw ag motorcycle division pre delivery check r1100 s 8
• Pre delivery check 8
• Maintenance and general instructions 9
• Checking brake fluid level 10
• Checking clutch fluid level 10
• Checking engine oil level when cold adding oil if necessary 10
• Checking headlight beam angle adjusting if necessary 10
• Checking that delivery is complete 10
• Checking the crate for damage 10
• Checking tightness of rear wheel studs 10
• Checking tyre pressures 10
• Contents pre delivery check 10
• Disengaging and raising the fuel tank 10
• Filling and charging the battery 10
• Final cleaning 10
• Final inspection and function check 10
• Front brake 10
• General view of crated motorcycle 10
• Handing over the motorcycle 10
• In case of damage in germany 10
• In case of damage in importer markets 10
• Inspecting motorcycle for damage 10
• Installing remaining items on motorcycle 10
• Pre delivery check 10
• Rear brake 10
• Unpacking the motorcycle 10
• Changing engine oil replacing oil filter element 11
• Changing oil in gearbox 11
• Changing oil in rear wheel drive cleaning inductive signal transmitter at rear wheel 11
• Checking battery fluid level and topping up if necessary cleaning and greasing the battery posts 11
• Checking brake disc wear 11
• Checking brake fluid level 11
• Checking brake pads and discs for wear replacing 11
• Checking front brake pad wear 11
• Checking rear brake pad wear 11
• Contents maintenance 11
• Front brake 11
• Key to maintenance intervals 11
• Maintenance 11
• Reading out moditec fault memory 11
• Rear brake 11
• Replacing brake pads front brake 11
• Replacing brake pads rear brake 11
• Replacing fuel filter 11
• Replacing intake air filter element 11
• Replacing poly v belt 11
• Bleeding front brake circuit changing brake fluid so 12
• Bleeding rear brake circuit changing brake fluid 12
• Changing brake fluid and bleeding brake system 12
• Changing the clutch fluid 12
• Checking adjusting valve clearances 12
• Checking clutch fluid level 12
• Checking function of side stand switch 12
• Checking rear wheel bearing play by tilting wheel 12
• Checking replacing spark plugs 12
• Checking swinging arm bearings adjusting if necessary 12
• Checking throttle cable for ease of movement abrasion and kinks repla cing if necessary checking throttle cable play checking adjusting idle speed and throttle valve synchronisation 12
• Checking tightness of rear wheel studs 12
• Contents maintenance 12
• Final inspection with road safety and functional check 12
• Greasing the side stand pivot 12
• Tightening cylinder heads 12
• Tightening torques 13
• Table of consumables 19
• General view of crated motorcycle 21
• Pre delivery check 21
• Checking that delivery is complete 22
• Checking the crate for damage 22
• In case of damage in germany 22
• In case of damage in importer markets 22
• Inspecting motorcycle for damage 22
• Installing remaining items on motorcycle 22
• Unpacking the motorcycle 22
• Disengaging and raising the fuel tank 23
• Filling and charging the battery 23
• Checking engine oil level when cold adding oil if 24
• Checking engine oil level when cold adding oil if necessary 24
• Checking brake fluid level 25
• Checking clutch fluid level 25
• Checking clutch fluid level checking brake fluid level 25
• Front brake 25
• Rear brake 25
• Checking headlight beam angle adjusting if necess 26
• Checking headlight beam angle adjusting if necessary 26
• Checking tightness of rear wheel studs 26
• Checking tyre pressures 26
• Final cleaning 27
• Final inspection and function check 27
• Handing over the motorcycle 27
• Changing engine oil replacing oil filter element 28
• Inspections i ii iii and iv 28
• Key to maintenance intervals 28
• Maintenance 28
• Reading out moditec fault memory 28
• Changing oil in gearbox 29
• Inspections iii and iv 29
• Or every 2 years at the latest 29
• Changing oil in rear wheel drive cleaning inducti 30
• Changing oil in rear wheel drive cleaning inductive signal transmitter at rear wheel 30
• Every 40 000 km 24 000 miles or every 2 years at 30
• Inspections i iii and iv 30
• In normal operating conditions every 40 000 km 24 31
• Inspection iii 31
• Replacing fuel filter 31
• Checking battery fluid level and topping up if nec 33
• Checking battery fluid level and topping up if necessary cleaning and greasing the battery posts 33
• In very dirty and dusty operating conditions repl 33
• Inspection iii 33
• Inspections iii and iv 33
• Replacing intake air filter element 33
• Every 60 000 km 36 000 miles 34
• Inspection iii 34
• Poly v belt adjusting procedure 34
• Replacing poly v belt 34
• Checking brake fluid level 35
• Checking brake system for correct operation and freedom from leaks repairing replacing if necessary 35
• Front brake 35
• Rear brake 35
• Checking brake disc wear 36
• Checking brake pads and discs for wear replacing 36
• Checking front brake pad wear 36
• Checking rear brake pad wear 36
• Inspections ii and iii 36
• Replacing brake pads front brake 37
• Replacing brake pads front brake replacing brake pads rear brake 37
• Replacing brake pads rear brake 37
• Bleeding front brake circuit changing brake fluid 38
• Change the brake fluid annually 38
• Changing brake fluid and bleeding brake system 38
• Inspection iv 38
• Additional information for abs 39
• Bleeding rear brake circuit changing brake fluid 40
• Changing the clutch fluid 41
• Checking clutch fluid level 41
• Every 40 000 km 24 000 miles or every 2 years at 41
• Inspections i ii and iii 41
• Inspections iii and iv 41
• Checking rear wheel bearing play by tilting wheel 42
• Checking swinging arm bearings adjusting if neces 42
• Checking swinging arm bearings adjusting if necessary 42
• Checking tightness of rear wheel studs 42
• Inspection i 42
• Inspection iii 42
• Inspections i and iii 42
• Checking function of side stand switch 43
• Checking replacing spark plugs 43
• Greasing the side stand pivot 43
• Greasing the side stand pivot checking replacing spark plugs 43
• Inspection ii check inspection iii replace 43
• Inspections i ii and iii 43
• Inspections i ii iii and iv 43
• Checking adjusting valve clearances 44
• Inspection i 44
• Inspections i ii and iii 44
• Tightening cylinder heads 44
• Tightening cylinder heads checking adjusting valve clearances 44
• Checking throttle cable for ease of movement abra 45
• Checking throttle cable for ease of movement abrasion and kinks replacing if necessary checking throttle cable play checking adjusting idle speed and throttle valve synchronisation 45
• Inspections i ii iii and iv 45
• Final inspection with road safety and functional c 46
• Final inspection with road safety and functional check 46
• Inspections i ii iii and iv 46
• Road safety check 46
• Roadworthiness check 46
• Assembling pistons 47
• Checking pistons and cylinders 47
• Contents 47
• Cooling oil circuit 47
• Cutaway drawing of engine lubricating oil circuit 47
• Disassembling assembling valve gear holder 47
• Disassembling checking repairing and reassembling cylinder head 47
• Disassembling engine 47
• Engine 47
• Locking the engine at tdc 47
• Removing alternator mount cover 47
• Removing and disassembling piston 47
• Removing and installing alternator mount cover with engine installed 47
• Removing and installing chain tensioner 47
• Removing and installing conrod 47
• Removing cylinder 47
• Removing cylinder head 47
• Removing cylinder head cover 47
• Removing engine 47
• Removing valve gear holder 47
• Replacing radial shaft seal in alternator mount cover 47
• Technical data 47
• Assembling engine 48
• Assembling engine block 48
• Checking conrods 48
• Contents 48
• Disassembling crankcase 48
• Installing auxiliary shaft drive 48
• Installing auxiliary shaft timing chains 48
• Installing clutch housing 48
• Installing conrods 48
• Installing crankshaft 48
• Installing cylinder 48
• Installing cylinder head 48
• Installing oil pump 48
• Installing piston 48
• Installing radial shaft seals on crankshaft 48
• Installing timing chain tensioning and slide rails 48
• Measuring big end bearing play 48
• Measuring crankshaft bearing play 48
• Removing and installing oil intake strainers 48
• Removing and installing oil thermostat 48
• Removing auxiliary shaft drive 48
• Removing conrods 48
• Removing crankshaft auxiliary shaft and timing chain tensioning and slide rails 48
• Removing oil pump 48
• Removing radial shaft seal from crankshaft with engine installed 48
• Replacing oil level sight glass 48
• Adjusting valve clearances 49
• Contents 49
• Installing alternator 49
• Installing alternator mount cover 49
• Installing engine 49
• Installing left cylinder head 49
• Installing magnetic gate belt pulley 49
• Installing right cylinder head 49
• Cutaway drawing of engine lubricating oil circuit 57
• Cooling oil circuit 59
• Removing engine 61
• Disassembling engine 63
• Removing cylinder head cover 64
• Firing tdc 65
• Locking the engine at tdc 65
• Removing and installing chain tensioner 66
• Work instructions timing chain tensioner 66
• Removing valve gear holder 67
• Disassembling assembling valve gear holder 68
• Removing cylinder head 70
• Disassembling checking repairing and reassemblin 71
• Disassembling checking repairing and reassembling cylinder head 71
• Removing and installing valves 71
• Removing valve stem seals 71
• Checking and repairing cylinder head 72
• Checking valve guide for wear 72
• Checking valves for wear 72
• Remachining valve seat 72
• Replacing valve guides 73
• Installing valve and valve stem seal 74
• Removing and disassembling piston 75
• Removing cylinder 75
• Assembling pistons 76
• Assembling pistons checking pistons and cylinders 76
• Checking pistons and cylinders 76
• Removing and installing conrod 77
• Removing alternator mount cover 78
• Removing and installing alternator mount cover wit 78
• Removing and installing alternator mount cover with engine installed 78
• Replacing radial shaft seal in alternator mount co 78
• Replacing radial shaft seal in alternator mount cover 78
• Removing auxiliary shaft drive 79
• Removing oil pump 80
• Removing radial shaft seal from crankshaft with en 81
• Removing radial shaft seal from crankshaft with engine installed 81
• S note 81
• Disassembling crankcase 82
• Removing crankshaft auxiliary shaft and timing ch 84
• Checking conrods 85
• Removing and installing oil intake strainers 85
• Removing and installing oil thermostat 85
• Removing conrods 85
• Replacing oil level sight glass 85
• Measuring crankshaft bearing play 86
• Measuring radial bearing play 86
• Installing main bearings 87
• Measuring axial bearing play 87
• Measuring big end bearing play 88
• Assembling engine 89
• Installing conrods 89
• Installing auxiliary shaft timing chains 90
• Installing crankshaft 90
• Installing crankshaft installing auxiliary shaft timing chains 90
• Installing timing chain tensioning and slide rails 90
• Assembling engine block 91
• Installing radial shaft seals on crankshaft 94
• Installing the clutch end radial shaft seal 94
• Installing the crankshaft end radial shaft seal 94
• Installing clutch housing 95
• Installing oil pump 96
• Installing auxiliary shaft drive 97
• Installing piston 98
• Installing cylinder 99
• Installing cylinder head 100
• Adjusting valve clearances 101
• Adjustment specification 102
• Installing right cylinder head 102
• Adjustment specification 103
• Installing left cylinder head 103
• Installing alternator mount cover 105
• Installing magnetic gate belt pulley 105
• Timing the ignition 106
• Installing alternator 107
• Installing engine 108
• Checking alternator 109
• Checking armature for short to ground earth 109
• Checking ignition coil resistance 109
• Checking starter motor 109
• Checking starter relay 109
• Contents 109
• Disassembling assembling alternator 109
• Disassembling assembling starter motor 109
• Engine electrics 109
• Option 50 a 109
• Removing and installing alternator 109
• Removing and installing coil and ignition leads 109
• Removing and installing magnetic gate 109
• Removing and installing starter motor 109
• Replacing carbon brushes 109
• Technical data 109
• Timing the ignition 109
• Checking ignition coil resistance 113
• Removing and installing coil and ignition leads 113
• Poly v belt adjusting procedure 114
• Removing and installing alternator 114
• Checking alternator 115
• Checking armature for short to ground earth 115
• Disassembling assembling alternator 115
• Checking alternator 116
• Checking armature for short to ground earth 116
• Disassembling assembling alternator 116
• Option 50 a 116
• Removing and installing starter motor 117
• Checking starter motor 118
• Checking starter relay 118
• Disassembling assembling starter motor 118
• Replacing carbon brushes 118
• Removing and installing magnetic gate 119
• Timing the ignition 120
• Contents 121
• Fuel preparation and control 121
• Removing and installing air filter housing 125
• Kemoving and installing throttle valve stub pipe 126
• Removing and installing throttle valve stub pipe 126
• Removing and installing motronic control unit 127
• Removing and installing throttle valve potentiomet 127
• Removing and installing throttle valve potentiometer 127
• Contents 129
• Fuel tank and lines 129
• Removing and installing fuel distributor and pressure regulator 129
• Removing and installing fuel filter 129
• Removing and installing fuel filter fuel pump and fuel level sensor 129
• Removing and installing fuel pump and fuel level sensor 129
• Removing and installing fuel tank 129
• Technical data 129
• Removing and installing fuel tank 133
• Removing and installing fuel filter 134
• Removing and installing fuel filter fuel pump and 134
• Removing and installing fuel filter fuel pump and fuel level sensor 134
• Checking fuel pump pressure 135
• Removing and installing fuel distributor and press 135
• Removing and installing fuel distributor and pressure regulator 135
• Removing and installing fuel pump and fuel level s 135
• Removing and installing fuel pump and fuel level sensor 135
• Contents 137
• Exhaust system 137
• Removing and installing exhaust manifolds 139
• Removing and installing exhaust system 139
• Removing and installing silencer muffler 139
• Clutch 141
• Contents 141
• Installing clutch 141
• Removing clutch 141
• Installing clutch 145
• Removing and installing clutch 145
• Removing clutch 145
• Removing and installing clutch hydraulic line 146
• Removing and installing clutch slave cylinder 146
• Filling bleeding clutch line 147
• Assembling gearbox 149
• Checking adjusting fully assembled length of gearbox shafts and selector drum 149
• Checking endplay 149
• Contents 149
• Disassembling assembling input shaft 149
• Disassembling assembling output shaft 149
• Disassembling assembling selector shaft 149
• Disassembling gearbox 149
• Gearbox 149
• Installing gearbox housing 149
• Installing input output and intermediate shafts 149
• Installing selector drum 149
• Installing selector shaft 149
• Removing and installing gear shift lever 149
• Removing gearbox 149
• Removing gearbox housing 149
• Removing gearbox shafts 149
• Removing selector drum 149
• Replacing grooved ball bearing on intermediate shaft 149
• Replacing the shaft sealing rings in the gearbox housing and gearbox cover 149
• Shimming selector shaft 149
• Technical data 149
• Removing and installing gear shift lever 153
• Removing gearbox 153
• Replacing input shaft sealing ring at input end 155
• Replacing output shaft sealing ring 155
• Replacing the shaft sealing rings in the gearbox h 155
• Replacing the shaft sealing rings in the gearbox housing and gearbox cover 155
• Replacing input shaft sealing ring at output end 156
• Replacing sealing ring for selector shaft 156
• Replacing shaft sealing ring for selector drum 156
• Disassembling gearbox 157
• Removing gearbox housing 157
• Disassembling assembling selector shaft 158
• Removing selector drum 158
• Removing gearbox shafts 159
• Replacing grooved ball bearing on intermediate sha 159
• Replacing grooved ball bearing on intermediate shaft 159
• Disassembling assembling input shaft 160
• Disassembling input shaft 160
• Assembling input shaft 161
• Disassembling assembling output shaft 162
• Disassembling output shaft 162
• Assembling output shaft 163
• Checking endplay 164
• Checking adjusting fully assembled length of gearb 165
• Checking adjusting fully assembled length of gearbox shafts and selector drum 165
• Checking adjusting fully assembled length of inter 165
• Checking adjusting fully assembled length of outpu 166
• Checking adjusting fully assembled length of input 167
• Checking adjusting fully assembled length of selec 168
• Shimming selector shaft 169
• Assembling gearbox 170
• Installing input output and intermediate shafts 170
• Installing selector drum 171
• Installing selector shaft 171
• Installing selector shaft installing selector drum 171
• Installing gearbox housing 172
• Assembling telescopic fork 175
• Contents 175
• Disassembling assembling leading link 175
• Disassembling assembling telescopic fork 175
• Disassembling telescopic fork 175
• Front fork 175
• Measuring telescopic fork 175
• Removing and installing front suspension strut 175
• Removing and installing leading link 175
• Removing and installing telescopic fork 175
• Technical data 175
• Removing and installing telescopic fork 179
• Removing and installing ball joint in fork bridge 180
• Removing and installing ball joint in slider tube 180
• Assembling telescopic fork 181
• Disassembling assembling telescopic fork 181
• Disassembling telescopic fork 181
• Checking runout of fixed tube 182
• Checking runout of slider tube 182
• Examining slider tube bridge and fork bridge 182
• Measuring telescopic fork 182
• Disassembling assembling leading link 183
• Removing and installing leading link 183
• Removing and installing front suspension strut 184
• Contents 185
• Steering 185
• Removing and installing left handlebar fitting 189
• Removing and installing right handlebar fitting 190
• Removing and installing handlebar 191
• Removing and installing bowden cable divider bow 192
• Removing and installing bowden cable divider bowden cable for throttle actuation and starting speed increase 192
• Disassembling bowden cable divider 193
• Assembling input bevel pinion 195
• Assembling installing crown wheel 195
• Checking adjusting backlash 195
• Checking tooth contact pattern 195
• Contents 195
• Disassembling input bevel pinion 195
• Installing drive shaft 195
• Installing housing cover 195
• Installing input bevel pinion 195
• Installing rear swinging arm 195
• Installing rear wheel drive 195
• Installing sliding element 195
• Rear wheel drive 195
• Removing and disassembling crown wheel 195
• Removing and installing flexible gaiter 195
• Removing and installing rear swinging arm 195
• Removing and installing suspension strut 195
• Removing and installing taper roller bearing 195
• Removing disassembling reassembling and installing rear wheel drive 195
• Removing drive shaft 195
• Removing input bevel pinion 195
• Removing rear swinging arm 195
• Removing rear wheel drive 195
• Shimming housing cover 195
• Technical data 195
• Removing disassembling reassembling and installi 199
• Removing disassembling reassembling and installing rear wheel drive 199
• Removing input bevel pinion 199
• Removing rear wheel drive 199
• Disassembling input bevel pinion 201
• Installing needle roller bearing for input bevel p 201
• Removing needle roller bearing for input bevel pin 201
• Assembling input bevel pinion 202
• Installing input bevel pinion 203
• Removing and disassembling crown wheel 204
• Assembling installing crown wheel 205
• Checking adjusting backlash 206
• Checking tooth contact pattern 207
• Installing housing cover 208
• Installing sliding element 208
• Shimming housing cover 208
• Removing and installing rear swinging arm 209
• Removing rear swinging arm 209
• Checking universal joint for wear 210
• Installing drive shaft 210
• Oo 8 57 210
• Removing and installing flexible gaiter 210
• Removing and installing taper roller bearing 210
• Removing drive shaft 210
• Installing rear swinging arm 211
• Installing rear wheel drive 212
• Removing and installing suspension strut 213
• Adjusting front abs sensor gap 215
• Adjusting rear abs sensor gap 215
• Assembling front brake caliper 215
• Assembling rear brake caliper 215
• Brakes 215
• Checking and adjusting play of piston rod 215
• Checking and adjusting sensor gap 215
• Contents 215
• Disassembling and assembling front brake caliper 215
• Disassembling and assembling rear brake caliper 215
• Disassembling front brake caliper 215
• Disassembling rear brake caliper 215
• Installing the abs unit 215
• Marking sensor wheel 215
• Removing and installing abs unit 215
• Removing and installing footbrake lever 215
• Removing and installing front abs sensor 215
• Removing and installing front brake caliper 215
• Removing and installing front brake disc 215
• Removing and installing rear abs sensor 215
• Removing and installing rear brake caliper 215
• Removing and installing rear brake disc 215
• Removing and installing rear brake master cylinder 215
• Removing the abs unit 215
• Technical data 215
• Contents 216
• Installing the abs relay 216
• Installing the abs relay base 216
• Removing abs relay 216
• Removing abs relay socket 216
• Removing and installing abs relay and relay socket 216
• Removing and installing brake line 216
• Removing and installing front brake line 216
• Removing and installing rear brake line 216
• Removing and installing front brake caliper 219
• Assembling front brake caliper 220
• Disassembling and assembling front brake caliper 220
• Disassembling front brake caliper 220
• Removing and installing rear brake caliper 221
• Assembling rear brake caliper 222
• Disassembling and assembling rear brake caliper 222
• Disassembling rear brake caliper 222
• Removing and installing front brake disc 223
• Removing and installing rear brake disc 224
• Removing and installing front abs sensor 225
• Adjusting front abs sensor gap 226
• Checking and adjusting sensor gap 226
• Marking sensor wheel 226
• Removing and installing rear abs sensor 227
• Adjusting rear abs sensor gap 228
• Checking and adjusting sensor gap 228
• Marking sensor wheel 228
• Checking and adjusting play of piston rod 229
• Removing and installing rear brake master cylinder 229
• Removing and installing footbrake lever 230
• Removing and installing abs unit 231
• Removing the abs unit 231
• Installing the abs unit 232
• Installing the abs relay 233
• Removing abs relay 233
• Removing and installing abs relay and relay socket 233
• Installing the abs relay base 234
• Removing abs relay socket 234
• Removing and installing brake line 235
• Removing and installing front brake line 235
• Removing and installing rear brake line 236
• Checking front rear wheel rim for runout 239
• Contents 239
• Installing front wheel 239
• Removing and installing front wheel 239
• Removing and installing rear wheel 239
• Removing and installing wheel bearings 239
• Removing front wheel 239
• Static balancing of front and rear wheels 239
• Technical data 239
• Wheels and tyres 239
• Installing front wheel 243
• Removing and installing front wheel 243
• Removing front wheel 243
• Removing and installing wheel bearings 244
• Removing and installing rear wheel 246
• Static balancing of front and rear wheels 247
• Checking front rear wheel rim for runout 248
• Checking running gear 249
• Contents 249
• Exploded view of fairing sections 249
• Measuring wheel track offset 249
• Removing and installing fairing 249
• Removing and installing fairing bracket 249
• Removing and installing frame tail section 249
• Removing and installing front frame 249
• Removing and installing front mudguard 249
• Removing and installing main frame 249
• Removing and installing number plate carrier 249
• Removing and installing rear mudguard 249
• Removing and installing rear side panels 7 249
• Removing and installing side panels 249
• Removing and installing side stand 249
• Removing and installing tail section 249
• Removing and installing tank trim 249
• Technical data 249
• Exploded view of fairing sections 253
• Removing and installing fairing 254
• Removing and installing side panels 254
• Removing and installing tank trim 254
• Removing and installing rear side panels 255
• Removing and installing tail section 255
• Removing and installing number plate carrier 256
• Removing and installing rear mudguard 256
• Removing and installing front mudguard 257
• Removing and installing fairing bracket 258
• Removing and installing front frame 259
• Removing and installing main frame 261
• Removing and installing frame tail section 264
• Removing and installing side stand 265
• Checking running gear 266
• Measuring wheel track offset 266
• Contents 269
• Equipment 269
• Removing and installing dualseat lock 269
• Removing and installing ignition light switch 269
• Removing and installing ignition switch steering lock 269
• Removing and installing lock barrel 269
• Removing and installing lock barrel for fuel tank filler cap 269
• Drilling out lock barrel 271
• Removing and installing dualseat lock 271
• Removing and installing ignition light switch 271
• Removing and installing ignition switch steering l 271
• Removing and installing ignition switch steering lock 271
• Removing and installing lock barrel 271
• Drilling out lock barrel 272
• Removing and installing lock barrel for fuel tank 272
• Removing and installing lock barrel for fuel tank filler cap 272
• Contents 273
• Removing and installing seat 273
• Removing and installing seat 275
• Contents 277
• General electrical equipment 277
• Wiring harness view from left 277
• Wiring harness view from right 277
• Fuse assignments 281
• Left fuse box 281
• Relay positions central electrical equipment box 281
• Right fuse box 281
• Frame wiring harness 282
• Wiring harness view from left 283
• Wiring harness view from right 287
• Contents 291
• Disassembling and assembling instrument panel 291
• Instruments 291
• Removing and installing instrument panel 291
• Technical data 291
• Disassembling and assembling instrument panel 295
• Removing and installing instrument panel 295
• Adjusting headlight 297
• Contents 297
• Lights 297
• Removing and installing headlight 297
• Technical data 297
• Adjusting headlight 301
• Removing and installing headlight 301

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23 Gearbox Contents Page Technical Data 3 Removing and installing gear shift lever 5 Removing gearbox 5 Replacing the shaft sealing rings in the gearbox housing and gearbox cover 7 Replacing input shaft sealing ring at input end 7 Replacing output shaft sealing ring 7 Replacing input shaft sealing ring at output end 8 Replacing shaft sealing ring for selector drum 8 Replacing sealing ring for selector shaft 8 Disassembling gearbox 9 Removing gearbox housing 9 Removing selector drum 10 Disassembling assembling selector shaft 10 Removing gearbox shafts 11 Replacing grooved ball bearing on intermediate shaft 11 Disassembling assembling input shaft 12 Disassembling input shaft 12 Assembling input shaft 13 Disassembling assembling output shaft 14 Disassembling output shaft 14 Assembling output shaft 15 Checking endplay 16 Checking adjusting fully assembled length of gearbox shafts and selector drum 17 Checking adjusting fully assembled length of intermediate shaft 17 Checking adjusting fully assembled length of output shaft 18 Checking adjusting fully assembled length of input shaft 19 Checking adjusting fully assembled length of selector drum 20 Shimming selector shaft 21 Assembling gearbox 22 Installing input output and intermediate shafts 22 Installing selector shaft 23 Installing selector drum 23 Installing gearbox housing 24 23 1