BMW K75 [51/236] Dismantling the engine unit preliminaries and general procedures

Содержание

• Binder1 pdf 1
• Bmw k100 75 owners workshop manual 1
• By jeremy churchill 1
• Haynes publications inc 1
• Haynes publishing group 1
• Lawrence drive newbury park california 91320 usa 1
• Models covered 1
• Sparkford nr yeovil somerset ba22 7jj england 1
• Contents 3
• Is 22 au wsj i 36 3
• About this manual 5
• Introduction to k100 and k75 models 5
• Introduction to the bmw k100 and 75 models 5
• Dimensions and weights 8
• Gross weight limit total of machine passenger s and luggage 8
• Ground clearance with rider weighing 165 lb 75 kg seated 8
• Kerb weight machine with full fuel tank tools etc 8
• Model dimensions and weights 8
• Overall height 8
• Overall length 8
• Overall width 8
• Seat height unladen 8
• Wheelbase with rider weighing 165 lb 75 kg seated 8
• At all times 9
• Ordering spare parts 9
• Produced 9
• Production 9
• Asbestos 10
• Essential dos and don ts 10
• Ignition ht voltage 10
• Mains electricity 10
• Safety first 10
• The battery 10
• Tools and working facilities 11
• Care and maintenance of tools 12
• Fastening systems 12
• Maintenance and minor repair tool kit 12
• Repair and overhaul toolkit 12
• Specialized tools 12
• Tools and working facilities 12
• Fastener type 13
• Jaw gap in spanner size jaw gap in spanner size 13
• Kgf m ibf ft 13
• Spanner size comparison 13
• Spanner sizes 13
• Standard torque settings 13
• Choosing and fitting accessories 14
• Fairings and windscreens 14
• Choosing and fitting accessories 15 15
• Crashbars 15
• Exhaust systems 15
• Handlebars 15
• Luggage 15
• Luggage racks or carriers 15
• Accessories general 16
• Choosing and fitting accessories 16
• Electrical equipment 16
• Abnormal engine noise 17
• Abnormal frame and suspension noise 17
• Abnormal transmission noise 17
• Acceleration poor 17
• Brake problems 17
• Clutch operating problems 17
• Contents 17
• Electrical problems 17
• Engine does not start when turned over 17
• Engine stalls after starting 17
• Exhaust smokes excessively 17
• Fault diagnosis 17
• Gear selection problems 17
• Knocking or pinking 17
• Oh pressure indicator lamp goes on 17
• Overheating 17
• Poor handling or roadholding 17
• Poor running at idle and low speed 17
• Poor running or lack of power at high speeds 17
• Starter motor problems 17
• Engine does not start when turned over 18
• Engine flooding 18
• Fault diagnosis 18
• Fuel not reaching cylinder 18
• Introduction 18
• No fuel flow to engine 18
• No spark at plug 18
• Starter motor and clutch function but engine will not turn over 18
• Starter motor not rotating 18
• Starter motor problems 18
• Starter motor rotates but engine does not turn over 18
• Acceleration poor 19
• Compression low 19
• Compression low 13 fuel air mixture incorrect 19
• Engine stalls after starting 19
• Fault diagnosis 19 19
• General causes 19
• Poor running at idle and low speed 19
• Poor running or lack of power at high speeds 19
• Weak spark at plug 19
• Weak spark at plug or erratic firing 19
• Clutch drag 20
• Clutch operating problems 20
• Clutch slip 20
• Compression low 20
• Fault diagnosis 20
• Firing incorrect 20
• Fuel air mixture incorrect 20
• Gear lever does not return 20
• Gear selection difficult or impossible 20
• Gear selection problems 20
• General causes 20
• Knocking or pinking 20
• Lubrication inadequate 20
• Miscellaneous causes 20
• Overheating 20
• Abnormal engine noise 21
• Abnormal transmission noise 21
• Clutch noise 21
• Fault diagnosis 21 21
• Jumping out of gear 21
• Knocking or pinking 21
• Other noises 21
• Overselection 21
• Piston slap or rattling from cylinder 21
• Valve noise or tapping from the cylinder head 21
• Black smoke caused by over rich mixture 22
• Directional instability 22
• Electrical system failure 22
• Engine lubrication system failure 22
• Exhaust smokes excessively 22
• Fault diagnosis 22
• Oh pressure indicator lamp goes on 22
• Poor handling or roadholding 22
• Steering bias to left or right 22
• Transmission noise 22
• White blue smoke caused by oil burning 22
• Abnormal frame and suspension noise 23
• Brake problems 23
• Brakes are spongy or ineffective disc brakes 23
• Fault diagnosis 23 23
• Front end noise 23
• Front fork judder when braking see also section 56 23
• Handlebar vibrates or oscillates 45 poor rear suspension performance 23
• Poor front fork performance 23
• Rear suspension noise 23
• Battery dead or weak 24
• Brake drag drum brakes 24
• Brake induced fork judder 24
• Brake lever or pedal pulsates in operation disc brakes 24
• Brake pedal pulsates in operation drum brakes 24
• Brakes are spongy or ineffective drum brakes 24
• Brakes drag disc brakes 24
• Disc brake noise 24
• Drum brake noise 24
• Electrical problems 24
• Fault diagnosis 24
• Battery overcharged 25
• Bulbs blowing repeatedly 25
• Circuit failure 25
• Fault diagnosis 25 25
• Total electrical failure 25
• Cycle parts 26
• Engine 26
• Recommended lubricants 26
• Routine maintenance 26
• Specifications 26
• Additional recommendations 27
• Cleaning the machine 27
• Daily pre ride check 27
• Introduction 27
• Routine maintenance 27 27
• Service intervals mileage 27
• Service intervals time 27
• 30 20 10 0 10 20 30 40 50 c 28
• Check the engine oil level 28
• Check the tyres 28
• Daily check 28
• Do not 28
• Engine oil viscosity selection chart 28
• I sae 15w 4cf 28
• Routine maintenance 28
• Sae 10w 30 i 28
• Sae 10w 50 28
• Sae 20 28
• Sae 30 28
• Sae 40 28
• ____ sae 10w 40 28
• _______ sae 15w 50 28
• Check the brakes 29
• Check the controls 29
• Check the coolant level 29
• Check the fuel level 29
• Check the tightness of all nuts and bolts 29
• Legal check 29
• Rear suspension settings 29
• Routine maintenance 29 29
• Check the battery 30
• Routine maintenance 30
• Change the engine oil and filter 31
• Minor service 31
• Routine maintenance 31 31
• Check the final drive case oil level 32
• Check the gearbox oil level 32
• Maximum 32
• Routine maintenance 32
• Lubricate the controls and stand pivots 33
• Routine maintenance 33 33
• Adjusting the valve clearances with service tools 34
• Check and adjust the valve clearances 34
• Checking the valve clearances 34
• It is essential 34
• Must not 34
• Routine maintenance 34
• Routine maintenance 35 35
• Adjusting the valve clearances without service tools 36
• Check and adjust the spark plugs 36
• Routine maintenance 36
• Air filter 37
• Change the engine oil and filter 37
• Final inspection 37
• Major service 37
• Routine maintenance 37 37
• Change the final drive case oil 38
• Change the front fork oil 38
• Change the gearbox oil 38
• Clean the speedometer impulse transmitter 38
• Major service 38
• Routine maintenance 38
• Spark plug conditions 39
• Spark plug maintenance 39
• Check and adjust the dutch 40
• Check the battery 40
• Check the cooling system 40
• Lubricate the controls and stand pivots 40
• Renew the air filter element 40
• Routine maintenance 40
• Check and adjust the valve clearances 41
• Check and overhaul the brakes 41
• Check the fuel system 41
• Disc brakes front and rear 41
• Renew the spark plugs 41
• Routine maintenance 41 41
• Routine maintenance 42
• Brake fluid renewal 43
• Keep the master cylinder reservoir topped up at all times 43
• Routine maintenance 43 43
• Check the steering head bearings 44
• Check the swinging arm pivot bearings 44
• Check the wheels and wheel bearings 44
• Drum rear brake 44
• Drum rear brake wear limit marks 44
• Front wheel bearings 44
• Rear wheel bearings 44
• Routine maintenance 44
• Wheels 44
• Final inspection 45
• Renew the fuel filter 45
• Routine maintenance 45 45
• Chapter 1 engine 46
• Compression pressure see section 2 46
• Contents 46
• Engine 46
• Late us 75 models 100 models 46
• Models 100 models 46
• Specifications 46
• Uk 75 models early us 75 models 46
• At size code a at size code b 47
• Camshafts and cam followers 47
• Chapter 1 engine 47 47
• Cylinder block 47
• Pistons and gudgeon pins 47
• Us models 47
• Valve clearances engine cold maximum coolant temperature 20 c 68 f 47
• Valve timing at 5 100 preload and 3 mm 0 2 in lift uk models 47
• Valves guides and springs 47
• Chapter 1 engine 48
• Connecting rods and bearings 48
• Crankshaft and main bearings 48
• Models 100 models 48
• Piston rings 48
• Primary drive 48
• Torque wrench settings component 48
• Carrying out a compression test 49
• Chapter 1 engine 49 49
• Component 49
• General description 49
• Nm ibf ft nm ibf ft 49
• Chapter 1 engine 50
• Dismantling the engine unit general 50
• Do not 50
• Removing the engine 50
• Removing the engine unit from the frame 50
• Chapter 1 engine 51 51
• Dismantling the engine unit preliminaries and general procedures 51
• Preliminary dismantling 51
• Cam chain engine front cover 52
• Chapter 1 engine 52
• Crankshaft engine right hand cover 52
• Cylinder head engine left hand cover 52
• Dismantling the engine 52
• Dismantling the engine unit removing the bellhousing and auxiliary drive shaft components 52
• Dismantling the engine unit removing the outer covers 52
• Do not 52
• General 52
• General procedures 52
• Chapter 1 engine 53 53
• Dismantling the engine unit removing the camshafts and cam chain 53
• Chapter 1 engine 54
• Fig 1 camshafts and cam chain 54
• Chapter 1 engine 55 55
• Dismantling the engine unit removing the cylinder head 55
• Chapter 1 engine 56
• Dismantling the engine unit removing the pistons and connecting rods 56
• Fig 1 cylinder head and valves 100 models 75 similar 56
• Chapter 1 engine 57
• Fig 1 crankshaft connecting rods and pistons 100 models 75 similar 57
• Chapter 1 engine 58
• Dismantling the engine unit removing the crankcase lower section and the output balancer shaft 58
• Do not 58
• Fig 1 method of removing gummed piston rings 58
• Chapter 1 engine 59 59
• Dismantling the engine unit removing the crankshaft 59
• Must be removed 59
• Always 60
• Chapter 1 engine 60
• Dismantling the engine unit removing bearings and oil seals 60
• Examination and renovation general 60
• Chapter 1 engine 61 61
• Examination and renovation bearings and oil seals 61
• Examination and renovation camshafts and camshaft drive mechanism 61
• Examination and renovation engine cases and covers 61
• Chapter 1 engine 62
• Chapter 1 engine 63 63
• Examination and renovation cylinder head 63
• Examination and renovation valves valve seats and valve guides 63
• Chapter 1 engine 64
• Chapter 1 engine 65 65
• Examination and renovation cylinder block 65
• Chapter 1 engine 66
• Examination and renovation connecting rods and big end bearings 66
• Examination and renovation pistons and piston rings 66
• Chapter 1 engine 67
• Examination and renovation crankshaft and main bearings 67
• Fig 1 fabricated small end bush drawbolt tool 67
• Chapter 1 engine 68
• Examination and renovation output balancer shaft 68
• Chapter 1 engine 69 69
• It is essential 69
• Fig 1 output balancer shaft 75 models 71
• Above all 72
• Chapter 1 engine 72
• Examination and renovation auxiliary drive shaft and starter clutch 72
• Fig 1 output shaft 100 models 72
• Chapter 1 engine 73
• Fig 1 auxiliary drive shaft and starter clutch components 73
• Chapter 1 engine 74
• Re assembly 74
• Reassembling the engine unit general 74
• Chapter 1 engine 75 75
• Reassembling the engine unit refitting bearings and oil seals 75
• Reassembling the engine unit refitting the crankshaft 75
• Chapter 1 engine 76
• Reassembling the engine unit refitting the output balancer shaft and the crankcase lower section 76
• Chapter 1 engine 77 77
• Fig 1 crankshaft balancer shaft timing marks 75 models 77
• Chapter 1 engine 79 79
• Reassembling the engine unit refitting the pistons and connecting rods 79
• Chapter 1 engine 81 81
• Fig 1 0 cylinder head bolt tightening sequence 75 models 81
• Fig 1 1 cylinder head bolt tightening sequence 100 models 81
• Reassembling the engine unit refitting the cylinder head 81
• Chapter 1 engine 82
• Do not 82
• Ensure that the number in each bearing cap matches the number cast into the cylinder head next to the bearing pedestal and that the number is above intake or below exhaust the threaded boss and can be read only from the rear 82
• Reassembling the engine unit refitting the camshafts and setting the valve timing 82
• Chapter 1 engine 83 83
• Exactly 83
• Stop immediately 83
• Chapter 1 engine 86
• Reassembling the engine unit refitting the auxiliary drive shaft components and the bellhousing 86
• Cam chain engine front cover 87
• Chapter 1 engine 87 87
• Crankshaft engine right hand cover 87
• Cylinder head engine left hand cover 87
• General 87
• Reassembling the engine unit refitting the outer covers 87
• All models 89
• All other models 89
• Chapter 1 engine 89 89
• Early 100 models 89
• Reassembling the engine unit refitting ancillary components 89
• Refitting the engine 89
• Refitting the engine unit to the frame 89
• Chapter 1 engine 90
• Chapter 1 engine 91 91
• Starting and running the rebuilt engine 91
• Taking the rebuilt machine on the road 91
• Chapter 2 clutch 92
• Clutch 92
• Clutch friction plate 92
• Clutch removal 92
• Contents 92
• General description 92
• Models 100 models 92
• Nm ibf ft nm ibf ft 92
• Specifications 92
• Torque wrench settings component 92
• Clutch assembly 75 models 93
• Fig 2 clutch assembly 100 models 93
• Chapter 2 clutch 94
• Clutch dismantling 94
• Clutch examination and renovation 94
• Chapter 2 clutch 95 95
• Clutch reassembly 95
• Fig 2 clutch friction plate centring tool 97
• Chapter 2 clutch 98
• Clutch release mechanism removal examination and reassembly 98
• Fig 2 side stand retracting mechanism late models 98
• Chapter 3 gearbox 101
• Contents 101
• Gearbox 101
• Gearbox lubrication 101
• Models 100 models 101
• Nm ibf f 101
• Nm ibf ft 101
• Specifications 101
• Torque wrench settings component 101
• Chapter 3 gearbox 102
• General description 102
• Removing the gearbox from the frame 102
• Chapter 3 gearbox 103 103
• Do not 103
• Fig 3 gearbox housing 103
• Gearbox dismantling 103
• Chapter 3 gearbox 104
• Gearbox removing and refitting the bearings and seals 104
• Chapter 3 gearbox 105 105
• Gearbox shafts dismantling and reassembly 105
• Input shaft 105
• Layshaft 105
• Output shaft 105
• Chapter 3 gearbox 108
• Fig 3 gearbox shafts 108
• Gearbox examination and renovation 108
• Chapter 3 gearbox 109 109
• Checking and resetting the gearbox shafts endfloat and preload 109
• Input shaft 109
• Layshaft and output shaft 109
• Preloaded 109
• Chapter 3 gearbox 110
• Fig 3 selector drum and forks 110
• Gearbox reassembly 110
• Fig 3 selector mechanism 111
• Chapter 3 gearbox 116
• Refitting the gearbox to the frame 116
• Chapter 4 cooling system 117
• Contents 117
• Coolant 117
• Coolant overheat warning lamp 117
• Cooling system 117
• Expansion tank 117
• Ibf ft 117
• Models 100 models 117
• Radiator 117
• Specifications 117
• Thermostat 117
• Torque wrench settings component 117
• Chapter 4 cooling system 118
• Cooling system draining 118
• Cooling system filling 118
• Cooling system flushing 118
• General description 118
• Standard 118
• Warning 118
• Chapter 4 cooling system 119 119
• Radiator removal cleaning and examination 119
• Chapter 4 cooling system 121 121
• Fig 4 radiator and fan 121
• Radiator pressure cap testing 121
• Chapter 4 cooling system 122
• Do not use excessive force 122
• Fig 4 cooling system hoses 122
• Hoses and connections removal refitting and checking for leaks 122
• Warning 122
• Chapter 4 cooling system 123 123
• Do not 123
• Thermostat removal and testing 123
• Chapter 4 cooling system 124
• Water pump removal renovation and refitting 124
• Chapter 4 cooling system 125 125
• Coolant temperature sensor 125
• Cooling fan removal examination and refitting 11 cooling system electrical components removal and refitting 125
• Temperature sensing switch unit 125
• Chapter 4 cooling system 126
• Coolant overheat warning lamp 126
• Chapter 5 fuel system and lubrication 127
• Contents 127
• Fuel system and lubrication 127
• Fuel tank capacity 127
• Recommended fuel grade see section 21 for full information 127
• Specifications 127
• Chapter 5 fuel system and lubrication 128
• Engine lubrication system 128
• Engine oil 128
• Fuel system 128
• General description 128
• Maximum 128
• Models 100 models 128
• Nm ibf ft nm 128
• Torque wrench settings component 128
• Chapter 5 fuel system and lubrication 129 129
• Chapter 5 fuel system and lubrication 130
• Fig 5 lubrication system 130
• Precautions to be observed when servicing the fuel system 130
• Warning 130
• Before 131
• Chapter 5 fuel system and lubrication 131 131
• Do not attempt 131
• Fuel system fault finding 131
• Relieving fuel system pressure 131
• Chapter 5 fuel system and lubrication 132
• Do not attempt 132
• Fuel tank removal and refitting 132
• Fig 5 fuel tank assembly 134
• Chapter 5 fuel system and lubrication 135 135
• Do not 135
• Evaporative emission control system 135
• External hoses 135
• Filler cap 135
• Fuel return valve 135
• Fuel tank components general 135
• Fuel tank general 135
• Internal hoses and pipes 135
• Tank insulation 135
• Chapter 5 fuel system and lubrication 136
• Fuel filter removal and refitting 136
• Fuel gauge sender unit removal and refitting 136
• Fuel pump removal and refitting 136
• Chapter 5 fuel system and lubrication 138
• Fuel pressure testing 13 fuel rail and injectors removal examination and refitting 138
• Fuel pump examination and renovation 138
• Pressure regulator removal examination and refitting 138
• Chapter 5 fuel system and lubrication 139 139
• Air filter housing removal and refitting 140
• Chapter 5 fuel system and lubrication 140
• Airflow meter removal and refitting 141
• Chapter 5 fuel system and lubrication 141 141
• Chapter 5 fuel system and lubrication 142
• Do not 142
• Throttle butterfly assembly and plenum chamber removal and refitting 142
• Airflow meter 144
• Chapter 5 fuel system and lubrication 144
• Do not 144
• Fuel injection control unit 144
• Fuel injection relay 144
• Fuel system electrical components removal examination and refitting 144
• Must not 144
• Throttle position switch 144
• Chapter 5 fuel system and lubrication 145 145
• Fast idle speed choke control cable 145
• Fuel system adjustments and checks 145
• Models 100 models 145
• Chapter 5 fuel system and lubrication 146
• Do not 146
• Exactly 146
• Idle mixture adjustment 146
• Idle speed and throttle cable 146
• Throttle butterfly synchronisation 146
• Chapter 5 fuel system and lubrication 147 147
• Checking for induction system air leaks 147
• Checking the air filter element 147
• General 147
• Idle speed mixture adjustment 147
• Mixture adjustment and checks using an exhaust gas analyser 147
• Chapter 5 fuel system and lubrication 148
• Compensating for high altitude us models 148
• Exhaust system removal and refitting 148
• Exhaust system removal refitting 148
• Leaded fuel 148
• Must not 148
• Premium grade fuel 148
• Recommended fuel general 148
• Regular grade fuel 148
• Unleaded fuel 148
• Chapter 5 fuel system and lubrication 149 149
• Oil pump removal examination and refitting 149
• Chapter 5 fuel system and lubrication 150
• Fig 5 oil water pump 150
• Chapter 5 fuel system and lubrication 151 151
• Oil pressure relief valve general 151
• Chapter 5 fuel system and lubrication 152
• Oil filter renewal 152
• Oil pump pick up filter gauze cleaning 152
• Chapter 5 fuel system and lubrication 153 153
• Oil pressure warning lamp general 153
• Chapter 6 ignition system 154
• Contents 154
• Crankshaft angle piston position 154
• General description 154
• Ignition ht coil 154
• Ignition system 154
• Models 154
• Models nm ibf ft 154
• Spark plug 154
• Specifications 154
• Torque wrench settings component 154
• Chapter 6 ignition system 155 155
• Fig 6 ignition system components 155
• Precautions to be observed when checking the ignition system 155
• Warning 155
• Chapter 6 ignition system 156
• Ignition control unit removal and refitting 156
• Ignition trigger assembly removal and refitting 156
• It is essential 156
• Chapter 6 ignition system 157 157
• Ignition ht coils removal refitting and testing 157
• Chapter 6 ignition system 158
• Do not 158
• Exactly 158
• Ignition and engine kill switches general 158
• Ignition ht leads general 158
• Ignition system fault finding 158
• Ignition timing adjusting 158
• Spark plugs general 158
• Take all the necessary precautions 158
• Vacuum switch general early 100 models only 158
• Chapter 6 ignition system 159 159
• Provided 159
• Chapter 7 frame and forks 160
• Contents 160
• Frame and forks 160
• Front forks 160
• Specifications 160
• Chapter 7 frame and forks 161 161
• General description 2 front forks removal 161
• Mm ibf ft nm ibf ft 161
• Models 100 models 161
• Torque wrench settings component 161
• Chapter 7 frame and forks 162
• Front forks dismantling 162
• Fig 7 front forks 163
• Chapter 7 frame and forks 164
• Front forks examination and renovation 164
• Chapter 7 frame and forks 165 165
• Do not 165
• Front forks reassembly 165
• Chapter 7 frame and forks 167 167
• Front forks refitting 167
• A ___________ ___________________________________ steering head bearings removal 168
• Chapter 7 frame and forks 168
• Front forks aligning the damping components 168
• Chapter 7 frame and forks 169 169
• Fig 7 steering head assembly 169
• Chapter 7 frame and forks 170
• Fig 7 fluidbloc steering damper installation 170
• Steering head bearings examination and renovation 11 fluidbloc steering damper general 75 models 170
• Steering head bearings refitting 170
• Chapter 7 frame and forks 171 171
• Fairing removal and refitting 171
• Footrests general 171
• Frame examination and renovation 171
• K75 c handlebar fairing 171
• K75 c k75t k100 headlamp surround 171
• K75 headlamp surround 171
• K75t windscreen 171
• Stands and controls general 171
• Chapter 7 frame and forks 172
• K100 rs fairing 172
• K75 s engine spoiler belly fairing 172
• K75 s fairing 172
• K75s fairing 172
• Chapter 7 frame and forks 173 173
• K100 fairing installation 173
• K100 rt k100 lt fairing 173
• Chapter 7 frame and forks 177 177
• Seat removal and refitting 177
• Bodywork removal and refitting 178
• Chapter 7 frame and forks 178 178
• Front mudguard 178
• Radiator cover panels k75 k75 c k75t k100 178
• Rear mudguard 178
• Side panels 178
• Tail unit 178
• Chapter 7 frame and forks 179 179
• Engine protection bars 179
• Mirrors removal and refitting 179
• Chapter 7 frame and forks 180
• Do not 180
• Instruments removal dismantling and reassembly 180
• Luggage removal and refitting 180
• Panniers 180
• Top box 180
• Very carefully 180
• Chapter 8 final drive and rear suspension 182
• Contents 182
• Final drive 182
• Final drive and rear suspension 182
• Final drive lubrication 182
• General description 182
• Models 100 models 182
• Optional 182
• Rear suspension 182
• Specifications 182
• Standard 182
• Torque wrench settings component 182
• Chapter 8 final drive and rear suspension 183 183
• Final drive removal 183
• Chapter 8 final drive and rear suspension 184
• Fig 8 final drive assembly 184
• Final drive examination and renovation 184
• Chapter 8 final drive and rear suspension 185 185
• Chapter 8 final drive and rear suspension 186
• Final drive refitting 186
• Chapter 8 final drive and rear suspension 187 187
• Fig 8 swinging arm and driveshaft 187
• Swinging arm and drive shaft removal 187
• Chapter 8 final drive and rear suspension 188
• Swinging arm examination and renovation 188
• Chapter 8 final drive and rear suspension 189 189
• Final drive shaft examination and renovation 189
• Swinging arm and drive shaft refitting 189
• Chapter 8 final drive and rear suspension 190
• Rear suspension unit adjustment removal and examination 190
• Chapter 8 final drive and rear suspension 191 191
• Fig 8 nivomat suspension unit 191
• Nivomat suspension unit general 191
• Chapter 8 final drive and rear suspension 192
• Do not 192
• Warning 192
• Chapter 9 wheels brakes and tyres 193
• Wheels brakes and tyres 193
• Chapter 9 wheels brakes and tyres 194
• Do not 194
• Front wheel removal and refitting 194
• General description 194
• Models 100 models 194
• Nm ibf ft 194
• Torque wrench settings component 194
• Tyre pressures tyres cold front rear 194
• Fig 9 front wheel 196
• Rear wheel removal and refitting 196
• Front wheel 197
• Rear wheel 197
• Wheel bearings removal examination and refitting 197
• Hydraulic brake overhaul general 198
• Caliper removal examination and refitting 199
• Fig 9 brake caliper 199
• Front brake master cylinder removal examination and refitting 199
• Fig 9 front brake master cylinder 200
• Fig 9 rear brake master cylinder 201
• Rear disc brake master cylinder removal examination and refitting 201
• Bleeding the hydraulic brake system 202
• Do not 202
• Rear drum brake examination and renovation k75 k75c k75t 204
• Opposite 205
• Tyres removal and refitting 205
• Fig 9 method of seating the beads on tubeless tyres 206
• Puncture repair and tyre renewal general 206
• The fitting of tubed tyres to these wheels is not recom mended 206
• Tyre valves examination and renewal 206
• Wheel balancing general 207
• Chapter 10 electrical system 208
• Contents 208
• Electrical system 208
• Fuse rating 208
• Specifications 208
• Battery examination and maintenance 209
• Component nm ibf ft 209
• Electrical system general information and preliminary checks 209
• Fig 10 simple testing apparatus 209
• General description 209
• Models nm ibf ft 209
• Alternator checking the output 210
• Alternator general 210
• Alternator removal and refitting 210
• Alternator overhaul 212
• Fig 10 alternator 212
• Chapter 10 electrical system 213 213
• Fuses general 214
• Fig 10 starter motor 215
• Starter motor removal and refitting 215
• Starter motor overhaul 216
• Chapter 10 electrical system 217 217
• Starter system checks 217
• Clutch interlock switch 218
• Coolant overheat warning lamp circuit testing 218
• Gear position indicator switch 218
• Interlock circuit diode 218
• Load shedding relay 218
• Oil pressure warning lamp circuit testing 218
• Starter button 218
• Cold start choke device indicator general 219
• Fuel level gauge circuit testing 219
• Switches general 219
• Tail lamp bulb monitoring device general 219
• Horn location and adjustment 220
• Relays location and renewal 220
• Turn signal relay location and testing 220
• Bulbs renewal 221
• Headlamp and parking lamp 221
• Headlamp beam alignment 221
• Radio general k100rt k100lt 221
• Chapter 10 electrical system 222
• Instrument panel bulbs 222
• Stop and tail lamp 222
• Turn signal lamps 222
• K75 wiring diagram 225
• Wiring diagram 75 models 225
• R a 5 ar 226
• Wiring diagram early k100 models 226
• Luzi 5 227
• S i a o 1 227
• Ç q 2 227
• Wiring diagram early k100 rs and rt models 228
• Rnstffürfnl 229
• Wiring diagram late k100 rs and rt models 229
• English american english american 230
• English american terminology 230
• Conversion factors 231
• Conversions 231
• Fuel consumption 231
• Length distance 231
• Mass weight 231
• Pressure 231
• Temperature 231
• Torque moment of force 231
• Velocity speed 231
• Volume capacity 231
• Accessories 232
• Acknowledgements 232
• Adjustments 232
• Air filter 37 40 140 147 airflow meter 141 144 alternator 232
• Auxiliary drive shaftr 232
• Balancer shaft 232
• Battery 232
• Bearings 232
• Bellhousing 232
• Bleeding hydraulic brakes 232
• Bodywork 232
• Caliper hydraulic brake 199 cam chain and tensioner 232
• Cam chain engine front cover 232
• Camshafts 232
• Choke cable 232
• Cleaning 232
• Clutch 232
• Compression test engine 49 connecting rods 232
• Control unit ignition 156 conversion factors 232
• Cooling system 232
• Crankcases 232
• Crankshaft 232
• Crankshaft engine right hand cover 232
• Cylinder block 232
• Cylinder head 232
• Cylinder head engine left hand cover 232
• Output balancer shaft balancing wheel 232
• В rakes 232
• Dimensions model 233
• Diode plate rectifier 233
• Drive shaft auxiliary 233
• Drive shaft final 233
• Drum bra ke 233
• Electrical system 233
• Engine 233
• Evaporative emission control system 233
• Exhaust system 233
• Fairing 171 fan 233
• Fault diagnosis 233
• Filter 233
• Final drive 233
• Footrests 233
• Front brake 233
• Front forks 233
• Front mudguard 233
• Front wheel 233
• Fuel system 233
• Alternator 234
• Gauge fuel 234
• Gearbox 234
• Generator 234
• Headlamp 234
• High altitude compensator 234
• Hoses radiator 234
• Ht coils 234
• Ht leads 234
• Hydraulic brake 234
• Idle speed 234
• Ignition system 234
• Injection control unit fuel 144 234
• Injectors fuel 234
• Instruments 234
• Lamps 209 221 load shedding relay 234
• Lubrication system 234
• Luggage 234
• Main bearings 234
• Maintenance routine 234
• Mirrors 234
• Mudguards 234
• Neutral indicator 234
• Nivomat rear suspension unit 234
• Oil engine 234
• Oil final drive 234
• Maintenance 235
• Oil gearbox 235
• Oil pressure relief valve 235
• Oil pressure warning lamp 235
• Oil pump 149 152 outer covers engine 235
• Output balancer shaft 235
• Panniers 235
• Parking lamp 235
• Parts ordering 235
• Pistons 235
• Plenum chamber 235
• Pressure regulator fuel 235
• Pump fuel 235
• Pump oil 235
• Radiator 235
• Rear brake drum 235
• Rear brake hydraulic 235
• Rear mudguard 235
• Rear suspension unit 235
• Rear wheel 235
• Rectifier diode plate 235
• Regulator voltage 235
• Relays 235
• Release mechanism clutch 235
• Routine maintenane 235
• Safety precautions 235
• Side panels 235
• Spare parts ordering 235
• Spark plugs 235
• Specifications 235
• Speedometer 235
• Stands 33 40 171 starter 235
• Steering 235
• Stop lamp 235
• Suspension 235
• Swinging arm 235
• Switches 235
• Tachometer 180 tail unit 235
• Tail lamp bulb renewal 222 tail lamp bulb monitoring device 219 tank fuel 132 135 temperature sensing switch unit 235
• Tensioner cam chain 235
• Thermostat 235
• Throttle cable 235
• Throttle butterfly 236
• Throttle position switch 236
• Timing ignition 236
• Top box 236
• Torque wrench settings 236
• Trigger ignition 156 turn signal 236
• Vacuum switch 236
• Valve engine 236
• Valve tyre 206 voltage regulator 236
• Water pump 124 weights model 236
• Wheels 236
• Wiring diagrams 236
• Working facilities 236

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Chapter 1 Engine 4 11 Ignition HT coil cover is retained by four Allen screws 100 models 4 13a Make a written note of connections before disconnecting ignition HT coil leads 4 13b Check that all wires are disconnected between engine transmission and frame note speedometer impulse transmitter wires 4 13c and ignition trigger assembly wires 51 5 Dismantling the engine unit preliminaries and general procedures Preliminary dismantling 4 13d Coolant temperature sensor connector is secured by a wire clip 1 If the engine transmission unit has been removed as a single unit withdraw the alternator and starter motor see Chapter 10 and separate the gearbox and final drive see Chapter 3 from the bellhousing noting that it will be necessary to remove the stand assembly to reach the two lowest gearbox bellhousing retaining screws There is no need to separate the final drive from the gearbox Dismantle the clutch as described in Chapter 2 2 As described in Chapter 5 remove the top half of the air filter assembly with the engine wiring harness attached to it disconnect the loom from all other electrical components Withdraw the air filter element and the air cleaner bottom half the fuel rail and injectors the plenum chamber and crankcase breather the throttle bodies and intake stubs and the EECS pressure relief valve and hoses where fitted 3 Remove the coolant hose stub See Chapter 4 4 Remove the ignition HT coils noting carefully where the HT leads are connected see Chapter 6 Remove the spark plugs and HT leads as described in Routine Maintenance 5 If necessary remove the sump oil pan and pump pick up as