Preparatory work
Drain coolant. See Group 00.
Place motorcycle on its centre stand.
Secure front wheel in position.
Remove seat.
Remove intake air silencer. See Group 13.
Disconnect battery negative terminal.
Remove engine guard.
Drain engine oil. See Group 00.
Remove rear wheel. See Group 36.
Remove exhaust manifold. See Group 18.
Disconnect oil feed and return lines from oil tank.
Remove cable cover (1) from the engine.
Cut the cable tie (arrow) at the voltage regulator.
Disconnect the plug of the voltage regulator.
Remove voltage regulator (4).
Straighten tab (2) and release breather line (3).
Note: The chain drive sprocket has to be removed at this point before engine disassembly can proceed.
Remove the chain sprocket. See Group 27.
Remove ground terminal (5) from the engine.
Disconnect plug of side-stand switch (6).
Unscrew connector for idle indicator (7).
Disconnect the plug of ignition trigger (8).
Disconnect plug of oil pressure sensor in oil filter housing.
Disconnect positive lead from starter motor.
Remove frame trussing.
Remove the chain from the drive sprocket.
Cut the cable tie at the adjusting-knob bracket (arrow).
Remove the fastener securing the adjustingknob bracket (10).
Disconnect the plug for the temperature sensor (9).
Slacken the hose clip at the throttle flap stub and disconnect the throttle flap stub from the intake pipe.
Disconnect the starter coil at the plug.
Pull spark plug connector off spark plug.
Remove the ignition-coil bracket complete with ignition coil from the cylinder head cover.
Disconnect clutch cable from release lever.
Disconnect breather hose for oil tank from the cylinder head cover.
Remove radiator. see Group 17.
Remove the right-hand coolant hose.
Remove fasteners for engine shell and remove engine shell with the bracket for the voltage regulator.
Remove swinging fork pivot pin.
Remove bottom rear engine mount fastener.
Secure the motorcycle by attaching two straps to the front forks.
Remove the brake pedal.
Remove the gear shift pedal.
Removing engine
Secure adapter, BMW No. 11 0 591, to the plate for the engine lifter.
Place engine lifter, BMW No. 00 1 540, under engine.
Secure the engine lifter by installing stud bolt (1) through bottom bore in engine block and securing stud (2) in top bore in engine block.
Remove screws securing cylinder head to frame on left and right. Use pin wrench, BMW No. 116661, to slacken the locknuts and back off the adjusting sleeves.
Lower the engine until the cylinder head is resting on the radiator fastening lug (arrow).
Continue lowering the engine; the engine tilts toward the rear.
Continue lowering the engine until the fastening lug is above the cylinder head cover.
Turn the engine toward the right and push it clear of the motorcycle.
Transferring engine to assembly frame
Secure threaded adapter, BMW No. 11 0 531, to engine mount.
Detach the engine from the engine lifter, leaving the engine on the lifting platform.
Lay the engine on its left side, as viewed in the forward direction of travel.
Secure engine adapter, BMW No. 11 0 640, to the right side of the engine without a spacer.
Position the assembly stand beside the lifting platform.
Manoeuvre the engine so that the engine adapter is level with the flange of the assembly stand.
Secure engine adapter (1) to the flange of the assembly stand (2).
Turn engine adapter.