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 (3) from the engine.
Cut the cable tie (arrow) at the voltage regulator.
Disconnect the plug of the voltage regulator.
Remove voltage regulator (6).
Straighten tab (4) and release breather line (5).
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 (1) from the engine.
Disconnect plug of side-stand switch (2).
Unscrew connector for idle indicator (3).
Disconnect the plug of ignition trigger (4).
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 (6).
Disconnect the plug for the temperature sensor (5).
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.
Lowering the engine
Secure adapter, BMW # 11 0 591, to the plate for the engine lifter.
Place engine lifter, BMW # 00 1 540, under engine.
Secure the engine lifter by installing stud bolt (7) through bottom bore in engine block and securing stud (8) in top bore in engine block.
Remove screws securing cylinder head to frame on left and right. Use pin wrench, BMW # 11 6 661, 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.
Installation is the reverse of the removal procedure: pay particular attention to the following.
Raise the engine and tilt it to the rear.
Manoeuvre the bottom engine mount into position.
Raise the engine and manoeuvre the fasteners at the cylinder head into position.
Install the bottom rear engine mount fastener.
Install the pivot pin of the swinging arm bearing.
Back off the adjusting screws for the cylinder head mounts until they are seated against the cylinder head on each side and the cylinder head itself is centered in the frame.
Tightening torques:
- Water pump drain screw: 10 Nm
- Intake air silencer to frame: 9 Nm
- Engine guard to frame: 9 Nm
- Engine oil drain plug: 40 Nm
- Rear quick-release axle: 100 Nm
- Drive chain tensioning screws: 10 Nm
- Exhaust manifold to cylinder head: 20 Nm
- Silencer to exhaust manifold: 55 Nm
- Footrest plate to main frame, left/right: 30 Nm
- Cable cover to engine: 5 Nm
- Voltage regulator to bracket: 7 Nm
- Chain drive sprocket to mainshaft (clean threads + Loctite 243): 140 Nm
- Sprocket cover to engine: 2 Nm
- Ground terminal to engine block: 8 Nm
- Connecting cable, idle indicator: 2 Nm
- Frame trussing to engine shell: 21 Nm
- Frame trussing to main frame: 21 Nm
- Spring-strut adjusting knob bracket to frame: 9 Nm
- Radiator to main frame at top: 9 Nm
- Swinging-arm pivot: 100 Nm
- Frame to engine at rear: 41 Nm
- Gearshift pedal to engine: 13 Nm
- Brake pedal to frame: 21 Nm
- Cylinder head to frame: 41 Nm
- Cylinder head to frame adjusting sleeve: zero play max. 5 Nm
- Cylinder head to frame locknut: 100 Nm