Removing brake lines/hoses
Preparatory work
- Remove left and right fairing side sections.
See Group 46.
- Remove left and right battery covers.
Caution: Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid destroys paint. Wrap cloths around the ends of the pressure lines to prevent residual brake fluid escaping.
- Drain the brake system.
Brake hose to brake calliper
- Open the cable ties.
- Disconnect the brake hose from the brake calliper.
- Disconnect the brake hose at union (1).
- Remove brake hose.
Brake hose to brake master cylinder
- Remove right engine spoiler.
- Remove the front right footrest plate.
- Remove screws (3) and remove brake master cylinder.
- Use an open-ended wrench to hold at the flats (arrow) and open fastener (2) for brake hose.
- Remove retaining plate (5) for brake line from the battery carrier.
- Remove banjo bolt (6) and remove brake hose (arrow).
Brake fluid reservoir with return hose
- Remove the front right footrest plate.
- Open non-reusable hose clip (4) and disconnect return hose (1).
- Remove brake fluid reservoir with return hose.
Brake line to brake calliper
Caution: Disconnect the negative battery terminal first, then the positive one.
- Remove the battery.
Warning: Comply with safety precautions when handling or working with fuel; note that the fuel lines are pressurised.
- Remove fuel tank.
See Group 16.
- Remove the rear suspension strut.
See Group 33.
- Remove retaining plate/union (5) for brake line from the battery carrier.
- Disconnect plugs from ABS pressure modulator and open cable ties (arrow).
- Disconnect brake lines from ABS pressure modulator.
- Open cable ties securing wiring harness to rear frame.
- If applicable, disconnect plug for seat heating on rear frame.
- Remove positive and negative terminals from frame.
- Disconnect brake hose to brake calliper at retaining plate/union.
- Remove securing screw (arrow) securing retaining plate/union to rear frame.
- Remove screws (1) securing the battery carrier to the main frame.
- Remove the holder (2) for the front brake lines from the main frame.
- Secure rear frame to workshop crane, BMW No. 465640.
- Remove fasteners securing rear frame to main frame.
Caution: When raising the rear frame, make sure that no lines are damaged.
- Slightly raise rear frame and pull toward rear.
- Remove brake lines.
Installing brake lines/hoses
- Installation is the reverse of the removal procedure: pay particular attention to the following.
- Apply Loctite 243 to threads of lower fasteners securing rear frame to main frame.
- Carefully re-route all lines in their original positions and secure with cable ties.
Caution: Renew sealing rings at brake line/hose.
- Always secure brake hose with stop plate.
- Always replace non-reusable hose clips and close with pliers, BMW No. 131500.
- Check play at brake master cylinder, adjust if necessary.
- Brake fluid grade — DOT 4
Tightening torques:
- Rear frame to main frame, top — 41 Nm
- Rear frame to main frame, bottom — 41 Nm (clean thread + Loctite 243)
- Battery carrier to frame M 6 — 9 Nm
- Retaining plate for brake line to battery carrier — 4 Nm
- Brake line to frame M 5 — 4 Nm
- Union, brake hose and brake line — 18 Nm
- Brake line to ABS pressure modulator — 18 Nm
- Brake hose to brake calliper — 18 Nm
- Brake line to master cylinder — 18 Nm
- Master cylinder to footrest plate — 9 Nm (clean thread + Loctite 243)
- Bleed screw in brake calliper/ABS pressure modulator — 10 Nm
- Fuel tank to frame, M 8 — 21 Nm
- Fuel tank to frame, M 6 — 9 Nm
- Lifter handle to rear frame — 9 Nm
- Saddle, rear, to rear frame — 9 Nm
- Suspension strut to swinging arm — 50 Nm
- Suspension strut to frame — 43 Nm
- Handwheel for adjusting spring strut to frame — 21 Nm
- Footrest plate to frame — 21 Nm
Checking brake pads for wear/replacing brake pads
See Group 00.
Checking brake fluid level
See Group 00.
Replacing brake fluid and bleeding brake system
See Group 00.