Removing engine
Note: Engine removal is necessary for:
- Removal of intermediate flange
- Removal of output shaft
- Removal of countershaft.
Caution: Disconnect the negative battery lead first, then the positive lead.
- Remove the battery.
- Drain engine oil.
Group: frame
- Remove rear footrest plates.
- Remove left and right side panels, engine spoilers and battery covers.
- Remove left and right skirt brackets.
Groups: radiators, fuel tank and fuel lines
Warning: Comply with safety precautions when handling or working with fuel; note that the fuel lines are pressurised.
- Remove fuel tank.
- Drain coolant.
- Remove left/right radiators with fans.
- Remove coolant adapters and coolant hose from water pump.
- Remove left-hand radiator bracket.
- Remove fuel injection rail.
- Remove throttle butterfly rail together with intake air silencer.
- Disconnect fuel lines and crankcase breather from engine.
Group: exhaust system
- Disconnect plug of lambda sensor.
- Remove exhaust system.
Groups: rear-wheel drive, wheels and tyres
- Remove rear-wheel inductive sensor.
- Remove rear-wheel brake caliper.
- Use cable ties to secure brake caliper and inductive sensor to frame.
- Remove rear wheel.
Warning: Note high release torques.
- Remove swinging arm.
Groups: frame and clutch
- Remove transverse tube.
- Disconnect or open plug connections for engine and gearbox.
- Remove switch for gear indicator, pull cable toward rear and remove.
- Disconnect clutch breather line from frame, pull breather line toward rear to remove.
- Remove clutch slave cylinder and use cable tie to secure cylinder to frame.
- Remove clutch pushrod.
Groups: engine electrical system and general vehicle electrics
- Remove temperature sensor for cylinder head.
- Disconnect ground cable from cylinder head.
- Unclip cables for side-stand switch and reverser inductive sensor and pull cables down to remove.
- Disconnect cables for oil-pressure indicator, temperature sensor water pump and magnetic gate in electronics box and pull cables forward to remove.
- Disconnect cables from alternator.
- Disconnect cables from starter motor.
Group: frame and gearbox
- Remove reverser switch unit.
- Remove front left footrest system.
- Slacken screws securing front right footrest system and use cable tie to secure footrest to frame.
- Disconnect gearshift linkage from selector lever.
- Attach hoist, BMW No. 00 1 510, to oil sump.
Note: Secure front wheel in position.
- Remove nuts securing front cross members to engine at left and right.
- Release screws securing gearbox to frame.
Caution: When raising the frame and maneuvering the engine beneath the motorcycle, take care not to damage lines and cables.
Maintain adequate clearance between frame and gearbox and between transverse tube at top and alternator; take care not to scratch the surfaces.
- Use workshop crane, BMW No. 46 5 640, to raise rear of frame high enough to take weight off gearbox mounts.
- Remove screws securing gearbox mounts.
- Use workshop crane, BMW No. 46 5 640, to raise frame until gearbox and starter motor are accessible.
- Remove gearbox complete with starter motor.
- Use hoist, BMW No. 00 1 510, to raise engine far enough to take weight off mounts of cross members.
- Lower hoist, BMW No. 00 1 510, and pull engine clear of motorcycle from below.
- Bolt engine carrier, BMW No. 11 0 610, to crankcase.
- Lower engine onto stand, BMW No. 00 1 490.
- Remove hoist, BMW No. 00 1 510.
- Remove alternator.
- Remove the clutch.
Installing engine
- Install the clutch.
- Secure engine to hoist, BMW No. 00 1 510, and disengage engine from stand, BMW No. 001490.
Groups: frame and gearbox
Caution: When maneuvering the engine below the motorcycle and raising and lowering the frame, always take care not to damage components or scratch surfaces.
- Install the alternator.
- Apply a coat of Optimoly MP 3 to the splines of the gearbox input shaft.
- Secure guide pins, BMW No. 23 1 820, to intermediate flange.
- Slide gearbox with starter motor over guide pins, BMW No. 23 1 820, and into position against intermediate flange.
- Install link for reverser, and secure mounts for link and gearbox to intermediate flange.
- Remove guide pins.
- Use hoist, BMW No. 00 1 510, to raise engine slightly and carefully lower frame just far enough to allow cables to be connected to starter motor and alternator: connect the cables.
- Continue lowering frame until gearbox mounts can be installed: install and tighten the gearbox mounts.
- Secure cross members on left and right.
- Pull down the centre stand.
- Fully lower hoist, BMW No. 00 1 510, and remove.
- Fully lower the frame.
- Remove workshop crane, BMW No. 465640.
- Connect inductive sensor for reverser.
- Connect selector lever to gearshift linkage.
- Install actuator unit for reverser.
Group: clutch
- Connect switch for gear indicator.
- Insert the clutch release rod.
- Install clutch slave cylinder with new paper seal.
- Insert clutch breather hose, working from rear toward front.
Groups: engine electrical system and general vehicle electrics
- Connect cable for side-stand switch.
- Connect ground cable to cylinder head.
- Install and tighten temperature sensor for cylinder head and reconnect cable.
- Connect cables for temperature sensor water pump, oil-pressure indicator and magnetic gate; use cable ties to secure.
- Install spark plugs and ignition leads.
- Install heat shield for cylinder head.
Groups: frame, rear-wheel drive, wheels and tyres
- Install transverse tube.
- Install swinging arm.
- Install the rear wheel drive.
- Install the rear wheel.
- Install rear brake and inductive sensor.
Group: exhaust system
- Install lambda sensor and connect cable.
- Install exhaust.
- Install exhaust heat shield.
Groups: radiators, fuel tank and fuel lines
Cauton: Make sure that all lines and cables are correctly routed.
- Secure fuel lines to engine.
- Install throttle butterfly rail complete with intake air silencer.
- Install fuel injection rail.
- Connect lines to injection valves and intake air silencer.
- Connect crankcase breather hose.
- Install left-hand radiator bracket.
- Install left and right radiators and coolant hoses.
- Install intake air pipe for air filter.
- Install fuel tank, connect lines and fuel hoses.
Group: frame
- Install left and right front footrest systems.
- Install front saddle.
- Install tank cover.
- Install left and right skirt brackets.
- Use cable tie to secure clutch breather hose to right-hand skirt bracket.
- Install fairing panels and engine spoilers.
- Install left and right rear footrests.
- Install skirts.
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