Note: Auxiliary shaft, timing chains, chain tensioner/guide rails and crankshaft can only be disassembled after the engine has been removed. All other components can be disassembled with the engine installed.
Remove the sump guard.
Drain engine oil.
Secure stand, BMW No. 00 1 520, to motorcycle with overlength bushes and screws, BMW No. 001527.
Note:
- Mount a washer on the screw on the right as viewed in the forward direction of travel.
- Depth of thread in tapped bore has been reduced!
Remove the seat.
Remove side panel.
Remove fuel tank fastener.
Caution: Fuel is flammable and a hazard to health. Observe relevant safety regulations.
Seal the fuel feed and return lines with hose clips, BMW No. 13 3 010, and disconnect.
Disconnect breather lines.
Disconnect plug of fuel pump unit.
Remove fuel tank.
Remove the battery.
Caution! Disconnect negative terminal first, then positive terminal.
Disconnect the air temperature sensor plug.
Disconnect the diagnostic plug.
Remove air filter cover.
Remove the intake air pipe.
Disconnect plug from Hall sensor.
Remove Motronic control unit.
Disconnect the Motronic control unit plug.
[ABS] Fully drain the brake system.
[ABS] Remove the unit.
Caution! Always follow the instructions in the Repair Manual. a Group 34, removing and installing the ABS unit.
Note: Secure the brake lines with cable ties.
Remove actuating cable for starting-speed increase.
Disengage throttle cable.
Remove Bowden-cable cover from fitting for throttle actuation.
Disengage throttle cable.
Disengage throttle cables from right and left throttle flap stubs.
Disengage the clamp securing the breather hose at the front of the engine.
Disconnect the breather hose at the front.
Remove battery holder with Bowden-cable divider.
Remove cable ties holding the cable below the battery holder.
Disconnect plug/oxygen sensor and remove cable.
Disconnect plug/NTC oil-temperature sensor.
Disconnect the leads from the alternator.
Disconnect ground lead from terminal at top of engine.
Disconnect right oil cooler line from engine.
Remove spark plug covers.
Pull off spark plug cap with special puller, BMW No. 123520.
Disconnect plugs of injection valves.
Disconnect hose clamps/throttle stub pipes and push the stubs into the air filter box.
Disconnect ground cable from left throttle stub pipe.
Disconnect plug of throttle-valve potentiometer.
Remove holders of injection valves.
Remove injection valves from throttle stub pipe.
Remove throttle stub pipe.
Loosen the fasteners securing the right and left footrest plates.
Remove top screws on left and right.
Note: When installing the footrest plates, use the long screws on the right and the short screws on the left.
Remove front fasteners of rear frame on left and right.
Remove manifold.
Remove rear silencer.
Remove front silencer.
Remove starter motor cover and disconnect cable to power socket.
Disconnect cables from starter motor.
Remove the starter motor.
Disconnect cable from oil pressure switch.
Disconnect plug (1) of side-stand switch.
Disconnect plug (2) of gear indicator.
Remove front cover.
Disconnect left oil cooler line from engine.
Remove rear brake fluid reservoir from its holder.
[ABS] Remove ABS sensor from rear wheel drive.
Remove rear brake caliper.
Disconnect brake line from swinging arm.
Use cable ties to secure the brake caliper to the rear frame.
Disconnect plug of rear brake light switch.
Remove fasteners of guard and rear brake master cylinder.
Use masking tape to cover the rear flow brake line in the vicinity of the fastener securing the rear frame to the gearbox.
Remove the main stand and the side stand.
Remove the leading link caps.
Remove the left screw cap.
Remove retaining ring on right.
Remove cap.
Remove the screw on the right.
Caution! If necessary, mask off the leading link to prevent it from being scratched.
Pull the shaft of the leading link out to the left.
Installing engine
Installation is the reverse of the removal procedure.