BMW - C650GT Manual13-15

C650GT
BMW-Motorrad - 0133 - C 650 GT, K19
Technical data 0133 - C 650 GT
00 - General maintenance and construction groups
Designation Precondition Value Valid

Length of motorcycle 2218 mm
Top speed 175 km/h
Width of motorcycle Across mirrors 916 mm
Height of motorcycle over windscreen at DIN 1410 mm
unladen weight
Unladen weight DIN unladen weight, 261 kg
ready for road, 90 %
load of fuel, without
optional extras
Front-seat height Without rider 805 mm
Rider's inside-leg arc, heel to heel Without rider 1910 mm
Permissible gross weight 445 kg
Maximum payload 184 kg
Permissible wheel load, front max 170 kg
Permissible wheel load, rear max 275 kg
Exhaust emissions standard EU 3
Starting capability on uphill 20 %
gradients
at permissible gross weight
Wheel load, rear, at unladen weight 132 kg
Wheel load, front, at unladen weight 129 kg
BMW Motorrad, UX-VA-4 1/1

11 - Engine

Engine type 652EA
Engine design Two-cylinder four-stroke DOHC
engine, 4 valves actuated by bucket
tappets, two balancing shafts, liquid
cooling, dry-sump lubrication
Compression ratio 11.6:1
Location of engine number Crankcase, left, below alternator
Nominal output at engine 44 kW
-1
speed 7500 min
Cylinder bore 79 mm
Torque at engine 66 Nm
-1
speed 6000 min
Piston stroke 66 mm
Displacement 3
647 cm
Compression test pressure Good ≥15 bar
Measured warm, throttle valve fully Normal 14...15 bar
open
Poor ≤11 bar
Maximum engine speed -1
max 8500 min
Engine oil, capacity with filter change approx. 3.1 l
Fluids and lubricants
Viscosity class
Engine oil capacity of oil tank with filter change approx. 2.8 l
Viscosity class
Engine oil, specified level Engine at regular Between MIN and MAX marks
operating temperature
Engine oil, quantity for topping up Difference between max 0.5 l

MIN and MAX
11 11 - Engine block
Projecting length of thread of tie bolt Replace the tie bolt, 77 mm
lubricate with engine oil
11 21 - Crankshaft with bearings
Identifier for crankshaft-bearing A Bearing shell red
shells
B Bearing shell green
Bearing shells in crankcase top
section C Bearing shell black

Identifier for crankshaft-bearing 1 Bearing shell red

shells
2 Bearing shell green
Bearing shells in bearing frame
3 Bearing shell black
Bearing journal diameter in Marks on the A/B/C
crankshaft main bearing crankshaft
Tolerance group
Mark for classification of the Mark I (inside): 1/2/3

crankshaft bearings identifier for main
on the bearing frame (underside) bearing bores
11 24 - Conrod with bearings

Overview of conrod marks A Production date, year
B Production date, month
C Serial number
11 27 - Balancing shaft
Mark for classification of the Mark II (outside): 1/2
balancing-shaft bearings identifier for balancing-
on the bearing frame (underside) shaft bores
Identifier for balancing-shaft bearing 1 Bearing shell blue/yellow

shells
on the bearing frame 2 Bearing shell red/brown
Identifier for balancing-shaft bearing A Bearing shell blue/yellow

shells
on the balancing shaft B Bearing shell red/brown
Mark for classification of the Marks on the balancing A/B

balancing-shaft bearings shaft
for identifying the bearing shells in
the top section of the crankcase

11 34 - Valves with springs

Inlet valve clearance Engine cold max 35 °C 0.20 +0.04 mm
−0.04
Exhaust valve clearance Engine cold max 35 °C 0.28 +0.04 mm

−0.04
11 40 - Oil supply
Operating pressure in engine oil Engine temperature operating temperature (fan running,
system oil-level indicator active)
at idle speed 1.5 +1.5 bar
−0.5
- at engine 4.5 +1.5 bar

speed approx. −1.5
-1
3500 min

12 - Engine electrical system

12 12 - Ignition wiring, spark plugs
Spark plugs, manufacturer and NGK LMAR8D-J
designation
Electrode gap of spark plug +0.1
0.8 −0.1 mm

13 - Fuel preparation and control

Recommended fuel grade Super unleaded max. 10 % ethanol,
E10
95 ROZ/RON
89 AKI

16 - Fuel supply

Usable fuel capacity approx. 16 l
Fuel reserve approx. 3 l

17 - Cooling

Cooling system - test pressure Test pressure must 1.5 bar
remain
unchanged min 5 min
Specified coolant level in expansion engine cold Between MIN and MAX marks
tank
Coolant capacity (total) 1.5 l

General consumable (Antifreeze and corrosion inhibitor)
Specified coolant level in radiator Engine cold Bottom edge of overflow bowl
Coolant, frost protection min −30 °C

17 11 - Radiator with fasteners
Coolant thermostat, opening 85 °C
temperature

21 - Clutch

Clutch type Centrifugal clutch
21 21 - Clutch with driver plate
Minimum height, clutch lining Projection past lining min 2.5 mm
backer

23 - Gearbox

Oil capacity, gearbox 250 ml
Gear oil (Castrol SAF-XO)

24 - Automatic gearbox

Gearbox type CVT (Continuously Variable
Transmission)
24 21 - Input, intermediate and output shafts
Primary transmission ratio 1:1.06
Transmission ratio, secondary 1:2.72
transmission
24 81 - CVT adjustment
Transmission ratio, CVT 1:10.7...4.6

31 - Front axle, front-wheel steering

Type of front suspension Upside-down telescopic fork
Spring travel, front At wheel 115 mm
Fork oil, capacity per fork leg 390 ml
Telescopic fork oil (Telescopic fork oil SAE 7.5)
Fork oil level, right (air cushion) right fork leg fully 130 mm
compressed,
compression spring
and spacer removed

32 - Steering

32 73 - Bowden cables
Setting of throttle-cable play at outermost diameter 3 mm
of rubber grip, engine
cold max 35 °C
Setting, throttle-closer cable at outermost diameter 3 mm
Forward idle travel against closer of rubber grip, engine
spring cold max 35 °C

33 - Rear axle, rear-wheel drive and rear-wheel guidance

Type of final drive Chain drive in oil bath
Type of rear suspension Cast aluminium single swinging arm
Spring travel, rear At wheel 115 mm
Oil capacity, swinging arm 500 ml
Gear oil (Castrol SAF-XO)
33 54 - Spring strut, mounting parts
Basic setting of spring preload, rear Full load of fuel, with increase 4 clicks from the lowest
rider 85 kg preload setting
Type of rear suspension Direct-pivot spring strut with
adjustable spring preload
33 82 - Traction drive, chain pinion, belt pinion
Secondary transmission ratio 1.688
Final drive, number of teeth 16 / 27
Pinion / sprocket
33 83 - Traction drive, chain, belt
Chain deflection max 15 mm

34 - Brakes

Brake fluid level, front Brake-fluid reservoir It is impermissible for the brake fluid
horizontal level to drop below the MIN mark.
Hydraulic fluid (Brake fluid, DOT4)
Brake fluid level, rear Brake-fluid reservoir It is impermissible for the brake fluid
horizontal level to drop below the MIN mark.
Hydraulic fluid (Brake fluid, DOT4)
34 11 - Front brake
Brake disc diameter, front 270 mm
Brake-pad material, front Sintered metal
Type of front brake Hydraulically actuated twin-disc
brake with 2-piston floating calipers
Brake-pad wear limit, front Friction pad only, min 1.0 mm
without backing plate.
The wear indicators
(grooves) must be
clearly visible.
Brake disc lateral runout, front At circumference max 0.15 mm

Brake disc thickness, front When new 5.0 mm
Wear limit 4.5 mm
Brake disc thickness, front Wear limit min 4.5 mm
Play of brake controls at end of lever approx. 11.5 mm
Front brake
34 21 - Rear brake
Type of rear brake Brake for riding Hydraulically actuated disc brake
with 2-piston floating caliper
Parking brake Bowden-cable-actuated disc brake
with 1-piston floating caliper
Brake-pad material, rear Organic material
Brake disc diameter, rear 270 mm
Brake disc thickness, rear When new 5.0 mm
Wear limit 4.5 mm
Brake disc thickness, rear Wear limit min 4.5 mm
Brake-pad wear limit, rear Friction pad only, min 1.0 mm

without backing plate.
Brake disc lateral runout, rear At circumference max 0.15 mm

Brake-pad wear limit of parking The wear indicators min 1.0 mm
brake (grooves) must be
clearly visible.
Play of brake controls at end of lever approx. 11 mm

Rear brake

36 - Wheels and tyres

36 30 - Motorcycle wheels
Permissible front-wheel imbalance max 5 g
Permissible rear-wheel imbalance max 5 g
Balancing weight for front wheel max 80 g
Weight must be divided equally
across both sides and weights
attached to rim on left and right.
Balancing weight for rear wheel max 80 g
Weight must be divided equally
across both sides and weights
attached to rim on left and right.
36 31 - Wheels with bearings
Front wheel type Cast aluminium, MT H2
Front wheel rim size 3.50" x 15"
Rear-wheel type Cast aluminium, MT H2
Vertical runout, front wheel max 1.5 mm
Lateral runout, front wheel max 1.5 mm
Rear wheel rim size 4.50" x 15"
Vertical runout, rear wheel max 1.5 mm
Lateral runout, rear wheel max 1.5 mm
36 32 - Tyres
Tyre designation, front 120/70 R15
Speed category, front/rear tyres required at S
least 180 km/h
Load index, rear tyre min. 64
Load index, front tyre min. 47
Tyre pressure, front Tyre cold 2.4 bar
Tyre designation, rear 160/60 R 15
Tyre pressure, rear One-up, tyre cold 2.5 bar
two-up and/or with 2.9 bar
luggage, tyre cold
Tyre tread depth, front and rear Wear limit, for min 1.6 mm
Germany only
Wear limit, outside Country-specific legal requirements
Germany
Wheel valve test pressure 4 bar
Recommended tyre sets Your authorised BMW Motorrad
dealer will be happy to supply an
up-to-date list of the approved
wheel/tyre combinations, or you can
check the information posted on the
bmw-motorrad.com website.

46 - Frame and mounted components

46 51 - Motorcycle frame
Frame type Bridge-type steel frame with cast
light-alloy bolt-on side parts
Type plate location Steering head, front right
Position of the Vehicle Identification Frame tube, front right
Number

61 - General vehicle electrics

61 13 - Plug, terminal
Fuse holder Fuse 9: Control unit, 30 A
instrument panel /
ignition switch
Fuse 10: Control unit, 30 A
anti-lock brake system
(ABS)
Fuse box Fuse 1: DME main 15 A
relay
Fuse 2: Control unit, 10 A
digital engine
electronics (DME)
Fuse 3: control unit, 4A
anti-theft alarm
(DWA) / tyre pressure
monitoring (RDC)
Fuse 4: Brake light 5A
switches, front brake /
rear brake / plug for
optional accessories /
socket in front stowage
compartment
Fuse 5: Fan 7.5 A
Fuse 6: Socket in rear 5A
stowage compartment
Fuse 7: Number-plate 4A
light
Fuse 8: Control unit, 4A
digital engine
electronics (DME) /
anti-lock brake system
(ABS) / instrument
panel
Electrical rating of on-board sockets Socket in rear stowage max 7.5 A
compartment
61 21 - Battery with holder
Battery type AGM (Absorbent Glass Mat) battery
Battery rated voltage 12 V
Battery rated capacity 12 Ah

63 - Lights

63 10 - Front lights, position lights and side lights
Bulb for parking light LED
63 12 - Headlight
Bulb for high-beam headlight H7 / 12 V / 55 W
Bulbs for the low-beam headlight H7 / 12 V / 55 W
Distance between headlight and 5m
vertical surface
For headlight adjustment
Distance between light/dark cut-off Vehicle loaded 7.5 cm
and mark at height of centre of with 85 kg
headlight
63 13 - Flashing turn indicators, front
Bulbs for flashing turn indicators, LED
front
63 21 - Rear-light cluster
Bulb for tail light/brake light LED / PR-21W / 12 V / 21 W
63 23 - Flashing turn indicators, rear
Bulbs for flashing turn indicators, LED
rear
63 26 - Number-plate light
Bulb for number-plate light W5W / 12 V / 5 W

65 - Audio, navigation, information systems

65 75 - Anti-theft alarm
Battery type CR 2032 lithium
for remote control
Activation time on arming 15 s
Alarm duration 26 s
Temperature range −40...85 °C
Operating voltage 9...16 V
Battery voltage 3V
for remote control
Reception standby for signal from after ignition OFF 1h
remote control
Activation time between two alarms 12 s
Range of the remote control 10 m
Signal frequency Broadband 25 kHz
Transmission frequency 433.92 MHz

00 60 257 Installing steering stop
Core activity
(-) Preparatory work
Set the windscreen to the highest position.

Remove the instrument carrier with instrument panel.
(-) Disengaging brake line
Remove screws (1), disengage brake line (2) from fork bridge (3).
(-) Installing steering stops
Insert steering stop (1) and connect cable ties (2), do not tighten.
Steering stop (1) can still be moved.
The cable tie heads (arrows) must be seated against steering stop (1).
Install steering stop (3) with cable ties (4) in the same way, do not
tighten.
Centre the heads of cable ties (1) between the edge and the holes
(arrows).
Push steering stops (1) until fully seated against bottom fork bridge
(2).

Align the gaps of steering stops (1) with screw heads (3).
ATTENTION
Component collision due to projecting cable ties.
Restricted clearance of the steering stop.
Cut off the projecting ends of the cable ties flush at the heads.
Alternately tighten cable ties (4) until the edges (arrows) of steering
stops (1) touch and there is no longer a visible gap.
Cut off the ends of cable ties (3).
(-) Securing screws (brake line to fork bridge) with thread-

locking compound
Clean screws (1) and apply thread-locking compound.
Thread-locking compound
Loctite 270, High strength 83 19 2 210 337
Insert screws (1) by hand.

Tighten screws (1), working from above through the hole (arrow).
Tightening torques
Brake line to bottom fork bridge
M6 x 12 8 Nm
Thread-locking compound (Loctite
270, High strength)
(-) Checking clearance of steering stop
Turn the handlebars all the way to the right and make sure that brake
line (1) cannot touch head of cable tie (2), there must be a visible gap.
If necessary, remove steering stop (3) and reposition.
Turn the handlebars all the way to the left and check operation of the
steering lock.
(-) Finishing work
Install the instrument carrier with instrument panel.

00 60 268 Checking and, if necessary, replacing brackets and threaded fasteners of luggage
carrier
Construction status:
January 2014
Core activity
(-) Checking luggage carrier and rear grab handle, replacing
bracket
Remove screws (1) and remove luggage-carrier top section (2).
Remove screws (1) and nuts (2).

Remove screws (3) and remove luggage-carrier bottom section (4).
Remove spacers (5).
Check
Check luggage-carrier bottom section (4) for cracks in the vicinity of
the threaded fasteners.
Result:
Cracks are perceptible.

Measure:
Replace the luggage-carrier bottom section.
Check
Check threaded bushes (1) in rear grab handle (2). They must be
countersunk or flush (arrow).
Tighten the screws until hand-tight and check that threaded bushes (1)
are secure.

Result:
Threaded bushes project or are loose in the rear grab handle.
Measure:
=> 46 72 501, Replacing rear grab handle (Billed as a separate item)
(-) Removing and disposing of bracket for luggage carrier
Remove screw (1).

Remove bracket (2) and spacer (3) and dispose of the parts in the
appropriate manner.
(-) Installing bracket (modified, without spacer) for luggage

carrier
Clean the threads.

Hold bracket (1) in position, noting the locator (arrow).
Install screw (2) with thread-locking compound and tighten until hand-
tight.
(-) Installing luggage-carrier bottom section
Clean the threads.

Apply thread-locking compound to all the screws.
Position luggage-carrier bottom section (1) with spacers (2) on the rear
grab handle (3) and bracket (4).
Hand-tighten screws (5).
Install screws (6) and new nuts (7) and tighten until hand-tight.

Tighten screws (5).
Tightening torques
Tighten screw (4).
Tightening torques
Tighten screws (6) with nuts (7).
Tightening torques
(-) Installing luggage-carrier top section
Position luggage-carrier top section (1) on luggage-carrier bottom

section (2) and install screws (3).
Tightening torques
Finishing work
Final check of work performed

00 60 270 Checking and, if necessary, replacing brackets and threaded fasteners of luggage
carrier (backrest installed)
January 2014
Core activity
(-) Checking luggage carrier, bracket and rear grab handle
Remove screws (1) and remove luggage-carrier top section (2).
Remove screws (1) and nuts (2).

Remove screws (3) and remove luggage-carrier bottom section (4).
Remove spacers (5).
Check
Check luggage-carrier bottom section (4) for cracks in the vicinity of

the threaded fasteners.
Result:
Cracks are perceptible.
Measure:
Replace the luggage-carrier bottom section.
Check bracket (1) for cracks, particularly at the front (arrow).

If cracks are visible, replace bracket (1).
Check threaded bushes (1) in rear grab handle (2). They must be

countersunk or flush (arrow).

Tighten the screws until hand-tight and check that threaded bushes (1)
are secure.
Check
Result:
Threaded bushes project or are loose in the rear grab handle.
Measure:
=> 46 72 501, Replacing rear grab handle (Billed as a separate item)
(-) Removing bracket for luggage carrier
Remove screw (1).

Remove bracket (2).
(-) Installing bracket for luggage carrier
Clean the threads.

Hold bracket (1) in position, noting the locator (arrow).
Install screw (2) with thread-locking compound and tighten until hand-
tight.
Clean the threads.

Apply thread-locking compound to all the screws.
Position luggage-carrier bottom section (1) on retaining plate (2) and

bracket (3).
Install screws (4) and tighten until hand-tight.
Install screws (5) and new nuts (6) and tighten until hand-tight.
Tighten screws (4).
Tightening torques
Tighten screw (3).
Tightening torques
Tighten screws (5) with nuts (6).
Tightening torques
(-) Installing luggage-carrier top section
Position luggage-carrier top section (1) on luggage-carrier bottom

section (2) and install screws (3).
Tightening torques
Note the maximum payload of the luggage carrier, see Rider's Manual.
Finishing work

00 60 288 Replacing timing-chain tensioner
Preparatory work
Removing filler cap flap
Opening seat
Removing centre cover
Removing front right footplate insert and footrest plate
Removing centre right footplate insert and footrest plate
Removing rear right footplate insert and footrest plate
Removing top right side panel
Removing bottom right fairing panel
Removing right side panel
Removing rear footplate
Removing air deflector
Disengaging expansion tank for coolant
Disengaging and lowering radiator
Removing ignition coils
Removing cylinder head cover
Core activity
(-) Setting engine to firing TDC and securing it in position
Remove screw (1) with seal (2).

Turn the engine in the normal direction of rotation until the mark on
crankshaft (arrow) points toward one of the line marks (arrow).
The corresponding cylinder 1 (alternator side) or 2 (timing-chain side)
is at TDC.
Remove screw (1) and seal (2).

Make sure that the hole (arrow) in crankshaft (3) is visible.
Insert locking pin , making sure that it engages in the hole (arrow) in
crankshaft (3).

(-) Removing timing-chain tensioner
Disengage the cable holder (arrow).

Remove screws (1), taking care to slacken them uniformly to prevent
the component from tilting.
Remove timing-chain tensioner (2) and gasket (3).
(-) Install the new timing-chain tensioner
Clean the sealing faces.

Position timing-chain tensioner (2) with a new gasket (3).
Install screws (1), taking care to tighten them uniformly to prevent
Tightening torques
Chain tensioner in crankcase
M6 x 25 10 Nm
Secure the cable holder (arrow).
Remove locking plate (transportation locking device) (1).

Timing chain is tensioned.
Install screw (2) with new sealing ring (3).
Tightening torques
Threaded plug in chain tensioner
M6 x 6 9 Nm
(-) Removing locator for TDC position
Remove locking pin (No. 11 0 841) from the hole (arrow) in crankshaft
(3).
Install new seal (2) and screw (1).
Tightening torques
Threaded plug (hole for locking pin) to engine cover, right
M16 x 1.5 20 Nm

(-) Checking timing
ATTENTION
Barring of the engine not in compliance with correct procedure.
Component damage
Bar the engine carefully. Stop the rotational movement if resistance is
perceptible.
Carefully turn the engine through several full revolutions of the

crankshaft and set the crankshaft to the TDC position.
crankshaft (arrow) points toward one of the marks I (arrow).
Cylinder 1 (alternator side) is at firing TDC (valves closed).
Check
Note the marks (arrows) on the camshafts:
The holes (arrows) are toward each other and parallel to sealing face
(1).
Result:
Marks are not correct.
Measure:
Install camshafts correctly.
(-) Installing threaded plug (crankshaft)
Check sealing ring (1); replace if necessary.

Install screw (2) with sealing ring (1).
Tightening torques

Threaded plug (crankshaft) to engine cover, right

M36 x 1.5 20 Nm
Finishing work
Installing cylinder head cover
Installing ignition coils
Securing radiator
Securing expansion tank for coolant
Installing air deflector
Installing right footplate
Installing right side panel
Installing bottom right fairing panel
Installing top right side panel
Installing rear right footplate insert and footrest plate
Installing centre right footplate insert and footrest plate
Installing front right footplate insert and footrest plate
Installing centre cover
Closing seat
Installing filler cap flap

00 98 000 Vehicle transport/recovery
Core activity
(-) Securing Maxi-Scooter for transportation
Use masking tape or soft cloths to protect all components that straps
can come into contact with against scratches.
ATTENTION
Vehicle can topple sideways.
Risk of damage to parts if vehicle topples.
Make sure that the vehicle is secured so that it cannot topple
sideways.
Push the Maxi-Scooter on to the transportation flat and hold it in

position: do not place it on the side stand or centre stand.
ATTENTION
Trapping of components.
Component damage
Do not trap components such as brake lines or cable legs.
At the front, secure the straps to the bottom fork bridge on both sides.
At the rear, secure the straps to the retaining plates of the centre stand
on both sides and tighten the straps.
Tighten all the straps uniformly; the suspension of the Maxi-Scooter

should be compressed as tightly as possible tightly front and rear.

11 00 040 Testing compression with BMW Motorrad diagnostic system

+ 11 00 567
Preparatory work
Opening seat
Removing front left footrest plate
Removing left side panel
Core activity
(-) Removing ignition coils
Disconnect plug (1).

Remove ignition coils (2) with puller (No. 12 3 561).
(-) Removing spark plugs
Clean the spark-plug recess with compressed air.

Remove spark plugs (1) with spark-plug wrench (No. 12 1 220).

(-) Testing compression with BMW Motorrad diagnostic

system
Check
Secure diagnosis adapter with non-return valve (No. 11 7 846) and
hose (No. 11 7 842).
Connect the MBOX and select the following functions:
Preset measurements
Pressure
Compression
Connect 0-25 bar pressure sensor and calibrate.
Switch on the ignition and crank the engine with the throttle valve open
until the pressure reading stops rising.
Read the measured value and switch off the ignition.
Technical data
Compression test Good ≥15 bar
pressure
Measured warm, Normal 14...15 bar
throttle valve fully
Poor ≤11 bar
open
Result:
Compression is below normal.
Measure:
Pinpoint the cause of the fault.
Possible causes:
Valves leaking
Piston and cylinder leaking

Cylinder-head gasket defective
Adopt the same procedure to check the compression of the other

cylinder.
Remove the tools.

(-) Installing spark plugs
Install spark plugs (1) with spark-plug wrench (No. 12 1 220).
Tightening torques
Spark plug to cylinder head
M10 x 1 12 Nm
Technical data
Spark plugs, NGK LMAR8D-J
manufacturer and
designation
(-) Installing ignition coils
Install ignition coils (1).

Connect plug (2).
Finishing work
Securing radiator
Installing left side panel
Installing front left footrest plate
Closing seat

11 00 050 Removing/installing engine

+ 11 00 541
Preparatory work
Opening seat
Removing top left fairing side panel
Removing front left footplate insert and footrest plate
Removing bottom left fairing panel
Removing centre left footplate insert and footrest plate
Removing rear left footplate insert and footrest plate
Removing left footplate
Removing left footplate carrier
Draining engine oil
Disconnecting battery leads
Removing underbody panel
Removing air deflector for radiator
Draining coolant from engine
Removing radiator
Removing right footplate carrier
Removing silencer with cover
Removing exhaust manifold with oxygen sensor
Removing left sound-absorbing hood
Disengaging side stand with pivot mount
Installing engine lifter
Disengaging brake hose and sensor cable
Draining oil from swinging arm
Removing swinging-arm housing cover
Removing bottom chain channel
Removing chain tensioner rail

Removing top chain channel

Disengage the judder damper
Removing rear wheel
Disengaging rear brake caliper and parking brake
Removing judder-damper housing and output shaft
Removing spring strut
Removing rear wheel swinging arm
Removing left frame side section
Removing right frame side section with centre stand
Removing pinion cover
Removing chain and pinion
Core activity
(-) Preparations for engine removal
Remove the following components:

Snap retainer (1)
Washer (2)
Radiator strut (3)
Disengage hoses (1).
Disconnect plug (1) for the camshaft sensor.

Disconnect plugs (2) for the ignition coils.

Remove screws (1) and disengage injection rail (2) with injection
nozzles (3) from the engine.
Slacken clamps (1) on left and right and disengage throttle-valve

assembly (2) from the engine.
Open clip (1) and disconnect hose (2).

Disconnect plug (3) for the temperature sensor.
Remove screw (4) and disengage ground connection (5).
Cut through the cable ties (arrows).

Disconnect plug (1) for the crankshaft sensor.

Disconnect plug (2) for the oil-level sensor.
Disconnect plug (3) for the voltage regulator and work it down and
clear of the vehicle.
(-) Removing engine
Secure cross-member (No. 46 5 651) to crane (No. 46 5 670).

Position crane (No. 46 5 670) above the Maxi-Scooter.
Secure two straps to engine bearer (frame triangle) (arrow) on left and
right and connect the straps to cross-member (No. 46 5 651).
Use straps to secure the handlebar grips to the crane (arrows).
Use straps to secure the grab handles to the crane.
Disconnect vent hose (1).

Remove screws (2).
Remove screws (1).

Lower engine (2) carefully.

ATTENTION
Work on components with permanent power supply (terminal 30).
Risk of short-circuit. Voltage peaks.
Disconnect the ground lead from the battery.
Insulate the end of the ground lead.
Remove cap (1) and nut (2), disconnect cable (3).

Remove screw (4) and disengage ground connection (5).
Raise the Maxi-Scooter until engine (1) is separated from the frame.
Work engine (1) to the rear to remove (direction of arrow).
Additionally secure the Maxi-Scooter to prevent it toppling and park it
safely.
(-) Replacing engine
Transfer the small items to the new component.
Tightening torques
Footplate carrier to engine
Right, M8 x 20 19 Nm
Left, M6 x 16 8 Nm
Pour the engine oil into the engine.
Technical data
Engine oil, capacity with filter approx. 3.1 l
change
Viscosity class
After completing work, check the engine oil level; adjust as necessary:
Engine at regular operating temperature
Place the Scooter on its centre stand

Allow the engine to idle for one minute
(-) Installing engine

Secure the Maxi-Scooter to cross-member (No. 46 5 651) and crane

(No. 46 5 670) (arrows).
Secure the grab handles to the cross-member.
Carefully position the Maxi-Scooter with the crane (No. 46 5 670)
above engine (1).
Secure cable (3) with nut (2).
Tightening torques
Wiring harness (positive contact) to starter
M6, Replace nut 8 Nm
(mechanical)
Install cap (1).

Secure ground connection (5) with screw (4).
Tightening torques
Wiring harness (earth lead) to crankcase
M6 x 12 8 Nm
Position the Maxi-Scooter carefully on the engine, if necessary

slightly raise engine (1).
Work engine (2) into position and insert screws (1), but do not tighten.

Tighten screws (2) on left and right.
Tightening torques
Engine to frame
M10 x 35 38 Nm
Connect vent hose (1).
Remove the straps from cross-member (No. 46 5 651).

Remove the straps from the handlebar grips (arrows).
Disengage the straps from engine bearer (frame triangle) (arrow) on
left and right and remove cross-member (No. 46 5 651) with crane (No.
46 5 670).
(-) Finishing work for engine installation
Secure hose (2) with clip (1).

Connect plug (3) for the temperature sensor.
H old ground connector (4) in position and secure with screw (5).
Tightening torques
Wiring harness (earth lead) to crankcase
M6 x 12 8 Nm

Secure injection rail (1) with injection nozzles (2) to the engine, noting
the sealing rings (arrow).
Install screws (3).
Tightening torques
Inj ection rail to adapter for throttle valve
M5 x 12 3 Nm
Thread-locking compound (Micro-
encapsulated)
or, Thread-locking compound
(Loctite 243, Medium strength)
Connect plug (1) for the camshaft sensor.

Connect plugs (2) for the ignition coils.
Secure hoses (1).
Secure throttle-valve assembly (2) to the engine.

Tighten clamps (1) on left and right.
Secure radiator strut (3) with washer and snap retainer (1).

Connect plug (1) for the crankshaft sensor.

Connect plug (2) for the oil-level sensor.
Connect plug (3) for the voltage regulator.
Close the cable ties (arrows).
Finishing work
Removing shaft sealing ring in output shaft
Replacing shaft sealing ring and felt ring for pinion cover
Replacing shaft sealing ring in swinging-arm cover
Installing pinion cover
Installing left and right frame side sections
Installing rear swinging arm
Installing spring strut
Replacing shaft sealing ring in swinging arm
Installing sprocket and output shaft
Securing rear brake caliper and parking brake
Installing rear wheel
Tightening judder damper
Installing swinging-arm housing cover
Pouring oil into swinging arm
Securing brake hose and sensor cable
Removing engine lifter
Installing side stand complete with pivot mount and switch
Installing sound-absorbing hood
Installing exhaust manifold with oxygen sensor

Installing silencer with cover and bracket

Install the right footplate carrier
Installing radiator
Filling cooling system
Checking cooling system for leaks
Installing air deflector for radiator
Installing underbody panel
Connecting battery leads
Checking, if necessary correcting date
Connecting B MW Motorrad diagnostic system to Maxi-Scooter
Performing vehicle test with B MW Motorrad diagnostic system,
reading out fault memory and resetting adaptation values
Disconnecting B MW Motorrad diagnostic system from Maxi-
Scooter
Installing left footplate carrier
Installing left footplate
Installing rear left footplate insert and footrest plate
Installing centre left footplate insert and footrest plate
Installing bottom left fairing panel
Installing front left footplate insert and footrest plate
Installing top left side panel
Closing seat
Checking basic setting and braking effect of parking brake
Pouring engine oil into engine

11 00 103 Disassembling and assembling engine (engine removed)

+ 11 00 648
ATTENTION
Timing chain jumping off sprocket.
Component damage
Do not attempt to turn the engine without chain tensioners fitted.
Preparatory work
Removing CVT cover
Removing CVT complete with clutch
Removing oil filter
Securing engine to engine-repair stand
Relieving tension on and locating chain tensioner
Removing right crankcase cover
Removing left crankcase cover
Core activity
(-) Removing oil line to CVT input shaft

Screws (1) and (2)
Oil line (3)
Sealing ring (4)
(-) Removing CVT drive shaft
Remove nut (1) and washer (3).

Secure nut (1) and turn the hexagon of CVT input shaft (2) clockwise.
Work CVT input shaft (3) to the right to remove (light taps with a
rubber-headed mallet).
Remove sealing ring (1).

(-) Removing bottom crankcase half
Remove screw (1) with sealing ring (2).

Remove oil intake pipe (3).
Remove screws (1).
Remove screws (1), remove bottom crankcase half (2).

Remove judder damper (3).

(-) Installing bottom crankcase half
Clean all sealing faces.
Replace sealing rings (1).

Install judder damper (2) in drive chain (3).
Seal bottom half of engine block (1).
Sealant
Dow Corning 07 58 0 397 777
Hold engine-block half (1) in position and locate it in this position with 2
opposing screws (2), do not tighten.
Check that oil pump union (3) is correctly positioned and tighten
screws (2) until hand-tight.
Tighten the screws in the sequence indicated (1) to (8).
Tightening torques
Assembly of crankcase
M8 x 50 See repair manual
23 Nm

Install oil intake pipe (1), noting the locator (arrows).

Install new sealing ring (2) and screw (3).
Tightening torques
Threaded plug to crankcase/gearbox cover
M20 x 1.5 15 Nm
(-) Installing CVT input shaft
Install drive shaft (1), noting judder damper (2).

Clean the threads.
Install washer (3).
ATTENTION
Shelf life of micro-encapsulated screws overshot.
Insufficient securing effect.
Use additional thread locking.
Install nut (4), counter-holding at hexagon of drive shaft (1).
Tightening torques
CVT input shaft to crankcase
M20 x 1.5 150 Nm
encapsulated)
Clean seat of radial shaft seal (1).

NOTICE
The outside of the shaft sealing ring must be dry on installation; if
necessary clean the seat in the housing.

Lightly lubricate only the sealing lip of radial shaft seal (1) with engine
oil, all other surfaces must be dry and free of grease on installation.
Insert sliding sleeve (No. 11 0 881) and new radial shaft seal (1).
Screw on assembly tool (No. 11 0 881) with thrust nut (No. 11 0 883)
until seated; in this process counter-hold at the hexagon (arrow) to
prevent the mandrel from turning.
Remove the tools.
(-) Installing oil line to CVT input shaft
Insert oil line (3) with new sealing ring (4).

Install screws (1) and (2).
Tightening torques
Oil line (CVT input shaft) to engine
M6 x 16 10 Nm
M6 x 40 10 Nm
Finishing work
Installing left crankcase cover
Installing right crankcase cover
Releasing locator for timing-chain tensioner
Separating engine from engine-repair stand
Installing oil filter
Installing CVT complete with clutch
Installing CVT cover

11 00 209 Oil change, engine, with filter

+ 11 00 611
Preparatory work
Removing rear left footrest plate and oil filler panel
Core activity
(-) Changing engine oil with filter
Draining off all engine oil
Remove screw (1) with sealing ring (2) and drain off the oil into a
suitable container.
Remove screw (1) with sealing ring (2).

Remove oil dipstick (3) and drain the oil from the oil tank into a
suitable container.
Remove oil strainer (4) and sealing rings (5).
Remove oil filter (1), using oil filter wrench (No. 11 4 661).
Allow all the oil to drain off.
Clean the sealing face (arrow).
Install new oil filter (1), using oil filter wrench (No. 11 4 661).
Tightening torques
Oil filter to engine
Lubricate seal with engine oil 11 Nm

Tightening torques
Oil drain plug in crankcase
M16 x 1.5 28 Nm
Clean oil strainer (4), check sealing rings (5); replace if necessary.
Install oil strainer (4).
Tightening torques
Threaded plug to crankcase/gearbox cover
M20 x 1.5 15 Nm
Pour in correct quantity of engine oil and install dipstick (3).
Technical data
Engine oil, capacity with filter approx. 3.1 l
change
Viscosity class
After completing work, check the engine oil level; adjust as necessary:
Engine at regular operating temperature
Place the Maxi-Scooter on its centre stand
Allow the engine to idle for one minute
Switch off the engine
Remove the oil dipstick and seat it on oil filler opening, but do not
engage the threads.
Check the oil level on the oil dipstick.
Technical data
Engine oil, specified level Engine at Between MIN
regular and MAX marks
operating
temperature

Finishing work
Installing rear left footrest plate and oil filler panel

11 12 256 Removing/installing and sealing or replacing cylinder-head cover

+ 11 12 821
Preparatory work
Opening seat
Core activity
(-) Removing cylinder head cover
Open hose clip (1) and disconnect breather hose (2).

Disconnect plug (3) for the camshaft sensor.
Screws (4)
Cylinder head cover (5)
Seal (6)
(-) Replacing cylinder-head cover
Remove screw (1), remove camshaft sensor (2) and seal (3).
Transfer camshaft sensor (2) with new seal (3) to the new part.
Install screw (1).

Tightening torques
Camshaft sensor to cylinder head cover
M6 x 16 10 Nm
(-) Installing cylinder head cover
Seal the new gasket (1) in the area shown (arrows).
Sealant
Dow Corning 07 58 0 397 777
Secure gasket (6) in cylinder head cover (5) with surface sealant.
Sealant
Dow Corning 07 58 0 397 777
Install cylinder head cover (5).

Check that gasket (6) is correctly positioned and install screws (4).
Tightening torques
Cylinder head cover to cylinder head

M6 tighten in
diagonally
opposite
sequence
10 Nm
Connect plug (3) for the camshaft sensor.

NOTICE
Discontinuation of the camshaft sensor with its wiring-harness plug from
model year 2014 onward.
Secure breather hose (2) with hose clip (1).
Finishing work
Securing radiator
Closing seat

11 12 516 Removing/installing cylinder head or replacing cylinder head gasket (engine

removed)
ATTENTION
Component damage
Preparatory work
Core activity
(-) Setting cylinder 1 to overlap TDC and securing (for
camshaft removal)
Turn the engine in the normal direction of rotation until the marks
(arrows) are pointing away from each other and parallel with sealing
face (1).
Make sure that the mark (arrow) in crankshaft (1) is pointing vertically
up.
Install locking pin (No. 11 0 841) in hole in crankshaft (1).
(-) Relieving tension on and locating chain tensioner


Prepare pretensioning tool (No. 11 0 842):

Pull out lock (1) and turn it.
Lock (1) is seated on turnable ring (2) and is held in position.
Install pretensioning tool (No. 11 0 842) in chain tensioner (3) until
seated.
Turn lock (4) until it engages and is flush with top turnable ring (5).
Turn top turnable ring (5) clockwise until the tension is off the chain
tensioner.
(-) Removing camshaft bearing cap
Back off screws (1) and (2) uniformly step by step and remove.
Remove contact spring (3) and chain guide (4).
Remove bearing cap (5).
(-) Removing spark-plug tubes
Remove spark-plug tubes (1) with sealing rings (2).

(-) Removing camshafts
Slightly lift inlet camshaft (1) and disengage it from timing chain (2).
Remove inlet camshaft (1).
Remove exhaust camshaft (3).
(-) Disengaging timing-chain rail
Remove screw (1).

Disengage timing-chain rail (2).
(-) Removing cylinder head

NOTICE
The sealing compound forms a strong bond and in some instances
engine components can be difficult to separate. Separate the engine
components by tapping them with a rubber mallet, without damaging
cooling ribs or other parts of the crankcase.
Screws (1)

Slacken nuts (2) step by step, working from the inside toward the
outside.
Cylinder head (3)
Gasket (4)
(-) Installing cylinder head
Clean the sealing face.

Install the following components:
new seal (4)
Cylinder head (3)
Nuts (2)
Screws (1)
Tighten nuts (2) uniformly step by step, working from the inside
toward the outside.
Tightening torques
Cylinder head to crankcase
M10, Thread oiled Tightening torque,
30 Nm
1st additional angle
of rotation, 90°
2nd additional
angle of rotation,
90°
Tighten screws (1).
Tightening torques
Cylinder head to crankcase
M6 x 50 10 Nm
(-) Securing timing-chain rail
Secure timing-chain rail (2) with screw (1).
Tightening torques
Chain slide rail to crankcase
M6 x 30 10 Nm

Make sure that the timing chain is routed correctly.
(-) Installing camshafts
Lubricate the bearing seats with engine oil.

Pull timing chain (1) taut on exhaust side and insert exhaust camshaft
(2), noting the marks.
The hole (arrow) is pointing out and is parallel to sealing face (1).
Insert inlet camshaft (1) in timing chain (2), noting the marks
The holes (arrows) are apart and parallel to the sealing face (3).
(-) Installing spark-plug tubes

Install spark-plug tubes (1)

(-) Installing camshaft bearing cap
Lubricate all bearing seats with engine oil.

Place the following components in position:
Camshaft bearing cap (5)
Chain guide (4)
Contact spring (3)
Press down on camshaft bearing cap (5) and install screws (1) and
(2) and tighten until hand-tight.
Tighten screws (1) and (2) uniformly and step by step in diagonally
opposite sequence.
Tightening torques
Camshaft bearing cap to cylinder head
M6 x 35 10 Nm
M6 x 60 10 Nm
(-) Releasing locator for timing-chain tensioner
Slightly raise top turning ring (1).

Timing-chain tensioner (2) turns to the working position.
Remove pretensioning tool (No. 11 0 842).
Install screw (1) with seal (2).

(-) Removing crankshaft locator
Remove locking pin (No. 11 0 841).
(-) Checking timing
ATTENTION
B arring of the engine not in compliance with correct procedure.
Component damage
perceptible.
Carefully turn the engine through two full revolutions of the crankshaft
and bring cylinder No. 1 (alternator side) to the TDC position.
Make sure that the mark (arrow) in crankshaft (1) is pointing vertically
up.
If applicable, install locking pin (No. 11 0 841) in the hole (arrow) in
crankshaft (1).
Check
(1).
Result:

Measure:
If applicable, remove locking pin (No. 11 0 841).
F inishing work
BMW Motorrad, UX-VA-4 7 /8



11 12 641 Replacing cylinder head (cylinder head removed)
ATTENTION
Installation of a camshaft bearing cap that has already been run-in a
new cylinder head.
Component damage
Install a correct, new camshaft bearing cap.
Core activity
(-) Disassembling cylinder head

Screws (1)
Intake stub (2)
Seal (3)
Remove intake stub (4) in the same way.
Remove temperature sensor (1).

Screw (2)
Angled adapter (3)
Gasket (4)
(-) Removing bucket tappet
Remove bucket tappets (1) and adjustment plates (2); sort the plates
into their corresponding positions in tray (No. 11 1 844).
NOTICE
Make a note of which bucket tappets belong to which valve.

(-) Removing valves
Secure mount (No. 11 0 853) to valve spring compressor (No. 11 0

851).
Adjust thrust cage (No. 11 0 852) for spring retainer (1).
Secure thrust cage (No. 11 0 852) to valve spring compressor (No. 11
0 851).
Position valve spring compressor on spring retainer (1) and valve (2),
press down spring retainer (1).
Remove valve collets (3) and remove the clamp.
Remove valve (2), spring retainer (1) and valve spring (4).
(-) Removing valve stem seals and spring retainers
Remove valve stem seal (1) with pliers (No. 11 1 250).

Remove spring retainer (2).
(-) Installing bottom spring retainer and valve stem seal
Install spring retainer (1).

Use a suitable tool to install valve stem seal (2) until seated.
(-) Installing valves
Lubricate the components with engine oil.

Secure mount (No. 11 0 853) to valve spring compressor (No. 11 0
851).
Adjust thrust cage (No. 11 0 852) for spring retainer (1) and secure on
valve-spring compressor (No. 11 0 851).
Insert valve (2).

Install valve spring (4) and spring retainer (1).

Position clamp on spring retainer (1), press down spring retainer (1).
Install valve collets (3) and remove the clamp.
(-) Checking valves for leaks
Check
WARNING
Fuel is highly flammable and hazardous to health.
Risk of fire. Health hazard.
Comply with the pertinent safety regulations.
Fill intake or exhaust port with fuel.

Result:
Fuel escapes at the valve heads.
Measure:
Rework valve / valve seat.
Result:
No fuel escapes at the valve heads.

Measure:
No rework needed.
(-) Installing bucket tappet

Install adjustment plate (1) from tray (No. 11 1 844), noting the sorting
sequence.
Chamfer (arrow) faces toward bucket tappet (2).
Install bucket tappet (2).
(-) Assembling new cylinder head

Install temperature sensor (1).
Tightening torques
Temperature sensor to cylinder head
M12 x 1,5 15 Nm
Secure new gasket (4) and coolant pipe (3) with screw (2).
Tightening torques
Coolant pipe to cylinder head
M6 x 25 10 Nm
Place intake stub (4) in position with new gasket (3).

Install screws (1).
Tightening torques
Air intake to cylinder head
M6 x 25 10 Nm
Install intake stub (4) in the same way.

11 14 075 Replacing engine-block cover, left

+ 11 14 858
Preparatory work
Opening seat
Draining engine oil from engine block
Core activity
(-) Removing left sound-absorbing hood
Disengage cable (1) (arrows).

Remove screws (2) and hood (3).
(-) Disengaging left crankcase cover
Open the cable tie (arrow) and disconnect plug (1) for the crankshaft
sensor.
Remove screws (2).
WARNING
Overstretching of cables and lines.
Malfunctions
Do not place strain on lines and cables.
Disengage cover (3) and ease it aside.
(-) Disengaging stator from crankcase cover


Screw (1)
Bracket (2)
Screws (3)
Carefully lay aside stator (4).
(-) Replacing left crankcase cover
Remove the left crankcase cover.
Remove screw (1) and sensor (2).

Transfer sensor (2) to the new part, in this process check sealing ring
(3); replace if necessary.
Tightening torques
Crankshaft sensor to engine cover
M6 x 16 10 Nm
(-) Securing stator in crankcase cover
Insert stator (1), noting the position of the cable pigtail (arrows).
Seal rubber grommet (2).
Sealant
Dow Corning 07 58 0 397 777
Install screws (3).
Tightening torques
Stator to housing cover
M6 x 30 10 Nm
Secure bracket (4) with screw (5).
(-) Securing left crankcase cover

Apply sealant thinly to the sealing face.
NOTICE

Exercise particularly meticulous care when sealing areas where two

sealing faces/joins meet.
Sealant
Dow Corning 07 58 0 397 777
Install cover (3) and screws (2).
Tightening torques
Crankcase cover, left, to crankcase
M6 x 25 tighten in
diagonally
opposite
sequence
10 Nm
Connect plug (1) for the crankshaft sensor and secure it with cable tie
(arrow).
(-) Installing sound-absorbing hood
Secure hood (3) with screws (2).
Tightening torques
Sound-absorbing hood to engine cover, right
M6 x 18 10 Nm
Secure cable (1) (arrows).
Finishing work
Closing seat


11 14 076 Sealing left engine-block cover

+ 11 14 868
Preparatory work
Opening seat
Core activity

sensor.
Remove screws (2).
WARNING
Malfunctions


NOTICE
Sealant
Dow Corning 07 58 0 397 777
Tightening torques
M6 x 25 tighten in
diagonally
opposite
sequence
10 Nm
(arrow).
Tightening torques
M6 x 18 10 Nm
Finishing work


Closing seat

11 14 085 Replacing right engine-block cover

+ 11 14 859
Preparatory work
Opening seat
Removing rear right footrest plate
Disengaging right footplate carrier with reservoir
Core activity
(-) Removing right crankcase cover
Open clips (1) with pliers (No. 17 5 571).

Open clips (2).
Disconnect hoses (3) and (4).
ATTENTION
Contamination due to dripping oil.
Environmental damage, damage to plastic and rubber parts, risk of
slipping if oil film forms on ground or floor.
Catch the dripping oil.
Place a suitable oil tray in position.

Remove screws (1), noting sealing washer (2)
Remove crankcase cover (3).
NOTICE

(-) Installing right crankcase cover

NOTICE
Sealant
Dow Corning 07 58 0 397 777
Align pump shaft (1) with driver (2).

Carefully set cover (3) in position.
Install the following parts and tighten until hand-tight:
Screws (4)
Install screw (5) with new seal (6)
Screws (7)
Tighten screws (4), (5) and (7) in diagonally opposite sequence.
Tightening torques
Crankcase cover, right, to crankcase
M6 x 25, with sealing washer 10 Nm
M6 x 30 10 Nm
M6 x 50 10 Nm
Secure hoses (3) and (4).

Secure clips (2).
Close clips (1) with pliers (No. 17 5 571).
Finishing work
Securing right footplate carrier with reservoir
Installing rear right footrest plate


Closing seat

11 14 086 Sealing right engine cover

+ 11 14 869
Preparatory work
Opening seat
Removing rear right footrest plate
Disengaging right footplate carrier with reservoir
Core activity
(-) Removing right crankcase cover
Open clip (1) with pliers (No. 17 5 571) and disconnect hose (2).
Slacken clips (3), turn them toward the outside and retighten.
ATTENTION
Contamination due to dripping oil.
Environmental damage, damage to plastic and rubber parts, risk of
slipping if oil film forms on ground or floor.
Catch the dripping oil.
Place a suitable oil tray in position.

Remove screws (1).
Remove screw (2), noting sealing washer (3).
Slacken screw (4) (for subsequent removal together with crankcase
cover (5)).
Separate crankcase cover (5) from the crankcase, taking care not to
put strain on radiator hoses (6) .
NOTICE


(-) Securing right crankcase cover

NOTICE
Sealant
Dow Corning 07 58 0 397 777
If applicable, align pump shaft (1) with driver (2).

Carefully place cover (3) with screws (4) in position.
Install screws (5).
Tighten screws (4) to (7) in diagonally opposite sequence.
Tightening torques
Crankcase cover, right, to crankcase
M6 x 25, with sealing washer 10 Nm
M6 x 30 10 Nm
M6 x 50 10 Nm
Connect hose (2).

Secure clip (1) with pliers (No. 17 5 571).
Slacken clip (3), turn it to the correct installed position and tighten.
Finishing work
Securing right footplate carrier with reservoir
Installing rear right footrest plate


Closing seat

11 21 501 Replacing crankshaft (engine disassembled)
Preparatory work
Locking engine in TDC position
Removing magnetic wheel
Removing starter gear with idler gear
Removing oil pump
Removing crankshaft locator
Core activity
(-) Removing bearing frame
Remove screws (1).
Remove screws (1).

Slightly raise drive chain (2) and remove bearing frame (3).
(-) Removing balancing shafts
Remove balancing shafts (1) and (2), noting the bearing shells (3).

(-) Removing crankshaft
Requirement
Timing-chain tensioner is backed off
Remove screw (1) and disengage chain slide rail (2).

Remove screw (3) and remove chain tensioner rail (4).
ATTENTION
Installation of parts that have not worn in together.
Running in procedure has to be repeated.
Do not mix up components.
Mark installed positions.
Remove screws (1) and remove conrod bearing cap (2), noting bearing
(3).
Remove conrod bearing cap (4) in the same way.
Slightly lift crankshaft (1) and disengage timing chain (2).

Remove crankshaft (1) and remove primary chain (3).

(-) Identifying and installing bearing shells for crankshaft
Use the colour codes of the bearing shells in the crankcase top
section to match the bearing shells to the marks on the crankshaft.
Technical data
Bearing journal diameter Marks on A/B/C
in crankshaft main bearing the
Tolerance group crankshaft
Identifier for crankshaft- A Bearing shell red

bearing shells
B Bearing shell
Bearing shells in green
crankcase top section
C Bearing shell
black
Install crankshaft bearing shells with groove (1) and without groove
(2), noting the locating lugs (arrows).
Use the colour codes of the bearing shells in the bearing frame to
match the bearing shells to the marks on the bearing frame
Technical data

Mark for classification of Mark I 1/2/3

the crankshaft bearings (inside):
on the bearing frame identifier
(underside) for main
bearing
bores
Identifier for crankshaft- 1 Bearing shell red

bearing shells
2 Bearing shell
Bearing shells in bearing green
frame
3 Bearing shell
black
Install crankshaft bearing shells (1), noting the locating lugs (arrows).
(-) Installing crankshaft
Requirement
Timing-chain tensioner is backed off
Loop primary chain (3) over crankshaft (1).

Insert crankshaft (1) and loop timing chain (2) into position.
Checking ignition timing; adjusting if necessary
Adjust the camshafts, noting the marks (arrows):

(1).

Mark (arrow) is at right angles to housing mating face (1).

Hole (2) in the crankshaft is visible through tapped hole (3).
If necessary, adjust ignition timing by turning the crankshaft.
Insert conrod bearing (1), making sure that the locating lug (arrow) is
positioned correctly.
ATTENTION
When installing conrod bearing caps (2) make sure that they are
correctly matched (matching serial numbers).
Technical data
Overview of conrod marks A Production date,
year
B Production date,
month
C Serial number
Insert conrod bearing cap (2), making sure that locating pins (3) are

Install screws (4).
Tightening torques
Conrod bolt
M8 x 1, Replace screw 1st tightening
torq ue, 5 N m
2nd tightening
torq ue, 20 N m
Additional angle of
rotation, 90°
Install conrod bearing cap (5) in the same way.

Secure chain slide rail (2) with screw (1).
Tightening torques
M6 x 30 10 N m
Install chain tensioner rail (4) and secure with screw (3).
Tightening torques
Chain tensioner rail to crankcase
M8 20 N m
(-) Installing balancing shafts
Install bearing shells (1) noting the position of the sickle-shaped

grooves (arrow).
Lubricate bearing shells (1) with engine oil.
Install balancing shafts (2) and (3), noting the drive gear (4) on the
crankshaft.
Check the position of balancing shafts (1) relative to crankshaft (2),

noting the marks (arrows):
Holes in balancing shafts (1) are facing up and to the outside,
respectively
Holes in crankshaft (2) are horiz ontal, keyway facing vertically down
Correct installed position, as applicable.

(-) Installing bearing frame

When assembling note bearing shells (1) and (2), for example check
that the locating lugs (arrows) are correctly positioned.

When assembling, note locators (2).
Slightly raise drive chain (1) and carefully manoeuvre bearing frame
(2) into position, noting the locator (arrow).

Tighten the screws in the seq uence indicated (1) to (18 ).
Tightening torques
B earing frame to crankcase (main bearing)
M9 x 1.25 1st step:
lubricate with engine oil 1st tightening
torq ue, 3 N m
M6 x 60 2nd step:
free of oil 1st tightening
torq ue, 3 N m
M9 x 1.25 3 rd step:
2nd tightening
torq ue, 18 N m

M6 x 60 4 th step:
2nd tightening
torq ue, 10 N m
M9 x 1.25 5th step:
Additional angle of
rotation, 90°
F inishing work
Installing oil pump
Locking engine in TDC position
Install the starter gear with idler gear
Installing magnetic wheel
Checking timing

11 25 510 Replacing all pistons (engine removed)
ATTENTION
Component damage
Preparatory work
Removing CVT cover
Setting cylinder 1 to overlap TDC and securing (for camshaft
removal)
Removing camshaft bearing cap
Removing spark-plug tubes
Removing camshafts
Disengaging timing-chain rail
Removing cylinder head
Removing chain slide rail
Removing oil line to CVT input shaft
Removing CVT drive shaft
Removing bottom crankcase half
Core activity
Remove screws (1).
Remove screws (1).

(-) Removing crankshaft
Slightly lift crankshaft (1) and disengage timing chain (2).

Remove crankshaft (1) and remove primary chain (3).
(-) Removing piston with conrod
Remove piston (1) with the conrod, noting conrod bearing (2).

(-) Removing piston

Circlip (1)
Piston pin (2)
Piston (3)
(-) Installing pistons

Position piston (1) on conrod (2), making sure that installed position is
correct.
Install piston pin (3) and new circlip (4).
(-) Installing piston with conrod
Make sure that the gaps of the piston rings are not in line with the
piston's axis of tilt.
Position the other piston rings (1) and (2) so that each gap is offset
120° from the top gap of oil wiper ring (3).
Position the gaps of oil wiper ring (3) so that they are offset approx.
30° from each other (detail).

Secure piston-ring compressor (No. 11 5 731) to piston (1) in such a

way that the piston rings are covered (arrow).
Install each piston (1) with the conrod one after the other, noting
conrod bearing (2).
(-) Installing crankshaft
Loop primary chain (3) over crankshaft (1).

Insert crankshaft (1) and loop timing chain (2) into position.
ATTENTION
Insert conrod bearing (1), making sure that the locating lug (arrow) is
When installing conrod bearing caps (2) make sure that they are
correctly matched (matching serial numbers).

Technical data
Overview of conrod marks A Production date,
year
B Production date,
month
C Serial number
Insert conrod bearing cap (2), making sure that locating pins (3) are
Install screws (1).
Tightening torques
Conrod bolt
M8 x 1, Replace screw 1st tightening
torque, 5 Nm
2nd tightening
torque, 20 Nm
Additional angle of
rotation, 90°
Install conrod bearing cap (5) in the same way.
Install bearing shells (1) noting the position of the sickle-shaped

grooves (arrow).
Install balancing shafts (2) and (3), noting the drive gear (4) on the
crankshaft.


H oles in balancing shafts (1) are facing up and to the outside,
respectively
H oles in crankshaft (2) are horiz ontal, keyway facing vertically down



Tightening torques
B earing frame to crankcase (main bearing)
M9 x 1.25 1st step:
torque, 3 Nm
M6 x 60 2nd step:
torque, 3 Nm
M9 x 1.25 3 rd step:
2nd tightening
torque, 18 Nm

M6 x 60 4 th step:
2nd tightening
torque, 10 Nm
M9 x 1.25 5th step:
Additional angle of
rotation, 90°
(-) Installing oil pump
Install sealing ring (1).

H old oil pump (2) in position, noting gearwheels (3).
Install screws (4).
Tightening torques
Oil pump to bearing frame
M6 x 30 10 Nm
(-) L ocking engine in TD C position
Turn the engine in the normal direction of rotation until the mark on the
crankshaft (arrow) is vertical and bore in crank web (1) is visible
through the tapped hole.
Cylinder 1 (alternator side) is at TDC.
Install locating pin (No. 11 0 841) hand-tight.
F inishing work
Installing chain slide rail
Installing cylinder head
Securing timing-chain rail
Installing camshafts
Installing spark-plug tubes
Installing camshaft bearing cap
Installing bottom crankcase half

Installing oil line to CVT input shaft


11 26 001 Replace reduction gear for starter motor

+ 11 26 608
Preparatory work
Opening seat
Removing rear left footrest plate with footplate insert and oil filler
panel.
Core activity

sensor.
Remove screws (2).
WARNING
Malfunctions

(-) Removing layshaft for starter
Remove shaft (1) and idler gear (2).
(-) Installing layshaft for starter

Install idler gear (2) and shaft (1).

NOTICE
Sealant
Dow Corning 07 58 0 397 777

Tightening torques
M6 x 25 tighten in
diagonally
opposite
sequence
10 Nm
(arrow).
Tightening torques
M6 x 18 10 Nm
Finishing work
Installing rear left footrest plate with footplate insert and oil filler
panel
Closing seat

11 27 506 Removing/installing balancing shaft (engine removed)
Preparatory work
Removing CVT cover
Setting engine to firing TDC (for checking valve clearance)
Removing oil line to CVT input shaft
Removing bottom crankcase half
Removing oil pump
Core activity
Remove screws (1).
Remove screws (1).


(-) Identifying and installing bearing shells for balancing

shafts
Use the colour codes of the bearing shells in the crankcase top
section to match the bearing shells to the marks on the balancing
shafts.
Technical data
Mark for classification of Marks on A/B
the balancing-shaft the
bearings balancing
for identifying the bearing shaft
shells in the top section of
the crankcase
Identifier for balancing- A Bearing shell

shaft bearing shells blue/yellow
on the balancing shaft B Bearing shell
red/brown
Insert bearing shells (1) into crankcase top section (2), noting the
locators (arrows).
Use the colour codes of the bearing shells in the bearing frame to
match the bearing shells to the marks on the bearing frame.

Technical data
Mark for classification of Mark II 1/2
the balancing-shaft (outside):
bearings identifier
on the bearing frame for
(underside) balancing-
shaft
bores
Identifier for balancing- 1 Bearing shell

shaft bearing shells blue/yellow
on the bearing frame 2 Bearing shell
red/brown
Insert bearing shells (1) into bearing frame (2), noting the locators
(arrows).

Holes in balancing shafts (1) are facing up and to the outside,
respectively
Holes in crankshaft (2) are horizontal, keyway facing vertically down

Install balancing shafts (1) and (2).




Tightening torques
Bearing frame to crankcase (main bearing)
M9 x 1.25 1st step:
torque, 3 Nm
M6 x 60 2nd step:
torque, 3 Nm
M9 x 1.25 3rd step:
2nd tightening
torque, 18 Nm

M6 x 60 4 th step:
2nd tightening
torque, 10 Nm
M9 x 1.25 5th step:
Additional angle of
rotation, 90°
F inishing work
Installing oil pump
Checking timing
Installing bottom crankcase half
Installing CVT input shaft
Installing oil line to CVT input shaft

11 31 079 Replacing timing-chain tensioner

+ 11 31 800
Preparatory work
Opening seat
Core activity

is at TDC.

crankshaft (3).

(-) Removing timing-chain tensioner
Disengage the cable holder (arrow).

Remove screws (1), taking care to slacken them uniformly to prevent
Remove timing-chain tensioner (2) and gasket (3).
(-) Install the new timing-chain tensioner

Position timing-chain tensioner (2) with a new gasket (3).
Install screws (1), taking care to tighten them uniformly to prevent
Tightening torques
Chain tensioner in crankcase
M6 x 25 10 Nm
Secure the cable holder (arrow).
Remove locking plate (transportation locking device) (1).

Timing chain is tensioned.
Tightening torques
M6 x 6 9 Nm

(3).
Tightening torques
M16 x 1.5 20 Nm
(-) Checking timing
ATTENTION
Component damage
perceptible.

Check
(1).

Result:
Measure:

Tightening torques
M36 x 1.5 20 Nm
Finishing work
Securing radiator


Closing seat

11 31 506 Replacing timing-chain tensioning rail (cylinder-head cover removed)
NOTICE
Replace the timing chain and the chain guide as well if a new timing-
chain tensioning rail is installed.
Preparatory work
removal)
Core activity
(-) Removing timing chain and camshaft when replacing
timing chain
Disengage inlet camshaft (1) from timing chain (2) and remove.
Disengage exhaust camshaft (3) from timing chain (2) and remove.
Secure timing chain (2) to prevent the part from slipping out of reach.
Remove screw (1) and disengage slide rail (2).

Remove screw (3) and work chain tensioner rail (4) up out of the
timing-chain cavity.
Disengage timing chain (5) from crankshaft sprocket (6) and remove.
(-) Installing timing chain and camshaft when replacing timing

chain
Working from above, insert new tensioning rail (4) and new timing
chain (5) into the timing-chain cavity
Loop timing chain (5) pulled taut on to crankcase sprocket (6) and
secure it in position.
Hold slide rail (2) in position and secure with screw (1), making sure
that timing chain (5) is routed correctly.

Tightening torques
M6 x 30 10 Nm
Secure tensioning rail (4) with screw (3).
Tightening torques
M8 20 Nm

Insert inlet camshaft (1) into timing chain (2), noting the marks
The holes (arrows) are apart and parallel to the sealing face .
Finishing work
Installing camshaft bearing cap when replacing timing chain
Removing pretensioning tool for timing-chain tensioner
Installing screw for timing-chain tensioner
Checking timing
Securing right crankcase cover

11 31 539 Replacing all camshafts (cylinder-head cover removed)
Core activity
camshaft removal)
crankshaft (arrow) points toward line mark I (arrow).
Cylinder 1 (alternator side) is at overlap TDC
Check
Note the marks (arrows).

Result:

Measure:
Turn the engine in its normal direction of rotation until the marks are as
shown in the graphic.

Insert locking pin (No. 11 0 841), making sure that it engages in the
hole (arrow) in crankshaft (3).

Release the cable (arrow).

Lock (1) is seated on turnable rings (2) and is held in position
seated.
tensioner.



Chain guide (4)
Contact spring (3)

opposite sequence.
Tightening torques
M6 x 35 10 Nm
M6 x 60 10 Nm
(3).
Tightening torques
M16 x 1.5 20 Nm
(-) Releasing pretensioning tool for timing-chain tensioner
Slightly raise top turnable ring (1) of pretensioning tool (No. 11 0

842).
(-) Checking timing
ATTENTION
Component damage
perceptible.


Check
(1).
Result:

Measure:
(-) Checking valve clearance
Using feeler gauge (1), measure clearance between camshaft base

circle and bucket tappet (arrow).
Check
Measure settings for all the valves of the cylinder.
Noting measured results
Note down the measured results on a record sheet.

Continue turning the engine until the right cylinder is at firing TDC
(both valves are closed).
Mark on crankshaft (dot) is toward line mark II.

Check valve clearance in the same way and note down the figure.
Technical data
Inlet valve E ngine 0.20 −
+ 0.04
mm
clearance cold max 35 ° 0.04
C
E xhaust valve E ngine 0.28 +− 0.04
mm
C
Result:
Valve clearance out of tolerance
Measure:
= > 11 34 504, Adj usting valve clearance (cylinder-head cover removed)
(Billed as a separate item)

Tightening torques
M36 x 1.5 20 Nm
(-) Removing pretensioning tool for timing-chain tensioner


Secure the cable (arrow).
(-) Installing screw for timing-chain tensioner
Tightening torques
M6 x 6 9 Nm

11 31 555 Replacing timing chain(cylinder head cover removed)
NOTICE
Replace the timing-chain tensioning rail and the chain guide as well if a
new timing chain is installed.
Preparatory work
removal)
Core activity
(-) Removing timing chain and camshaft when replacing
timing chain
Disengage inlet camshaft (1) from timing chain (2) and remove.
Disengage exhaust camshaft (3) from timing chain (2) and remove.
Secure timing chain (2) to prevent the part from slipping out of reach.
Remove screw (1) and disengage slide rail (2).

Remove screw (3) and work chain tensioner rail (4) up out of the
timing-chain cavity.
Disengage timing chain (5) from crankshaft sprocket (6) and remove.
(-) Installing timing chain and camshaft when replacing timing

chain
Working from above, insert new tensioning rail (4) and new timing
chain (5) into the timing-chain cavity
Loop timing chain (5) pulled taut on to crankcase sprocket (6) and
secure it in position.
Hold slide rail (2) in position and secure with screw (1), making sure
that timing chain (5) is routed correctly.

Tightening torques
M6 x 30 10 Nm
Secure tensioning rail (4) with screw (3).
Tightening torques
M8 20 Nm

Insert inlet camshaft (1) into timing chain (2), noting the marks
The holes (arrows) are apart and parallel to the sealing face .
Finishing work
Installing camshaft bearing cap when replacing timing chain
Removing pretensioning tool for timing-chain tensioner
Installing screw for timing-chain tensioner
Checking timing
Securing right crankcase cover

11 34 001 Checking valve clearance

+ 11 34 501
Preparatory work
Opening seat
Core activity
(-) Setting engine to firing TDC (for checking valve clearance)

Cylinder 1 (alternator side) is at firing TDC.

(1).


Check

Technical data
Inlet valve 0.20 +0.04 mm
clearance Engine −0.04
cold max 35 °

C
Exhaust valve Engine 0.28 +0.04 mm
clearance cold max 35 ° −0.04
C
Result:
Measure:
=> 11 34 504, Adjusting valve clearance (cylinder-head cover removed)
Finishing work
Installing threaded plug (crankshaft)
Securing radiator
Closing seat

11 34 502 Checking valve clearance (for maintenance)
Preparatory work
Core activity
(-) Setting engine to firing TDC (for checking valve clearance)

Cylinder 1 (alternator side) is at firing TDC.

(1).

Check


Technical data
Inlet valve Engine +0.04
0.20 −0.04 mm
clearance cold max 35 °
C
Exhaust valve Engine 0.28 +0.04 mm
clearance cold max 35 ° −0.04
C
Result:
Measure:
=> 11 34 504, Adjusting valve clearance (cylinder-head cover removed)
Finishing work
Installing threaded plug (crankshaft)

11 34 504 Adjusting valve clearance (cylinder-head cover removed)
ATTENTION
Component damage
Core activity
camshaft removal)
Cylinder 1 (alternator side) is at overlap TDC
Check

Result:

Measure:
Turn the engine in its normal direction of rotation until the marks are as
shown in the graphic.

Insert locking pin (No. 11 0 841), making sure that it engages in the
hole (arrow) in crankshaft (3).

Release the cable (arrow).

Lock (1) is seated on turnable rings (2) and is held in position
seated.
tensioner.

(-) Adjusting valve clearance
Mark the installed position of each bucket tappet (1).

NOTICE
Make a note of which bucket tappets belong to which valve.
Remove bucket tappet (1).

NOTICE
Take care when removing the bucket tappets; the adjustment plates can
drop into the engine.
Remove adjustment plates (2) and place them, correctly sorted, in tray
(No. 11 1 844).
Check the thickness of shims (2) on removal with a caliper gauge.
Before installing, check the thickness of each new shim.

Change adjustment plates (1) to suit the measured values; note that
the chamfer (arrow) must face up.
Install bucket tappets (2) in their respective, correct locations.



Chain guide (4)
Contact spring (3)
opposite sequence.
Tightening torques
M6 x 35 10 Nm
M6 x 60 10 Nm
(3).
Tightening torques
M16 x 1.5 20 Nm
(-) Removing pretensioning tool for timing-chain tensioner

Secure the cable (arrow).

(-) Checking timing
ATTENTION
B arring of the engine not in compliance with correct procedure.
Component damage
perceptible.

Check
(1).
Result:
Measure:
(-) Rechecking valve clearance
After assembly and turning the engine through several complete

revolutions, recheck the clearance of all valves; if necessary repeat the
adjustment procedure.

Technical data
Inlet valve E ngine 0.20 −
+ 0.04
mm
C
E xhaust valve E ngine 0.28 + 0.04
mm
clearance cold max 35 ° − 0.04
C
(-) Installing screw for timing-chain tensioner
Tightening torques
M6 x 6 9 Nm

Tightening torques
M36 x 1.5 20 Nm

11 41 502 Replacing oil pump (engine disassembled)
Preparatory work
Removing chain guide
Core activity
(-) Removing oil pump
Remove screws (1).

Remove oil pump (2), noting sealing ring (3).
(-) Installing oil pump
Install sealing ring (1).

Hold oil pump (2) in position, noting gearwheels (3).
Install screws (4).
Tightening torques
Oil pump to bearing frame
M6 x 30 10 Nm
Finishing work
Installing chain guide

11 61 176 Removing/installing/sealing or replacing one intake stub

+ 11 61 578
Preparatory work
Opening seat
Removing centre trim panel
Removing handlebar trim
Removing top handlebar cover
Removing bottom handlebar cover
Removing instrument panel with carrier
Removing leg guard
Remove the intake air pipe
Disengaging ignition switch/steering lock
Removing intake air silencer
Removing throttle valve
Disengaging injection line with injection valves
Core activity
(-) Removing air intake stub
Remove clip (1).

Remove screws (2) and air intake (3), noting seal (4).
Use a clean cloth to plug the intake ducts (arrows).

(-) Installing air intake stub
Remove the cloth from the intake ducts (arrows).

Check seal (4); replace if necessary.
Hold air intake stub (3) in position and secure it with screws (2).
Tightening torques
Air intake to cylinder head
M6 x 25 10 Nm
Place clip (1) in position.
Finishing work
Securing injection line with injection valves
Installing throttle valve
Checking play of throttle cable
Installing intake air silencer
Securing ignition switch/steering lock
Installing intake air pipe
Installing leg guard


Installing centre trim panel
Installing instrument panel with carrier
Installing bottom handlebar cover
Installing top handlebar cover
Installing handlebar trim
Closing seat

11 78 000 Replacing oxygen sensor

+ 11 78 500
Preparatory work
Opening seat
Core activity
(-) Removing oxygen sensor
Disconnect connector (1), noting the locators (arrows).

Remove oxygen sensor (2).
(-) Installing oxygen sensor
Install oxygen sensor (2).
Tightening torques
Oxygen sensor to exhaust manifold
M12 x 1.25 25 Nm
Lubricate thread, Lubricant
(Optimoly TA)
ATTENTION
Routing of oxygen-sensor cable not in compliance with correct
procedure.
Damage to oxygen-sensor cable when vehicle is ridden.
Make sure that the oxygen-sensor cable is routed correctly.
Route the cable, noting the locators (arrows).

Connect and secure plug (1).
Finishing work
Connecting BMW Motorrad diagnostic system to Maxi-Scooter
Performing vehicle test with BMW Motorrad diagnostic system,
Disconnecting BMW Motorrad diagnostic system from Maxi-
Scooter
Closing seat

12 00 014 Performing vehicle test with BMW Motorrad diagnostic system

+ 12 00 516
Preparatory work
Opening seat
Core activity
(-) Connecting BMW Motorrad diagnostic system to Maxi-
Scooter
Connect the BMW Motorrad battery charger to the battery.

NOTICE
When carrying out diagnosis and programming, use a battery charger
with 30 A approved by BMW Motorrad that ensures an on-board
system voltage of 13 V.
Disengage diagnosis plug (1) from the holder (arrow) and remove
protective cap (2).
Connect diagnosis plug (1) to the BMW Motorrad diagnostic system.
NOTICE
See the information about the BMW Motorrad diagnostic system for all
further instructions.
(-) Performing vehicle test with BMW Motorrad diagnostic

system
Perform the vehicle test with the BMW Motorrad diagnostic system
and read out the fault memory.
NOTICE
When working with the BMW Motorrad diagnostic system, always follow
the instructions it issues.
Follow instructions or use the diagnosis options, as applicable.
(-) Disconnecting BMW Motorrad diagnostic system from

Maxi-Scooter
Close all diagnostic programs and switch off the ignition.

Disconnect the BMW Motorrad diagnostic system from diagnosis plug
(1) and install cap (2).
Secure diagnosis plug (1) in the holder (arrow).
Disconnect the BMW Motorrad battery charger from the Maxi-
Scooter.

Finishing work
Closing seat

12 12 011 Renewing all spark plugs

+ 12 12 513
Preparatory work
Opening seat
Core activity



Tightening torques
M10 x 1 12 Nm
Technical data
manufacturer and
designation

Connect plug (2).
Finishing work
Securing radiator


Closing seat

12 12 509 Replace all spark plugs (for maintenance)
Preparatory work
Core activity



Tightening torques
M10 x 1 12 Nm
Technical data
manufacturer and
designation

Connect plug (2).
Finishing work
Securing radiator

12 13 155 Replacing direct ignition coil

+ 12 13 655
Preparatory work
Opening seat
Removing expansion tank for coolant
Core activity


Connect plug (2).

Finishing work
Securing radiator
Installing expansion tank for coolant
Scooter
Closing seat

12 31 021 Replacing stator

+ 12 31 684
Preparatory work
Opening seat
panel.
Removing left sound-absorbing hood
Core activity
(-) Removing stator

Screw (1)
Bracket (2)
Screws (3)
Stator (4)
(-) Installing stator

Sealant
Dow Corning 07 58 0 397 777
Install screws (3).

Tightening torques
M6 x 30 10 Nm
Tightening torques
Holder for alternator cable to crankcase cover
M6 x 12 10 Nm
Finishing work
Installing sound-absorbing hood
panel
Closing seat

12 31 022 Replace generator

+ 12 31 673
Preparatory work
Opening seat
panel.
Core activity

is at TDC.

crankshaft (3).


(-) Removing left crankcase cover
Disconnect plug (1) for the regulator and disengage the cable (arrows).
sensor.
Remove screws (2) and cover (3).
NOTICE

(-) Removing stator

Screw (1)
Bracket (2)
Screws (3)
Stator (4)
(-) Installing stator
Sealant
Dow Corning 07 58 0 397 777
Install screws (3).
Tightening torques
M6 x 30 10 Nm
Tightening torques
Holder for alternator cable to crankcase cover
M6 x 12 10 Nm
(-) Removing magnetic wheel

Requirement
Engine locked.
Insert screw (No. 11 0 831) (Order No. 83 30 2 297 981) into puller
(No. 12 5 510).
Remove screw (1) and washer (2).
Remove magnetic wheel (3) with puller (No. 12 5 510).
(-) Installing magnetic wheel
Requirement
Engine locked.
Carefully clean the tapers of crankshaft (1) and magnetic wheel (2).
Place magnetic wheel (2), noting the locator (arrows).
Install washer (3) and screw (4)
Tightening torques
Magnetic gear to crankshaft
M12 x 1 150 Nm
(-) Installing left crankcase cover

Sealant
Dow Corning 07 58 0 397 777
Tightening torques
M6 x 25 tighten in
diagonally

opposite
sequence
10 Nm
(arrow).
Route the cable, connect plug (1) for the regulator and secure the
cable (arrows).
Tightening torques
M6 x 18 10 Nm
(3).
Tightening torques
M16 x 1.5 20 Nm


Tightening torques
M36 x 1.5 20 Nm
F inishing work
panel
Closing seat
F inal check of work performed

12 31 023 Replacing magnetic wheel

+ 12 31 685
Preparatory work
Opening seat
panel.
Core activity

is at TDC.

crankshaft (3).


sensor.
Remove screws (2).
WARNING
Malfunctions
(-) Removing magnetic wheel
Requirement
Engine locked.
Insert screw (No. 11 0 831) (Order No. 83 30 2 297 981) into puller
(No. 12 5 510).
Remove screw (1) and washer (2).
Remove magnetic wheel (3) with puller (No. 12 5 510).

(-) Installing magnetic wheel
Requirement
Engine locked.
Carefully clean the tapers of crankshaft (1) and magnetic wheel (2).
Place magnetic wheel (2), noting the locator (arrows).
Install washer (3) and screw (4)
Tightening torques
Magnetic gear to crankshaft
M12 x 1 150 Nm

NOTICE
Sealant
Dow Corning 07 58 0 397 777
Tightening torques
M6 x 25 tighten in
diagonally

opposite
sequence
10 Nm
(arrow).
Tightening torques
M6 x 18 10 Nm
(3).
Tightening torques
M16 x 1.5 20 Nm

Tightening torques
M36 x 1.5 20 Nm
Finishing work


panel
Closing seat

12 32 000 Removing/installing voltage regulator

+ 12 32 500
February 2014
Preparatory work
Core activity
(-) Removing voltage regulator
Disengage relay carrier (1).

Remove screws (2).
ATTENTION
Hard or sharp-edged objects.
Component damage
Take care not to scratch components; cover or mask as necessary.
Remove voltage regulator (3) by working it down, taking care not to

damage the front wheel cover.
(-) Installing voltage regulator
Hold voltage regulator (3) in position.
Tightening torques
Voltage regulator to fairing bracket
M6 x 25 8 Nm
Install screws (2).

Connect plug (1).
Secure relay holder (1).

Finishing work

12 41 025 Replacing starter

+ 12 41 528
Preparatory work
Opening seat
Removing front right footrest plate
Removing hinge
Removing fuel-pump cover
Removing cover for fuel tank
Removing seat
Removing carpet for luggage compartment
Removing left rear trim panel
Removing right rear trim panel
Removing rear grab handle
Disengaging rear light with cover
Removing top luggage-compartment cover
Removing fuel tank
Removing heat shield foil
Core activity
(-) Removing starter
Remove safety cap (1).

Remove nut (2) and disconnect positive lead (3).
Remove screws (4).
Remove starter (5), noting O-ring (6).
(-) Installing starter
Lubricate O-ring (6).

Lubricant
Klüberpaste 46 MR 401 11 00 7 660 831
Install starter (5).

Install screws (4).
Tightening torques
Starter to crankcase
M6 x 25 10 Nm
Hold positive lead (3) in position and install nut (2).
Tightening torques
Wiring harness (positive contact) to starter
(mechanical)
Install safety cap (1).
Finishing work
Installing heat shield foil
Securing fuel tank
Installing top luggage-compartment cover
Securing rear light with cover
Installing rear grab handle
Installing right rear trim panel
Installing left rear trim panel
Installing carpet for luggage compartment
Installing seat
Installing cover for fuel tank
Installing fuel-pump cover
Installing hinge
Installing front right footrest plate
Closing seat



12 61 001 Replacing oil-level/oil-temperature sensor

+ 12 61 567
Preparatory work
Opening seat
Core activity
(-) Removing oil-level/oil-temperature sensor
Remove the cable ties (arrows).

Disconnect plug (1) for the oil-level/oil-temperature sensor.
Remove screws (2).
Remove oil-level/oil-temperature sensor (3) with sealing ring (4).
(-) Installing oil-level/oil-temperature sensor
Clean the threads.

Install oil-level/oil-temperature sensor (3), noting sealing ring (4).
Install screws (2).
Connect plug (1) for the oil-level/oil-temperature sensor.
Install the cable tie (arrow).
Finishing work


Closing seat

12 62 010 Replacing coolant-temperature sensor

+ 12 62 510
Preparatory work
Opening seat
Core activity
(-) Removing coolant-temperature sensor
Disconnect connector (1).

CAUTION
Working on hot cooling system.
Risk of burn injury
Always allow the cooling system to cool down before starting work.
Remove coolant-temperature sensor (2).
(-) Installing coolant-temperature sensor
Install coolant-temperature sensor (2).
Tightening torques
Temperature sensor to cylinder head
M12 x 1,5 15 Nm
Connect plug (1).
Finishing work
Performing vehicle test with BMW Motorrad diagnostic system, reading out
fault memory and resetting adaptation values
Disconnecting BMW Motorrad diagnostic system from Maxi-Scooter
Closing seat

12 72 001 Replacing crankshaft sensor

+ 12 72 501
Preparatory work
Opening seat
Core activity
(-) Removing crankshaft sensor

Remove screw (2).
Remove crankshaft sensor (3).
(-) Installing crankshaft sensor

Install crankshaft sensor (2).
Install screw (3).
Tightening torques
Crankshaft sensor to engine cover
M6 x 16 10 Nm
Connect and secure plug (4).
Finishing work


Closing seat

12 72 020 Replacing camshaft sensor

+ 12 72 520
NOTICE
Discontinuation of the camshaft sensor with its wiring-harness plug from
model year 2014 onward.
Preparatory work
Core activity
(-) Removing camshaft sensor
Remove screw (2).
Remove camshaft sensor (3) with seal (4).
(-) Installing camshaft sensor
Install camshaft sensor (3) with new seal (4).

Install screw (2).
Tightening torques
Camshaft sensor to cylinder head cover
M6 x 16 10 Nm
Connect plug (1).
Finishing work

13 53 000 Renewing injector pipe

+ 13 53 500
Preparatory work
Opening seat
Core activity
(-) Removing injection line
Use a screwdriver to ease open hose clip (1).

Disengage fuel feed hose (2) from holder (3).
Disconnect plug (1) for the injection valves.

Remove screws (2).
ATTENTION
Escape of fuel when pressurised fuel lines are opened.
Damage to component surfaces.
Employ suitable means to catch escaping fuel.

Seal off fuel feed hose (3) with hose clamp (No. 13 3 010).
Disengage fuel feed hose (3) from injection line (5).
Remove injection line (5) with injection valves (6), noting O-rings (7).
Remove spring clips (4).
Remove injection valves (6) with O-rings (7) from injection line (5).
(-) Installing injection line
Clean the threads.

Replace O-rings (1) and lubricate
Care products
Rubber care product 83 12 0 397 018
Secure injection valves (2) with spring clips (3) in new injection line (4),
noting O-rings (1).
Insert injection line (4), noting O-rings (1).
Install screws (5).
Tightening torques
Injection rail to adapter for throttle valve
M5 x 12 3 Nm
encapsulated)
Position hose clip (6) on fuel feed hose (7).

Connect fuel feed hose (7) to injection line (4).
Remove hose clamp (No. 13 3 010) from fuel feed hose (7).
Connect plug (8) for the injection valves.
Align hose clip (1) so that it is accessible but there is no possibility of
other components chafing against it.
Secure hose clip (1) with pliers (No. 13 1 500).
Secure fuel flow hose (2) in holder (3).

Finishing work
Closing seat

13 54 016 Removing/installing power reduction

+ 13 54 528
Preparatory work
Opening seat
Core activity
(-) Removing power-output restrictor (sheet-metal stop)
Remove screws (1) and remove sheet-metal stop (2).
(-) Installing power-output restrictor (sheet-metal stop)
Clean the threads of screws (1).

Insert sheet-metal stop (2) and secure with screws (1).
Tightening torques
Metal stop (power reduction) to throttle valve
M5 x 12 3 Nm
encapsulated)
Check that the throttle cables are in working order and move freely.
Finishing work


Closing seat

13 54 017 Replacing complete throttle-valve assembly

+ 13 54 521
Preparatory work
Opening seat
Removing leg guard
Core activity
(-) Removing throttle valve
Remove screw (1) and remove cover (2).

Slacken adjusting screws (3) and set play to maximum.

Remove lock washer (1) and disengage throttle-closer cable (2) from
holder (3), noting spring (4).
Disengage throttle-closer cable (2) from cable pull (5).
Push rubber grommet (6) up along throttle cable (7).
Disengage throttle cable (7) from holder (3).
Disengage throttle cable (7) from cable pull (5).
Disconnect plug (1) from throttle-valve sensor (2).

Slacken clips (3) and remove throttle-valve assembly (4).
(-) Installing throttle valve
Hold throttle-valve assembly (4) in position and secure it with clips (3)
Connect plug (1) to throttle-valve sensor (2)
Secure throttle cable (7) in cable pull (5).

Seat throttle cable (7) in holder (3) and secure with rubber grommet
(6).
Seat throttle-closer cable (2) in holder (3), noting spring (4).
Install lock washer (1).
Install throttle-closer cable (2) in cable pull (5).

Place cover (1) in position and secure with screw (2).
Finishing work
Scooter
Closing seat



13 61 510 Replacing engine management control unit (not including checking/programming

software)
NOTICE
Before removal, test the control unit with the BMW Motorrad diagnostic
system and make a backup copy of the data.
Preparatory work
Core activity
(-) Remove the control unit
Open the cable tie (arrow).

Remove screws (1).
Disengage control unit (2) and disconnect plug (3).
(-) Installing control unit
Connect plug (3).

Secure control unit (2) with screws (1).
Tightening torques
Control unit to bracket
M5 x 10 6 Nm
Secure the cable tie (arrow).
Finishing work
=> Testing software (Description in item: 61 00 502,

Billed as a separate item)
=> Programming control units of vehicle (along with

testing software) (Description in item: 61 00 510, Billed
as a separate item)

13 61 522 Programming control unit of engine management system (along with testing
software)
Core activity
(-) Programming engine-management control unit
Start ISTA/P.
Start the programming routine and follow the instructions issued by the
BMW Motorrad diagnostic system.

13 62 010 Replacing intake-air temperature sensor

+ 13 62 501
Preparatory work
Core activity
(-) Removing intake-air temperature sensor
Disconnect plug (1) for the intake-air temperature sensor.

Press the retainer (arrow) and remove sensor (2) with O-ring (3).
(-) Installing intake-air temperature sensor
Check O-ring (3) for damage; replace if necessary.

Lubricate O-ring (3).
Care products
Install sensor (2) with O-ring (3).

The locking tab (arrow) engages with an audible click.
Connect plug (1) for the intake-air temperature sensor.
Finishing work
Opening seat
Scooter
Closing seat

13 63 002 Replacing throttle-valve sensor

+ 13 63 525
Preparatory work
Opening seat
Core activity
(-) Removing throttle-valve switch

Remove screw (2).
Remove throttle-valve switch (3).
(-) Installing throttle-valve switch
Install throttle-valve switch (3).

Engage screw (2), do not tighten.
Connect plug (1).
(-) Adjusting throttle-valve switch (potentiometer)


Connect the BMW Motorrad battery charger to the battery.

NOTICE
When carrying out diagnosis and programming, use a battery charger
with 30 A approved by BMW Motorrad that ensures an on-board
system voltage of 13 V.
Disengage diagnosis plug (1) from the holder (arrow) and remove
protective cap (2).
Connect diagnosis plug (1) to the BMW Motorrad diagnostic system.
NOTICE
See the information about the BMW Motorrad diagnostic system for all
further instructions.
Open the Service functions program.
Run the "Adjust throttle-valve sensor" service program.

Turn potentiometer (1) until the value is OK.
Tighten screw (2).
Tightening torques
Throttle-valve switch (potentiometer) to throttle-valve stub
M5 x 16 4 Nm

Perform the vehicle test and read out the fault memory.
Perform all requisite repair work.
Reset the adaptation values.
This is the only way of ensuring correct operation of the motorcycle.

Scooter
Close all diagnostic programs and switch off the ignition.
Disconnect the BMW Motorrad diagnostic system from diagnosis plug
(1) and install cap (2).
Secure diagnosis plug (1) in the holder (arrow).

Disconnect the BMW Motorrad battery charger from the Maxi-

Scooter.
Finishing work
Scooter
Closing seat

13 63 020 Replace idle actuator

+ 13 63 520
Preparatory work
Core activity
(-) Removing idle actuator
Disconnect plug (1)

Remove screws (2).
Remove idle actuator (3).
(-) Installing idle actuator
Hold idle actuator (3) in position.

Install screws (2).
Tightening torques
Idle actuator to intake air silencer
Screw for plastic, 5 x 20 2.5 Nm
Connect plug (1).
Finishing work

13 64 165 Renewing one injector

+ 13 64 501
Preparatory work
Opening seat
Core activity
(-) Removing injection valves
Disconnect plug (1) for the injection valves.

Remove screws (2).
ATTENTION
Seal off feed hose (3) with hose clamp (No. 13 3 010).
Remove spring clip (4).
Disengage injection rail (5) from injection valves (6).
Remove injection valve (6) with O-rings (7).
(-) Installing injection valve
Check O-rings (7) for damage; replace if necessary.

Lubricate O-rings (7).

Care products
Install injection valve (6) in injection rail (5), noting O-ring (6).
Install spring clip (4).
Insert injection rail (5).
Install screws (2).
Tightening torques
Injection rail to adapter for throttle valve
M5 x 12 3 Nm
encapsulated)
Connect plug (1) for the injection valve.

Remove hose clamp (No. 13 3 010) from hose (3).
Finishing work
Scooter

Closing seat

13 71 010 Replace intake-air silencer

+ 13 71 510
Preparatory work
Opening seat
Removing leg guard
Core activity
(-) Removing intake air silencer
Disconnect hoses (1).

Disconnect plug (4) for the idle actuator.
Disconnect plug (1) for the intake-air temperature sensor.

Open clips (2) with pliers (No. 17 5 500).

Remove intake air silencer (3), noting the locators (arrows).
(-) Replacing intake air silencer

Screw (1)
Idle actuator (2)
O-ring (3)
Air-temperature sensor (4) with O-ring (5)
Replace intake air silencer (6).
Check O-rings (5) and (3) for damage; replace if necessary.
Transfer the reusable parts removed to new intake air silencer (6).
Tightening torques
Idle actuator to intake air silencer
Screw for plastic, 5 x 20 2.5 Nm
(-) Installing intake air silencer
Install intake air silencer (3), noting the locators (arrows).

Secure clips (2) with pliers (No. 17 5 500), making sure that clips (2)
are correctly seated.
Connect plug (1) for the intake-air temperature sensor.
Connect plug (4) for the idle actuator.

Connect hose (3) and close hose clip (2) with pliers (No. 17 5 571).
Secure hoses (1).

Finishing work
Closing seat

13 71 020 Replacing air intake duct

+ 13 71 520
Preparatory work
Opening seat
Removing windscreen
Removing left slipstream deflector
Removing right slipstream deflector
Removing top instrument carrier
Removing left mirror
Removing battery
Removing right mirror
Disengaging battery holder
Removing complete headlight
Disengaging coolant filler neck
Core activity
(-) Remove the intake air pipe
Remove screws (1) and (2).

Disconnect hose (3).
Remove intake air pipe (4), noting rubber grommet (5) and rubber seal
(6).
(-) Installing intake air pipe

Install intake air pipe (4), noting rubber seal (6) and rubber grommet
(5).
Care products
Connect hose (3).

Tightening torques
Air intake duct to fairing bracket
M6 x 25 8 Nm
Air intake duct to intake air silencer
M6 x 16 5 Nm
Finishing work
Securing coolant filler neck
Installing headlight
Installing top instrument carrier
Installing left slipstream deflector
Install the right slipstream deflector
Installing windscreen
Installing right mirror
Securing battery holder
Installing battery
Closing seat

Checking setting for low-beam headlight


13 72 001 Renewing air cleaner insert

+ 13 72 532
Preparatory work
Core activity
(-) Removing air filter

Screws (1)
Cover (2)
Air filter (3)
(-) Installing air filter
Clean the inside of intake air silencer (1).

Air filter (2)
Cover (3)
Screws (4)
Finishing work

13 72 505 Replace air filter cartridge (for maintenance)
Preparatory work
Core activity
(-) Removing air filter

Screws (1)
Cover (2)
Air filter (3)
(-) Installing air filter
Clean the inside of intake air silencer (1).

Air filter (2)
Cover (3)
Screws (4)
Finishing work

16 11 030 Removing/installing fuel tank

+ 16 11 533
Preparatory work
Opening seat
Removing hinge
Removing seat
Disengaging rear light with cover
Core activity
(-) Removing fuel tank
Open the cable ties (arrows).
Disconnect plug (1) for the fuel pump.

Disconnect plug (2) for the fuel-level sensor.
Disconnect breather hose (3) from the fuel tank.
Seal off fuel hose (4) with hose clamp (No. 13 3 010).
ATTENTION

Press retaining ring (5) down and pull out fuel hose (4).
Remove the line holders (arrows).

Remove screws (1).
Remove the line holders (arrows).

Remove screws (1) and fuel tank (2).
(-) Installing fuel tank
Make sure that heat shield (1) is correctly positioned.

ATTENTION
Crushed or disconnected hoses.
Malfunctions
Do not crush or seal off hoses.
Place fuel tank (2) in position, secure screws (1) on left and right.
Tighten screws (1).
Tightening torques
Fuel tank to frame
M6 x 16 8 Nm
Secure the line holders (arrows).

Tighten screws (1).
Tightening torques
Fuel tank to frame
M6 x 16 8 Nm
Secure the line holders (arrows).
Secure fuel hose (4), making sure that retaining ring (5) engages.
Remove hose clamp (No. 13 3 010) from fuel hose (4).
Connect vent hose (3).
Connect plug (2) for the fuel-level sensor.
Connect plug (1) for the fuel-pump unit.

Finishing work
Securing rear light with cover
Installing seat
Installing hinge
Closing seat

17 00 010 Checking cooling system for leaks (with cooling system tester)
+ 17 00 502
Preparatory work
Opening seat
Core activity
(-) Checking cooling system for leaks
Check
If applicable, remove cap (1).
Secure pump (No. 17 0 511), adapter (No. 17 0 512), hose, main
element (No. 17 5 521), plug (No. 17 5 522) and spring clip (No. 17 5
523) to the filler neck (arrow).
Apply the test pressure to the cooling system.
Technical data
Cooling system - Test pressure must 1.5 bar
test pressure remain
unchanged min 5 min
Result:
Cooling system is losing pressure.

Measure:
Rectify the leak.
Remove the tools.

Install cap (1).
Finishing work


Closing seat

17 00 020 Checking coolant composition

+ 17 00 503
CAUTION
Risk of burn injury
Preparatory work
Core activity
(-) Checking coolant composition
Remove cap (1).
General consumable
Antifreeze and corrosion inhibitor 83 19 2 211 191
Check
Check the ability of the coolant to resist freezing temperatures by
checking the coolant composition in expansion tank (2).
Technical data
Coolant, frost min −30 °C
protection
Result:
Ability to resist freezing temperatures is not ensured.
Measure:
If necessary, increase the proportion of antifreeze until ability to resist
freezing temperatures is ensured (start the engine and allow it to run
briefly to make sure that the antifreeze mixes thoroughly).
Install cap (1).
Finishing work

17 00 035 Draining coolant, refilling/bleeding system

+ 17 00 504
Preparatory work
Opening seat
Core activity
(-) Draining coolant from engine
CAUTION
Risk of burn injury
Remove coolant drain plug (1) and seal (2), drain off the coolant.
(-) Draining coolant from radiator
Remove cap (1).

Remove coolant drain plug (2) and drain the coolant.
(-) Filling cooling system

Tightening torques
Drain plug to coolant pump
M6 x 10 10 Nm
If the system is not refilled with fresh coolant, check the coolant to
ensure that the proportion of antifreeze is sufficient to ensure
resistance to freezing temperatures.
Technical data
protection
Install coolant drain plug (2).

If applicable, remove cap (1) and pour in coolant to correct level.
Technical data
Specified coolant level in Engine Bottom edge of
radiator cold overflow bowl
Coolant capacity (total) 1.5 l

General consumable (Antifreeze and
corrosion inhibitor)
(-) Checking cooling system for leaks
Check
If applicable, remove cap (1).

Secure pump (No. 17 0 511), adapter (No. 17 0 512), hose, main
element (No. 17 5 521), plug (No. 17 5 522) and spring clip (No. 17 5
523) to the filler neck (arrow).
Apply the test pressure to the cooling system.
Technical data
Cooling system - 1.5 bar
test pressure Test pressure must
remain

unchanged min 5 min
Result:
Cooling system is losing pressure.

Measure:
Rectify the leak.
Remove the tools.

Install cap (1).
Finishing work
Closing seat

17 11 008 Removing/installing radiator (without draining/refilling coolant system)

+ 17 11 508
Preparatory work
=> Draining coolant, refilling/bleeding system

(Description in item: 17 00 504, Billed as a separate item)
Core activity
(-) Disengaging expansion tank for coolant
Remove screws (1) and disengage expansion tank (2).

Disengage vent hose (3) from the holder (arrow).
(-) Removing radiator
Open the cable tie (arrow) and disconnect plug (1) for the fan.
Disengage cable (2) for the fan from the holder (arrows).
Disengage hose (3) from the holder (arrow).
Release clips (1) with pliers (No. 17 5 571) and disconnect hoses (2).

Remove retaining clips (1) and washers (2).

Remove radiator (3), noting the lines.
Drain the remaining coolant from radiator (5).
(-) Installing radiator
Insert radiator (3), noting the lines.

Install washers (2) and retaining clips (1).
Install hose (4) and clip (3) with pliers (No. 17 5 500).
Install hoses (2) and clips (1) with pliers (No. 17 5 571).

Secure hose (3) in the holder (arrow).

Route cable (2) for the fan and secure it in the holders (arrows).
Connect plug (1) for the fan and secure it with cable tie (arrow).
(-) Securing expansion tank for coolant
Seat breather hose (3) in the holder (arrow), making sure that routing
is correct.
Secure expansion tank (2) with screws (1).
Tightening torques
Expansion tank to footplate carrier
M6 x 16 8 Nm
Finishing work

17 11 037 Replacing air inlet duct for radiator

+ 17 11 545
Core activity
(-) Removing air deflector
Remove body-bound rivets (1) and screws (2) on left and right.
Remove air deflector (3).
(-) Installing air deflector
Insert air deflector (3).

Install screws (2) and body-bound rivets (1) on left and right.
Finishing work

17 12 114 Replacing all coolant lines for heat exchanger (without draining/refilling coolant
system)
+ 17 12 614
Preparatory work
Core activity
(-) Removing coolant lines for heat exchanger
Open hose clips (1)
Remove coolant lines (2).
(-) Installing coolant lines for heat exchanger
Install coolant lines (2).

Tighten hose clamps (1).
Finishing work

17 13 001 Replace expansion tank

+ 17 13 501
Preparatory work
Opening seat
Core activity
(-) Removing expansion tank for coolant
Place a tray in position to catch the coolant.

Open clip (1) and disconnect hose (2); plug the hose with a suitable
tool and catch escaping coolant in a suitable manner.
Remove screws (3).
Disengage breather hose (5) from the holder (arrow) and remove
expansion tank (4).
(-) Replacing expansion tank for coolant
Transfer cap (1), hose (2) and small items to the new part.
(-) Installing expansion tank for coolant
Secure expansion tank (4) with screws (3).

Tightening torques
Expansion tank to footplate carrier
M6 x 16 8 Nm
Connect hose (2) and secure with clip (1).

Seat breather hose (5) in the holder (arrow), making sure that routing
is correct (see graphic).
(-) Filling expansion tank
If the system is not refilled with fresh coolant, check the coolant to
ensure that the proportion of antifreeze is sufficient to ensure
resistance to freezing temperatures.
Technical data
protection
Disengage cap (1) and fill expansion tank (2) with coolant.
Technical data
Specified coolant level in engine Between MIN and
expansion tank cold MAX marks
Secure cover (1).
Finishing work
Closing seat


17 21 006 Replacing heat exchanger (without draining/refilling coolant system)

+ 17 21 506
Preparatory work

Removing oil filter
Core activity
(-) Remove the heat exchanger
Open clips (1) and disconnect hoses (2).

oil filter adapter (3)
heat exchanger (4)
sealing ring (5)
(-) Installing heat exchanger

Install sealing ring (1) and heat exchanger (2), noting the locator
(arrow).
Install oil filter union (3).
Tightening torques
Oil filter adapter to crankcase
M20 x 1.5 35 Nm
Connect hoses (4) and secure with clips (5).
Finishing work
Installing oil filter

17 40 000 Removing/installing or replacing fan

+ 17 40 500
Preparatory work
Opening seat
Core activity
(-) Removing fan
Push radiator (1) forward and remove nuts (2) with washers (3).
Remove fan (4).
(-) Installing fan
Position fan (4) on radiator (1).

Install washers (3) and nuts (2).
Tightening torques
Radiator cowl to radiator
M4 x 35, Screw
(mechanical)
Finishing work

Securing radiator
Closing seat

17 65 000 Replacing thermostat for coolant (without draining/ refilling coolant system)
+ 17 65 500
Preparatory work

Core activity
(-) Removing thermostat
Remove spring clip (1).

Remove thermostatic cap (2) with sealing ring (3).
Remove thermostatic insert (4).
(-) Installing thermostat
Install thermostat insert (3).

Lubricate sealing ring (1) with coolant and install.
Install thermostatic cap (2) in radiator (4), noting the locators (arrows).
Install spring clip (5).

18 51 000 Replacing silencer

+ 18 51 500
Core activity
(-) Removing silencer
Remove screws (1), shouldered bushings (2) and cover (3), noting
insulating washers (4).
Release clip (1).

Remove nut (2), screw (3), washer (4) and, if applicable, bushing (5).
Remove silencer (6).
(-) Replacing silencer

Secure clip (1) to the new part.
(-) Installing silencer
Lubricate the inside of silencer pipe and clamp (1).

Lubricant
Optimoly TA 18 21 9 062 599
Hold silencer (6) in position.

Install nut (2), screw (3), washer (4) and, if applicable, bushing (5).
Tightening torques
Silencer to bracket
M8 x 30 20 Nm
Turn clamp (1) to the position shown and tighten.
Tightening torques
End silencer to front silencer
M8 x 30 19 Nm
Install cover (3), shouldered bushings (2) and screws (1), noting
Tightening torques
Cover to rear silencer
M6 x 16 8 Nm
Finishing work

18 51 001 Replacing exhaust manifold

+ 18 51 502
Preparatory work
Opening seat
Core activity
(-) Removing silencer
Remove screws (1), shouldered bushings (2) and cover (3), noting
Release clip (1).

Remove nut (2), screw (3), washer (4) and, if applicable, bushing (5).
Remove silencer (6).
(-) Removing exhaust manifold
Disengage the cable for oxygen sensor (1) (arrows).

Disengage sensor housing (2).
Remove nuts (1) and disengage exhaust manifold (2).

Remove exhaust manifold (2) and gaskets (3); if applicable lubricate
retaining pins (4).
Installation tool
Silicone spray 83 19 2 208 609
(-) Installing exhaust manifold
Lubricate retaining pins (5).
Installation tool
Install new gaskets (4) and seat exhaust manifold (3) on retaining pins
(5).
Secure exhaust manifold (3) with nuts (2).
Tightening torques
Manifold to cylinder head
M7 14 Nm
Connect plug (1) for the oxygen sensor, making sure that the routing of
the cable is correct.
Secure sensor housing (2).
Tightening torques
Oxygen sensor to exhaust manifold
M12 x 1.25 25 Nm
Lubricate thread, Lubricant

(Optimoly TA)
Secure cable for oxygen sensor (1) (arrows).
(-) Installing silencer
Lubricate the inside of silencer pipe and clamp (1).
Lubricant
Optimoly TA 18 21 9 062 599
Hold silencer (6) in position.

Install nut (2), screw (3), washer (4) and, if applicable, bushing (5).
Tightening torques
Silencer to bracket
M8 x 30 20 Nm
Turn clamp (1) to the position shown and tighten.
Tightening torques
End silencer to front silencer
M8 x 30 19 Nm
Install cover (3), shouldered bushings (2) and screws (1), noting
Tightening torques
Cover to rear silencer
M6 x 16 8 Nm
Finishing work
Securing radiator


Closing seat

21 21 000 Removing and installing or replacing clutch

+ 21 21 606
Preparatory work
Opening seat
Removing rear right footplate carrier
Removing CVT sound-absorbing hood
Removing CVT cover
Core activity
(-) Slackening threaded fasteners of CVT adjuster unit and
CVT output
If applicable, secure drive belt (1) with a cable tie (arrow).
Bend up tabs of lock washer (1)

Engage holder (No. 24 0 511).
Slacken nut (2).
Turn shaft (3) clockwise to slacken nut (4).
Remove holder (No. 24 0 511).

(-) Removing CVT adjuster unit

Nut (1)
Lock washer (2)
Spacer (3)
Remove CVT adjuster unit (1) and sleeve (2).
(-) Removing CVT output with drive belt and clutch bell
Remove nut (1), while counter-holding at shaft (2) if necessary.

Remove lock washer (3).
Remove CVT output (1) with drive belt (2).

Remove clutch bell (1).
(-) Removing clutch package
Insert clutch package (1) with CVT output in pretensioning tool (No. 24
0 512), making sure that CVT output (1) is secured so that it cannot
twist out of position.
Slipstream deflectors engage the retainers (arrows).
Slacken nut (2) with socket (No. 24 0 513), securing the socket so that
it cannot slip.
Pretension clutch package (1) with pretensioning tool (No. 24 0 512) .

Remove nut (2).
Relieve the tension on pretensioning tool (No. 24 0 512) and remove
clutch package (1) with the CVT output.

Remove clutch package (1), spring sleeve (2) and spring (3).
(-) Installing clutch package
Place spring (3), spring sleeve (2) and clutch package (1) in position.
Insert clutch package (1) with CVT output into pretensioning tool (No.
24 0 512), noting the locator in the pretensioning tool.
Pretension clutch package (1) with pretensioning tool (No. 24 0 512)
and tighten nut (2) until hand-tight.
Relieve tension on pretensioning tool (No. 24 0 512).
Tighten nut (2) with socket wrench insert (No. 24 0 513).
Tightening torques
Clutch package to CVT output
M48 x 1 85 Nm
Remove clutch package (1) with CVT output from the pretensioning
tool.

(-) Installing CVT output with drive belt and clutch bell
Installing drive belt in CVT output
When installing drive belt (1), make sure that the direction of rotation
(arrow) is correct: arrows point in direction of rotation.
Use a tyre lever to hold down thrust washer (1), taking care not to
damage the friction faces (arrows).
Pull drive belt (1) as tight to the pulley as possible and secure the
loose end with a cable tie (arrow).
Drive belt (1) is secured to permit subsequent assembly of the CVT
adjuster unit.
Install clutch bell (1).

Install CVT output (1) with drive belt (2).
Position lock washer (3) on shaft (2).

Install nut (1) and tighten until hand-tight.
(-) Installing CVT adjuster unit
Clean CVT spacing sleeve (1).

Lubricate the cavity (arrow).
L ubricant
Unirex N3 83 19 2 160 349

Install CVT spacing sleeve (2) and removing escaping grease.

N O TICE
The friction faces of the CVT belt, CVT belt and coupling must be clean
and free of grease.
Install CVT adjuster unit (1).
Make sure that engagement of the splines (arrow) between guide plate
(1) and CVT shaft (2) is correct.
Install spacer (3) and lock washer (2).

Make sure that installation is correct: with nut (1) installed, the groove
(arrow) in CVT shaft (2) must be visible.
(-) Securing threaded fasteners of CVT adjuster unit and CVT

output

Tighten nut (2).
Tightening torques
CVT (front) to CVT input shaft
M22 x 1.5, secure with lock 100 Nm
washer
Turn shaft (3) to tighten nut (4).
Tightening torques
CVT output to CVT output shaft
washer

Bend up the tabs of locking washer (1).
If applicable, remove the cable tie (arrow) from drive belt (1).
F inishing work
Installing CVT sound-absorbing hood
Installing rear right footplate carrier
Closing seat


21 21 001 Checking clutch

+ 21 21 614
Preparatory work
Opening seat
Removing CVT cover
Core activity
CVT output

Slacken nut (2).


Nut (1)
Lock washer (2)
Spacer (3)


(-) Checking clutch
Check
Check clutch (1) and clutch bell (2) for wear.
Technical data
Minimum height, Projection min 2.5 mm
clutch lining past lining
backer
Result:
Clutch linings are worn or damaged, clutch bell shows scoring on
friction face.
Measure:
=> 21 21 511, Replacing clutch package (CVT output removed) (Billed
as a separate item)

adjuster unit.



Lubricant
Unirex N3 83 19 2 160 349

NOTICE
and free of grease.



output

Tighten nut (2).
Tightening torq ues

washer

Tightening torq ues

washer

F inishing work
Closing seat

21 21 511 Replacing clutch package (CVT output removed)
Core activity
(-) Removing clutch package
Insert clutch package (1) with CVT output in pretensioning tool (No. 24
0 512), making sure that CVT output (1) is secured so that it cannot
twist out of position.
Slacken nut (2) with socket (No. 24 0 513), securing the socket so that
it cannot slip.
Pretension clutch package (1) with pretensioning tool (No. 24 0 512) .

Remove nut (2).
Relieve the tension on pretensioning tool (No. 24 0 512) and remove
clutch package (1) with the CVT output.
Remove clutch package (1), spring sleeve (2) and spring (3).
(-) Installing clutch package
Place spring (3), spring sleeve (2) and clutch package (1) in position.

Insert clutch package (1) with CVT output into pretensioning tool (No.
24 0 512), noting the locator in the pretensioning tool.
Pretension clutch package (1) with pretensioning tool (No. 24 0 512)
and tighten nut (2) until hand-tight.
Relieve tension on pretensioning tool (No. 24 0 512).
Tighten nut (2) with socket wrench insert (No. 24 0 513).
Tightening torques
Clutch package to CVT output
M48 x 1 85 Nm
Remove clutch package (1) with CVT output from the pretensioning
tool.

21 21 600 Check clutch (clutch removed)
Core activity
(-) Checking clutch
Check
Technical data
backer
Result:
friction face.
Measure:
as a separate item)

24 11 001 Removing/installing CVT cover

+ 24 11 501
Preparatory work
Opening seat
Core activity
(-) Removing CVT sound-absorbing hood
Remove screws (1) and disengage sound-absorbing hood (2).
Disengage the cable (arrows) and remove the sound-absorbing hood.
(-) Removing CVT cover
Remove screws (1) and remove cover (2).

(-) Installing CVT cover
Install cover (2) and secure with screws (1).
Tightening torques
CVT cover to crankcase
M6 x 45 10 Nm
(-) Installing CVT sound-absorbing hood
Secure CVT sound-absorbing hood (2) with screws (1).
Tightening torques
Sound-absorbing hood to CVT cover
M6 x 18 10 Nm
Secure the cable (arrows).

Finishing work
Closing seat

24 11 002 Removing/installing or sealing secondary gearbox cover

+ 24 11 502
Preparatory work
Opening seat
Draining engine oil from oil tank
Removing silencer
Removing rear wheel


Disengaging side stand complete with pivot mount and switch
Releasing right centre-stand mount
Releasing exhaust manifold
Draining gearbox oil
Core activity
(-) Removing secondary gearbox cover
Remove screws (1) and remove oil-level sensor (2).

Heat the bearing seat.
Technical data
Release/mating 80 °C
temperature

NOTICE
(-) Removing rotary shaft seal

Using a suitable tool, remove sealing ring (1).
(-) Installing secondary gearbox cover

Thinly apply sealing compound to the sealing face, paying particular
attention to the partition (arrow).
Sealant
Dow Corning 07 58 0 397 777
Technical data
temperature
Tightening torques
Gearbox cover to crankcase
M6 x 25 tighten in
diagonally
opposite
sequence
10 Nm
Lightly lubricate only the sealing lip of shaft sealing ring (1) with gear
NOTICE
Using a suitable tool, install sealing ring (1) flat.

Replace O-ring (1).

Insert oil-level sensor (2) and install screws (3).
Tightening torques
Oil-level sensor to gearbox cover
M5 x 16 5 Nm
Connect hose (4).
(-) Removing shaft sealing ring in output shaft
Remove shaft sealing ring (1).

Note bushing (2); the tapered end (arrow) must face toward the
inside.
Install new shaft sealing ring (1) with the open side facing out until
seated
(-) Replacing shaft sealing ring and felt ring for pinion cover
Replace shaft sealing ring (1) and felt ring (2), when installing use
sliding sleeve (No. 33 6 786).
Install shaft sealing ring (1) with the open side toward the swinging
arm.

(-) Replacing shaft sealing ring in swinging-arm cover
Use a suitable tool to remove shaft sealing ring (1).

Drive in a new shaft sealing ring (1), with the open side toward the
chain, until seated.
(-) Replacing shaft sealing ring in swinging arm
Remove shaft sealing ring (1) with a suitable tool, using circlip (2) as a
tool rest; do not under any circumstances apply the tool to bearing (3).
Finishing work
Pouring engine oil into oil tank
Fill the gearbox with oil to correct level
Securing exhaust header
Securing right centre-stand mount
Securing side stand complete with pivot mount and switch
Installing pinion and chain

Installing left frame side section

Installing chain tensioner rail
Installing bottom chain channel
Installing top chain channel
Installing silencer
Securing radiator
Closing seat

24 11 003 Replacing CVT sound-absorbing hood

+ 24 11 503
Preparatory work
Opening seat
Core activity

Tightening torques
M6 x 18 10 Nm
Finishing work
Closing seat

24 11 004 Replacing rear CVT dust filter

+ 24 11 504
Preparatory work
Opening seat
Core activity
(-) Removing CVT dust filter
Remove intake air pipe (1).

Remove filter (2).
(-) Installing CVT dust filter
Install filter (1).

Install intake air pipe (2); if applicable align the marks (arrow).
Finishing work


Closing seat

24 11 006 Replacing front CVT dust filter

+ 24 11 506
NOTICE
Clean the area with compressed air prior to removal of the CVT dust
filter.
Preparatory work
Opening seat
Core activity
(-) Removing CVT dust filter
Clear area above filter (1) with compressed air.

Push the lever (arrow) down and remove filter (1).
(-) Installing CVT dust filter
Install filter (1), making sure that the lever (arrow) engages.

Finishing work
Closing seat

24 21 004 Sealing gearbox output shaft

+ 24 21 504
Preparatory work
Opening seat
Draining engine oil from oil tank
Removing silencer
Removing rear wheel


Disengaging side stand complete with pivot mount and switch
Releasing right centre-stand mount
Releasing exhaust manifold
Draining gearbox oil
Core activity
(-) Removing secondary gearbox cover
Remove screws (1) and remove oil-level sensor (2).

Technical data
temperature

NOTICE
(-) Removing rotary shaft seal

(-) Disassemble the gearbox output shaft
Remove circlip (1).

Position a suitable support, e.g. drift (No. 11 0 541) on gearbox output
shaft (2).
Remove spacing sleeve (3), O-ring (4) and bearing (5) with puller (No.
33 1 830).
(-) Assembling gearbox output shaft
ATTENTION
Installation not in compliance with correct procedure.
Damage to roller bearings.
When installing, apply pressure to the bearing inner race only.
Using a suitable tool, press new bearing (1) on to gearbox output shaft
(2).
Install new O-ring (3) (sits on bearing (1)).
Using a suitable tool, press on new spacing sleeve (4), shoulder
(arrow) is toward bearing (1).
Install new circlip (5) in bottom groove.
(-) Installing gearbox output shaft
Install gearbox output shaft (1), making sure the teeth engage (arrow).

Install circlip (1).

Install shaft sealing ring (2) with a suitable tool, for example socket
wrench insert (No. 36 3 681).
(-) Installing secondary gearbox cover

Thinly apply sealing compound to the sealing face, paying particular
attention to the partition (arrow).
Sealant
Dow Corning 07 58 0 397 777
Technical data
temperature
Tightening torques
Gearbox cover to crankcase
M6 x 25 tighten in

diagonally
opposite
sequence
10 Nm
Lightly lubricate only the sealing lip of shaft sealing ring (1) with gear
NOTICE
Using a suitable tool, install sealing ring (1) flat.
Replace O-ring (1).

Insert oil-level sensor (2) and install screws (3).
Tightening torques
Oil-level sensor to gearbox cover
M5 x 16 5 Nm
Connect hose (4).

inside.
seated


F inishing work
Pouring engine oil into oil tank
F ill the gearbox with oil to correct level
Securing exhaust header
Securing right centre-stand mount
Securing side stand complete with pivot mount and switch
Installing pinion and chain
Installing left frame side section


Installing silencer
Securing radiator
Closing seat

24 21 500 Sealing CVT output shaft (CVT removed)
Core activity
(-) Removing radial shaft seal of CVT output shaft
Drill into radial shaft seal (1), using drill stop (No. 00 8 586).
Remove radial shaft seal (1) with pull rod (No. 00 8 581), impact
weight (No. 00 8 582) and adapter, tapping screw (No. 00 8 587).
Carefully remove all metal particles.
(-) Installing shaft sealing ring of CVT output shaft

NOTICE
Lightly lubricate only the sealing lip of radial shaft seal (1) with gear oil,
all other surfaces must be dry and free of grease on installation.
Insert sliding sleeve (No. 11 0 882) and radial shaft seal (1).
Remove the tools.

24 21 501 Replacing CVT output shaft (CVT removed)
Core activity
(-) Removing CVT output shaft with bearings
Drill into shaft sealing ring (1), using drill stop (No. 00 8 586).
Remove shaft sealing ring (1) with pull rod (No. 00 8 581), impact
Remove circlip (2).
Remove CVT output shaft with bearing (3).
Use a cloth to cover the opening underneath circlip (1).

Remove circlip (1).
Heat seat of bearing (2).
Technical data
temperature
Remove bearing (2) with internal puller (No. 00 8 563), threaded

adapter (No. 13 5 252) and adapter (No. 13 5 256).
(-) Install the CVT output shaft with bearings
Heat seat of bearing (1).
Technical data
temperature
Install bearing (1) with drift (No. 23 4 660) and handle (No. 00 5 500).
Remove the cloth from the opening underneath circlip (2).
Install CVT output shaft (1) with bearing, making sure that teeth
engagement is correct.


NOTICE
Lightly lubricate only the sealing lip of radial shaft seal (1) with gear oil,
all other surfaces must be dry and free of grease on installation.
Remove the tools.

24 21 502 Sealing CVT input shaft (CVT (removed)
Preparatory work
Removing air guide plate
Core activity
(-) Removing radial shaft seal of CVT input shaft
Drill into radial shaft seal (1), using drill stop (No. 00 8 586).
Remove radial shaft seal (1) with pull rod (No. 00 8 581), impact
Carefully remove all metal particles.
(-) Installing shaft sealing ring of CVT input shaft

NOTICE
Remove the tools.
Finishing work
Installing air guide plate

24 21 503 Replacing CVT input shaft (CVT (removed)
Preparatory work
Opening seat
Core activity

sensor.
Remove screws (2).
WARNING
Malfunctions
(-) Removing oil line to CVT input shaft


Screws (1) and (2)
Oil line (3)
Sealing ring (4)
(-) Removing CVT drive shaft
Remove nut (1) and washer (3).

Secure nut (1) and turn the hexagon of CVT input shaft (2) clockwise.
Work CVT input shaft (3) to the right to remove (light taps with a
rubber-headed mallet).
Remove sealing ring (1).
(-) Replacing CVT input shaft
Press bearing (1) on to CVT input shaft (2).

Install circlip (3) and bearing (4).
Lubricate bearing (4) with engine oil.

(-) Removing bearing for CVT input shaft (magnetic-gear end)
Remove circlip (1).

Secure internal puller (No. 00 8 573) to threaded adapter (No. 13 5
256).
Secure threaded adapter (No. 13 5 256) to pull rod (No. 13 5 251) and
impact weight (No. 13 5 253).
Remove bearing (2) with internal puller (No. 00 8 573).
(-) Installing bearing for CVT input shaft (magnetic-gear end)
ATTENTION
Installation not in compliance with correct procedure.
Damage to roller bearings.
When installing, apply pressure to the bearing outer race only.
Install new bearing (1) with drift (No. 00 1 692) and handle (No. 00 5
500).
(-) Installing CVT input shaft
Install drive shaft (1), noting judder damper (2).

Clean the threads.
Install washer (3).
ATTENTION
Shelf life of micro-encapsulated screws overshot.
Insufficient securing effect.

Use additional thread locking.
Install nut (4), counter-holding at hexagon of drive shaft (1).
Tightening torques
CVT input shaft to crankcase
M20 x 1.5 150 Nm
encapsulated)

NOTICE
Insert sliding sleeve (No. 11 0 881) and new radial shaft seal (1).
Remove the tools.
(-) Installing oil line to CVT input shaft
Insert oil line (3) with new sealing ring (4).

Tightening torques
Oil line (CVT input shaft) to engine
M6 x 16 10 Nm
M6 x 40 10 Nm

NOTICE

Sealant
Dow Corning 07 58 0 397 777
Tightening torques
M6 x 25 tighten in
diagonally
opposite
sequence
10 Nm
(arrow).
Tightening torques
M6 x 18 10 Nm
Finishing work
Closing seat

24 80 000 Removing/installing or replacing CVT

+ 24 80 500
Preparatory work
Opening seat
Removing CVT cover
Core activity
CVT output

Slacken nut (2).


Nut (1)
Lock washer (2)
Spacer (3)
(-) Removing CVT output with drive belt


(-) Removing clutch bell and CVT thrust plate

Clutch bell (1)
CVT thrust plate (2)
Sleeve (3)
(-) Installing clutch bell and CVT thrust plate

Sleeve (3)
CVT thrust plate (2)
Clutch bell (1)

adjuster unit.



Lubricant
Unirex N3 83 19 2 160 349

NOTICE
and free of grease.



output

Tighten nut (2).
Tightening torq ues

washer

Tightening torq ues

washer

F inishing work
Closing seat

24 81 501 Disassembling/assembling CVT output (CVT removed)
Preparatory work
Removing clutch package
Core activity
(-) Disassembling CVT output
Heat shouldered bushing (1).
Technical data
temperature
Pry shouldered bushing (1) off left variator plate (2) and remove.
Remove guide pins (1) and guide rollers (2).

Remove left variator plate (3) from right variator plate (4).
Clean variator plate (4), remove all traces of lubricant.
Remove O-rings (1).

Remove sealing rings (2).
Remove spacing sleeve (1).


Remove circlip (1).

Drive out bearing (2) with drift (No. 36 5 541).
Engage socket (No. 36 3 681) over needle bearing (1).

Remove needle bearing (1) with short spindle with pull-in nut (No. 36 5
552), washer without thread (No. 36 5 554) and washers with thread
(No. 36 5 553).
Washer without thread, dia. 62 mm
Washer with thread, dia. 35 mm
Needle bearing (1) is drawn into socket.
Remove the tools.
(-) Assembling CVT output
Clean the bearing seats.

Engage nut (1), allowing it to project slightly in order to protect the
threads.
Install bearing (2) with short spindle with pull-in nut (No. 36 5 552),
washer without thread (No. 36 5 554) and washers with thread (No. 36
5 553):
Washer dia. 42 mm
Pull in bearing (2) until seated; alternatively note installed depth.

Technical data
Installation depth of 7 mm
the needle roller
bearing in the
variator plate
Remove tools and nut (1).

Pack bearing (2) with lubricant.
Lubricant
Acid-free friction-bearing grease 81 22 9 407 174
Install bearing (1) with short spindle with pull-in nut (No. 36 5 552),
washer without thread (No. 36 5 554) and washers with thread (No. 36
5 553):
Washer without thread, dia. 55 mm
Pull in bearing (1) until seated.
Remove the tools.
Install circlip (1) in the groove (arrow).
Pack the spaces (arrows) with lubricant (grease gun).
Lubricant
Unirex N3 83 19 2 160 349

Pack sealing lips of sealing ring (1) with lubricant.
Lubricant
Unirex N3 83 19 2 160 349
Using a suitable tool install sealing ring (1) open side in until seated
on needle roller bearing (2); sealing ring (1) must be flush with the
chamfer (arrow).
Install spacing sleeve (3).
Install new O-rings (1).

Lubricate new sealing rings (2) with engine oil.
Install new sealing rings (2) with the open side facing in.
Position left variator plate (1) on right variator plate (2).

Lubricate the guide grooves and lube bores (arrows), repeatedly
turning the variator plates to spread the lubricant.
Lubricant
Unirex N3 83 19 2 160 349
Lubricate guide rollers (3) and guide pins (4).
Lubricant
Unirex N3 83 19 2 160 349
Align guide grooves and lube bores (arrows) and install guide rollers
(3) with guide pins (4).
Heat shouldered bushing (1).
Technical data
temperature
Push shouldered bushing (1) on to left variator plate (2) until seated.

Carefully remove all traces of lubricate from the outside of the CVT
output.
NOTICE
and free of grease.
Finishing work
Installing clutch package

24 82 000 Replacing CVT belt

+ 24 82 500
Preparatory work
Opening seat
Core activity
(-) Removing CVT cover


CVT output

Slacken nut (2).

Nut (1)
Lock washer (2)
Spacer (3)



(-) Checking clutch
Check
Technical data
backer
Result:
friction face.
Measure:
as a separate item)
(-) Replacing CVT belt
When installing belt (1), make sure that the direction of rotation (arrow)
is correct: arrows point in direction of rotation.

adjuster unit.



L ubricant
Unirex N3 83 19 2 160 349

N O TICE
and free of grease.



output

Tighten nut (2).
Tightening torq ues

washer

Tightening torq ues

washer

(-) Installing CVT cover
Tightening torq ues

CVT cover to crankcase
M6 x 45 10 Nm
Tightening torq ues

M6 x 18 10 Nm

F inishing work
Closing seat

31 42 011 Checking steering-head bearing

+ 31 42 511
Core activity
(-) Checking steering-head bearing
ATTENTION
Vehicle can topple sideways.
Risk of damage to parts if vehicle topples.
Make sure that the vehicle is secured so that it cannot topple
sideways.
Raise the Maxi-Scooter with a suitable lifter to take the weight off the
front wheel.
Check
Take a grip of slider tubes (1) and pull the forks back and forth.
Result:
Steering-head bearing evinces play.
Measure:
=> 31 42 514, Adjusting steering-head bearing (with checking steering-
head bearing) (Billed as a separate item)
Check
Turn the handlebars to full left and right lock.

NOTICE
The steering must move smoothly from lock to lock. There should be no
perceptible catching and no notching at the straight-ahead position.
The steering-head bearing must be free of play.
Result:
Dirt or old, solidified grease makes the handlebars stiff, or there is a
perceptible notching effect when the handlebars reach the straight-
ahead position.
Measure:
=> 31 42 879, Replacing both steering-head bearings (Billed as a
separate item)
Finishing work

31 42 028 Replace upper fork bridge

+ 31 42 528
Preparatory work
Securing forks of Maxi-Scooter
Removing handlebars
Core activity
(-) Removing top fork bridge
Loosen screws (1) and (2).

Remove adjusting screw (3) with washer (4).
Remove fork bridge (1).

Washer (2)
Bearing shell (3)
Bearing race (4)
(-) Installing top fork bridge
Clean and lubricate bearing shell (3) and bearing ring (4).
Lubricant

Bearing race (4)

Bearing shell (3)
Washer (2)
Fork bridge (1)
Install washer (1) and adjusting screw (2) and tighten until hand-
tight.
Finishing work
Releasing fork locator
Securing handlebars
Adjusting steering-head bearing play

31 42 029 Replace lower fork bridge

+ 31 42 527
WARNING
Premature reaching of tightening torque due to traces of thread-
locking compound.
Risk of crash due to loose fork clamps.
Check the fork-leg clamps for residual traces of old thread-locking
compound as specified.
Preparatory work
Disengaging intake air pipe
Removing both brake calipers
Releasing front wheel-speed sensor
Removing front-wheel cover
Removing front wheel
Disengaging brake line
Removing left fork leg
Removing right fork leg
Checking threaded fasteners of bottom fork-leg clamps for traces
of thread-locking compound
Removing handlebars
Core activity
(-) Removing top and bottom fork bridges
Slacken screw (1).

Remove adjusting screw (2), noting washer (3)
Remove top fork bridge (4) and bottom fork bridge (5).
(-) Removing top steering-head bearing

Dust cap (1)

Inner race (2)
Bearing race (3)
Remove bearing outer race (1) with reaction support (No. 00 8 562),
internal puller 37-46mm (No. 00 8 561) and protective ring (No. 31 6
500).
(-) Installing top steering-head bearing (bearing outer race) in

frame
Install new bearing outer race (1) until seated, using spindle long (No.
36 5 551), disc 55 mm with thread (No. 36 5 553) and disc 55 mm (No.
36 5 554).
Remove the tools.
(-) Removing bottom steering-head bearing
internal puller 37-46mm (No. 00 8 561) and support ring (No. 31 6
500).

(-) Installing bottom steering-head bearing (inner race)
Install new bearing outer race until seated, using spindle (No. 36 5
551), discs 55 mm and 42 mm with thread (No. 36 5 553) and disc 55
mm without thread (No. 36 5 554).
Remove the tools.
Heat inner race (1).
Technical data
temperature
Install inner ring (1) until seated.

Allow inner ring (1) to cool down and install dust cap (2).
Lubricate new bearing race (1) and install.
Lubricant

(-) Installing top and bottom fork bridges
Lubricate new bearing shell (2) and bearing ring (3).
Lubricant

Bearing race (3)
Bearing shell (2)
Washer (1)
Place bottom fork bridge (1) and top fork bridge (2) in position.
Lay washer (3) in position and install adjusting screw (4) and tighten
until hand-tight.
Finishing work
Securing handlebars
Securing brake line to bottom fork bridge
Installing left fork leg
Install the right fork leg
Installing front wheel
Securing both brake calipers
Securing front wheel-speed sensor
Installing front-wheel cover


Securing intake air pipe

31 42 321 Replacing both steering-head bearings

+ 31 42 879
Preparatory work
Removing handlebars
Removing forks with bottom fork bridge
Core activity
(-) Removing fork bridge and top steering-head bearing

Fork bridge (1)
Dust cap (2)
Inner race (3)
Bearing race (4)
internal puller 37-46mm (No. 00 8 561) and protective ring (No. 31 6
500).

internal puller 37-46mm (No. 00 8 561) and support ring (No. 31 6
500).
Remove bearing ring (1).
Remove dust cap (1).
Lubricate the threads of puller (No. 31 3 701).
Lubricant
Optimoly TA 18 21 9 062 599
Insert adapter dia. 35 - 40 mm (C) into nut (B) (No. 31 3 701) and
press on to inner bearing race (1).

Place puller (A) (No. 31 3 701) in position and screw it into nut (B).
Tighten puller (A) and nut (B) with ring spanners (D).
Remove inner bearing race (1) with puller (No. 31 3 701).
Technical data
temperature
Install inner ring (1) until seated.

Allow inner ring (1) to cool down and install dust cap (2).

Lubricate new bearing race (1) and install.
Lubricant
(-) Installing top steering-head bearing (bearing outer race) in

frame
Install new bearing outer race (1) until seated, using spindle long (No.
36 5 551), disc 55 mm with thread (No. 36 5 553) and disc 55 mm (No.
36 5 554).
Remove the tools.
Install new bearing outer race until seated, using spindle (No. 36 5
551), discs 55 mm and 42 mm with thread (No. 36 5 553) and disc 55
mm without thread (No. 36 5 554).
Remove the tools.
Finishing work
Installing forks with steering-head bearing and top fork bridge
Securing handlebars



31 42 341 Removing/installing left fork leg

+ 31 42 841
WARNING
locking compound.
Preparatory work
Core activity
(-) Removing left fork leg
Remove cable ties (1) and remove steering stop (2).
Slacken screws (1) and (2).

Carefully work fork leg (3) down, easing the clamps apart in the
process if necessary.
(-) Checking threaded fasteners of bottom fork-leg clamps for

traces of thread-locking compound
Check

Examine loosened screws (1) of bottom fork bridge (2) for traces of
thread-locking compound (arrows).
Result:
Traces of thread-locking compound are present on the fork-leg
clamping screws.
Measure:
Remove screws (1).

Thoroughly clean the threads of screws (1) and the tapped bores in
fork bridge (2).
(-) Installing left fork leg
Insert fork leg (1), noting projection (A).
Technical data
Projection of fixed from fork 10 mm
fork tube in top fork bridge to top
bridge edge of
sealing cap
Turn fork leg (3) to correct alignment, with label facing out.
Tighten screws (2) and (1).
Tightening torques
Fork leg to top fork bridge
M8 x 25 19 Nm
Fork leg to bottom fork bridge
M8 x 25 Tighten screws
six times in
alternate
sequence
19 Nm

Secure steering stop (1) with cable tie (2), do not tighten.
The latches (arrows) of cable ties (2) must be on the outside.
Slide steering stop (1) all the way down.
Align the gap of steering stop (1) with screw heads (3).
Alternately tighten cable ties (2) until they touch the edges of steering
stop (1) and there is no longer a visible gap.
Turn the handlebars all the way to the right and make sure that brake
line (1) cannot come into contact with cable tie (2), there must be a
visible gap.
If necessary, remove steering stop (3) and reposition correctly.
Turn the handlebars all the way to the left and check operation of the
steering lock.
Finishing work

31 42 342 Removing/installing right fork leg

+ 31 42 842
WARNING
locking compound.
Preparatory work
Core activity
(-) Disengaging intake air pipe
Carefully disengage the lug (arrow) of intake air pipe (1) from locator
(2).
(-) Removing right fork leg
Remove cable ties (1) and remove steering stop (2).
Slacken screws (1) and (2).

Carefully work fork leg (3) down, easing the clamps apart in the
process if necessary.

(-) Checking threaded fasteners of bottom fork-leg clamps for

traces of thread-locking compound
Check
Examine loosened screws (1) of bottom fork bridge (2) for traces of
thread-locking compound (arrows).
Result:
Traces of thread-locking compound are present on the fork-leg

clamping screws.
Measure:
Remove screws (1).

Thoroughly clean the threads of screws (1) and the tapped bores in
fork bridge (2).
(-) Install the right fork leg
Insert fork leg (1), noting projection (A).
Technical data
Projection of fixed from fork 10 mm
fork tube in top fork bridge to top
bridge edge of
sealing cap
Turn fork leg (3) to correct alignment, with label facing out.

Tightening torques
M8 x 25 19 Nm
Fork leg to bottom fork bridge
M8 x 25 Tighten screws
six times in
alternate
sequence
19 Nm
Secure steering stop (1) with cable tie (2), do not tighten.
The latches (arrows) of cable ties (2) must be on the outside.
Slide steering stop (1) all the way down.
Align the gap of steering stop (1) with screw heads (3).
Alternately tighten cable ties (2) until the gap is very narrow.
Alternately tighten cable ties (2) until they touch the edges of steering
stop (1) and there is no longer a visible gap.
(-) Securing intake air pipe
Engage the lug (arrow) of intake air pipe (1) in locator (2).
Finishing work

31 42 514 Adjusting steering-head bearing (with checking steering-head bearing)
Preparatory work
Core activity
(-) Adjusting steering-head bearing play
Lower the Maxi-Scooter until the forks are supported:

Front wheel contacts the ground
Forks are not yet compressed
Slacken clamping screws (1) and (2).
Use an electronic torque wrench/angle-of-rotation tightening tool when

adjusting steering-head play.
Workshop equipment
Electronic torque wrench/angle-of-rotation tightening tool
Using an electronic torque wrench / angle-of-rotation tightening tool,
initially tighten and then slacken steering-head screw (1), then
retighten it to specification.
Tightening torques
Adjusting screw (steering-head adjustment) to fork bridge
M18 x 1 Tightening torque,
30 Nm
Swing the forks 3x
to left/right through
full arc of travel
Loosen, 60°
Tightening torque
(forks turned fully to
right), 20 Nm
Tighten clamping screws (1) and (2).

Tightening torques
M8 x 25 19 Nm
Fork bridge, top, to adjusting screw (steering-head adjustment)
M8 x 35 19 Nm
Complete the process by rechecking the setting.
Finishing work

31 42 516 Disassembling and assembling left fork fork leg (fork leg removed)
Core activity
(-) Disassembling left fork leg
Firmly and repeatedly compress the fork leg to free any dirt that may
be inside.
Clamp the fork bottom in a vice with protective jaws.

Slacken sealing cap (1).
Move locknut (2) on rod (3) all the way down, counter-hold in this way.
Remove sealing cap (1).
Remove slider tube (1) from fixed fork tube (2).
Remove sealing boot (1) and circlip (2).

Pad the edge (arrow) to prevent damage.
Remove sealing ring (3) with a suitable tool, such as a tyre lever.
Remove washer (4).
(-) Removing slide bushes from slider tube
Remove slide bushes (1) and tube (2) with a suitable tool.

(-) Installing slide bushes in slider tube
Install slide bushes (1) and tube (2) with a suitable tool.
(-) Assembling left fork leg
Install washer (1).

Install shaft sealing ring (2) (lettering up) with sleeve (No. 31 1 511).
Install circlip (3) in the bottom groove (arrow).
Pack the grease chamber of sealing boot (1) with grease.
Lubricant
Unirex N3 83 19 2 160 349
Slip sealing boot (1) on to fixed fork tube (2).

Lubricate fixed fork tube (1) with Fork oil and insert into slider tube (2).
Install boot (3).
Pouring oil into left fork leg
Pour in the correct quantity of oil.
Technical data
Fork oil, capacity 390 ml
per fork leg
Compress and extend the piston rod a few times to make sure that the
damper is completely filled.
Move locknut (2) on rod (3) all the way down, install cover (4).
Secure cover (4) with locknut (2).
Tightening torques
Locknut to cover
M8 15 Nm
Tighten cap (4).
Tightening torques
Cap to slider tube
20 Nm


31 42 517 Disassembling and assembling right fork fork leg (fork leg removed)
Core activity
(-) Disassembling right fork leg
Secure mount (No. 31 3 715) and extensions (No. 31 3 717) on

pretensioning tool (No. 31 3 712).
Insert adapter (No. 31 3 716) into extensions (No. 31 3 717).
Firmly and repeatedly compress the fork leg to free any dirt that may
be inside.
Disengage fixed fork tube (1) and press sleeve (2) down.
Insert the fork leg into mount (No. 31 3 715) and adapter (No. 31 3
716) (between sleeve (2) and fork cap (4)).
Secure fork leg (1) in pretensioning tool (No. 31 3 712) with rubber
retainer (A).
Operate hold-down tool (B) of pretensioning tool (No. 31 3 712) until

locknut (1) is accessible.
Locate locknut (1) with an open-ended spanner and remove fork cap
(2).
Relieve hold-down tool (B).
Disengage rubber retainer (A) and remove fork leg (1) from
pretensioning tool (No. 31 3 712).

Remove sleeve (1) and spring (2).

Remove slider tube (1) from fixed fork tube (2).
Remove sealing boot (1) and circlip (2).

Pad the edge (arrow) to prevent damage.
Remove sealing ring (3) with a suitable tool, such as a tyre lever.
Remove washer (4).
(-) Removing slide bushes from slider tube

Remove slide bushes (1) and tube (2) with a suitable tool.
(-) Installing slide bushes in slider tube
Install slide bushes (1) and tube (2) with a suitable tool.
(-) Assembling right fork leg
Install washer (1).

Install shaft sealing ring (2) (lettering up) with sleeve (No. 31 1 511).
Install circlip (3) in the bottom groove (arrow).
Lubricate parts with fork oil.
Telescopic fork oil

Telescopic fork oil SAE 7.5 83 19 2 182 459
Pack the grease chamber of sealing boot (1) with grease.
Lubricant
Unirex N3 83 19 2 160 349
Slip sealing boot (1) on to slider tube (2).

Lubricate slider tube (1) with fork oil and install it in fixed fork tube (2).
Install boot (3).
Pouring oil into right fork leg
Pour in the correct quantity of oil.
Technical data
Fork oil, capacity 390 ml
per fork leg
Compress and extend the piston rod a few times to make sure that the
damper is completely filled.
Allow the oil to settle for a few minutes.
Push fixed fork tube all the way in.
Use dipstick (No. 31 6 551) to correct the fluid level.
Technical data
Fork oil level, right right fork leg 130 mm
(air cushion) fully
compressed,
compression
spring and
spacer
removed
Install spring (2) and sleeve (1).

Seat fork leg (1) in mount (No. 31 3 715).

Secure fork leg (1) with rubber retainer (A) in pretensioning tool (No.
31 3 712).
Operate hold-down tool (B) of pretensioning tool (No. 31 3 712) until

locknut (1) is accessible.
Screw fork cap (2) on all the way.
Locate locknut (1) with an open-ended spanner and tighten fork cap
(2).
Tightening torques
Locknut to cover
M8 15 Nm
Relieve hold-down tool (B).
Remove fork leg (3) from adapter (No. 31 3 716), mount (No. 31 3 715)
and pretensioning tool (No. 31 3 712).

Sleeve (2) is seated against fork cap (4)

Screw fixed fork tube (1) and fork cap (4) together until hand-tight.
Fork cap can be tightened only with the fork leg installed. Comply with
specified tightening torque.

32 72 001 Replacing throttle twistgrip

+ 32 72 620
Preparatory work
Removing right handlebar weight
Removing right multifunction switch
Core activity
(-) Removing throttle twistgrip
Remove screw (1) and remove cover (2).

Slacken adjusting screws (3) and set play to maximum.
Disengage throttle-closer cable (1).

Disengage throttle-opener cable (2).
Remove screw (3).
Disengage throttle-cable guide (4) and remove throttle twistgrip (5).
(-) Installing throttle twistgrip
Install throttle twistgrip (5).

Install screw (3).
Tightening torques
Handlebar grip to handlebar
M3.5 x 30 1 Nm
Hold throttle-cable guide (4) in position.

Engage throttle-opener cable (2) and throttle-closer cable (1).
Secure cover (2) with screw (1).

Finishing work
Installing right multifunction switch
Installing right handlebar weight
Adjusting throttle-cable play.

32 72 075 Replacing lever for rear-wheel brake

+ 32 72 575
Core activity
(-) Removing handbrake lever
Remove nut (1) and screw (2).

Remove handbrake lever (3).
(-) Installing handbrake lever
Lubricate the bearing seats.
Lubricant
Teflon spray 83 23 0 154 884
Insert handbrake lever (3).

Install bolt (2) with nut (1).
Tightening torques
Brake lever to handlebar fitting
M6 tighten the screw
first, then the nut
6 Nm
Finishing work

32 72 076 Replacing lever for front-wheel brake

+ 32 72 576
Core activity
(-) Removing handbrake lever
Remove nut (1) and screw (2).

Remove handbrake lever (3).
(-) Installing handbrake lever
Lubricate the bearing seats.
Lubricant
Teflon spray 83 23 0 154 884
Insert handbrake lever (3).

Install bolt (2) with nut (1).
Tightening torques
Brake lever to handlebar fitting
M6 tighten the screw
first, then the nut
6 Nm
Finishing work

32 72 077 Replacing brake handlebar fitting for rear wheel

+ 32 72 577
Preparatory work
Draining brake-fluid reservoir for rear brake
Core activity
(-) Removing handbrake lever fitting for rear wheel
Disconnect plug (1) for the brake-light switch.

Remove banjo bolt (2) and sealing rings (3).
Disengage brake line (4).
ATTENTION
Brake fluid on painted surfaces, plastic and rubber components.
Material damage
Do not allow brake fluid to come into contact with painted surfaces,
plastic or rubber components.
Remove screws (5), remove clamp (6) and handbrake lever fitting (7).
(-) Install the handbrake lever fitting for rear wheel
Hold handbrake lever fitting (1) with camp (2) in position, noting the
marks (arrows).
Gap aligned with mark on handlebar, arrow on clamping block up.
Install screws (3).
Tighten screws (3), alternating repeatedly, until both screws are
tightened to the specified tightening torque.
Tightening torques
Handlebar fitting to handlebar
M5 x 22 tighten top until
fully closed
10 Nm
Secure brake line (4) with banjo bolt (5) and new sealing rings (6).
Tightening torques
Brake hose with banjo bolt to components
M10 x 1 24 Nm
Connect plug (7) for the brake-light switch.
Finishing work

Filling and bleeding rear brake-fluid reservoir


32 72 078 Replacing brake handlebar fitting for front wheel

+ 32 72 578
Preparatory work
Draining brake-fluid reservoir for front brake
Core activity
(-) Removing handbrake lever fitting for front wheel
Disconnect plug (1) for the brake-light switch.

ATTENTION
Material damage
Remove banjo bolt (2) and sealing rings (3).

Disengage brake line (4).
ATTENTION
Material damage
Remove screws (5), remove clamp (6) and handbrake lever fitting (7).
(-) Installing handbrake lever fitting for front wheel
Hold handbrake lever fitting (1) with camp (2) in position, noting the
marks (arrows).
Gap aligned with mark on handlebar, arrow on clamping block up.
Install screws (3).
Tighten screws (3), alternating repeatedly, until both screws are
tightened to the specified tightening torque.
Tightening torques
Handlebar fitting to handlebar
M5 x 22 tighten top until
fully closed
10 Nm
Secure brake line (4) with banjo bolt (5) and new sealing rings (6).

Tightening torques
M10 x 1 24 Nm
Connect plug (7) for the brake-light switch.
Finishing work
Filling and bleeding front brake-fluid reservoir

32 72 097 Replacing left handlebar grip

+ 32 72 632
ATTENTION
Opening of switch unit.
Damage to the conductors coated with protective sealing lacquer.
Do not separate the top and bottom parts of the switch unit.
Preparatory work
Removing handlebar weight
Removing left handlebar grip with multifunction switch
Core activity
(-) Removing multifunction switch from left handlebar grip
Carefully push up retainer (1).

Remove multifunction switch (2) from the handlebar grip.
(-) Installing multifunction switch on left handlebar grip
Push multifunction switch (1) on to the handlebar grip.

Retainer (2) engages.

Finishing work
Installing left handlebar grip with multifunction switch
Installing handlebar weight

33 35 000 Replacing rear wheel swinging arm

+ 33 35 501
Preparatory work
Opening seat
Removing silencer
Remove the chain slide rail
Removing rear wheel
Core activity
(-) Removing rear wheel swinging arm

Slacken screw (2), but do not remove it.
Remove threaded sleeve (3).
Remove inner bearing race (4).


Slacken screws (2), but do not remove.
Remove swinging-arm shaft (3) and inner bearing race (4).
Support the swinging arm and remove screws (1).
Remove swinging arm (1), remove spacer (2).
(-) Removing left frame side section


Remove nuts (3).
Remove left frame side section (4).
(-) Removing pinion cover
Remove screws (1).

Work rear pinion cover (2) to the rear over the chain.
Remove front pinion cover (3).

(-) Preparing rear wheel swinging arm and output shaft for
installation
Insert spacer (1).

Heat bearing seat of bearing (2).
Technical data
temperature

Press in new bearing (2) until seated in new part, using a suitable tool
that applies pressure only to the outer bearing race.
Install new circlip (3) in the groove (arrow).
Insert thrust piece (No. 36 5 514) into output shaft (1).

Technical data
temperature
Remove inner ring (2) with puller/separator (No. 00 7 500).

Remove spacing sleeve (3).
Check grooved ball bearing (4) for damage and year; replace if
necessary and remove with puller/separator (No. 00 7 500).
Technical data
temperature
If necessary, carefully heat grooved ball bearing (1).
Technical data
temperature
If applicable, press grooved ball bearing (1) on to output shaft (2) until
seated, using a suitable tool.
Place spacing sleeve (3) in position.
Technical data
temperature
Press inner ring (4) on to output shaft (2) until seated, using a suitable
tool.
Allow the components to cool down.
(-) Installing pinion cover

Install new sealing ring (1) in front pinion cover (2) (open side toward
the inside).
Clean the sealing face and seal, taking particular care at the corners
(arrows).
NOTICE
When using fluids and lubricants, always comply with specifications such
as flash time or drying time.
See the data sheets/product information publications for more details.
Sealant
Dow Corning 07 58 0 397 777

Install new square-section sealing ring (1) on rear pinion cover (2).
Install front pinion cover (3).

Work rear pinion cover (2) over the chain.
Install screws (1), noting the tightening sequence.
Tightening torques
Pinion cover, front section to rear section
M5 x 16 Tightening
sequence: 1st: top
(from front), 2nd
bottom (from
behind)
4.5 Nm
Seal the sealing face (arrow) against the swinging arm.
Sealant
Dow Corning 07 58 0 397 777
(-) Installing left frame side section
Remove sealing washer (1).

Remove circlip (1) and support ring (2).

If applicable, install fitted bushing (1).
Make sure that screws (1) and (2) are fully seated.
Insert adjusting tools (B) and (C) (No. 33 6 784) into the removed left
frame side section (1) and preload.

Insert adjusting tool (D) (No. 33 6 782) into the removed left frame
side section (1).
Insert adjusting tool (A) (No. 33 6 785) into gearbox shaft (1) and
preload.
Hold left frame side section (2) in position with tools (B), (C) and (D)
installed.
Insert adjusting tools (E ) and (F ) (No. 33 6 783) into right frame side
section (1) and preload.
Insert shaft (D) until seated.
Insert screws (1) into centre stand (2).

Install screws (5).
Secure right frame side section (6) with nuts (3) and (4).
Tightening torques
F rame side section to engine
M10 x 230, Screw
(mechanical)
M12 x 297, Screw

(mechanical)
Tightening torques
F rame side section to frame
M8 x 25 - 10.9 22 Nm
Centre-stand mount to frame side section
M8 x 25 - 10.9 22 Nm
Remove the shaft and adjusting tools.

Clean the seat of sealing washer (1).
Thinly apply adhesive to the outer sealing face of sealing washer (1).
A dhesive
L octite 5970 83 19 0 404 517
Install sealing washer (1).

Install circlip (2) and support ring (1).
(-) Installing rear swinging arm
Insert locator (No. 33 6 781) and secure it with the retainer (arrow) in
the hole.
Support the installed swinging arm, to ensure that excessive strain
is not placed on the retainer (arrow).


Install spacer (2).
Insert chain (4) into swinging arm (1).
Hold swinging arm (1) in position, noting spacing washer (2).
NOTICE
Make sure that the brake hose is routed above the swinging arm.
Install screws (1).
Clean the bearing seat (arrow).

L ubricate inner bearing race (2).
L ubricant
Position sliding sleeve (No. 33 6 787) on swinging-arm shaft (1).

Install inner bearing race (2) and swinging-arm shaft (1).
Remove sliding sleeve (No. 33 6 787).
Remove locator (No. 33 6 781), while raising the swinging arm

slightly to ensure that excessive strain is not placed on the retainer
(arrow).
Clean the bearing seat.

L ubricant
Tighten threaded bush (3).
Tightening torques
Threaded bush to swinging-arm shaft (torquing specification for
swinging-arm pivot bearing)
10 Nm
slacken
Tightening torque,
7 Nm
Push the swinging arm all the way to the left and tighten screw (2).
Tightening torques
Swinging arm, left, to threaded bush
M10 x 50 38 Nm
Install bearing cap (1).
Tighten screws (1).
Tightening torques
Swinging arm, right, to swinging-arm shaft
M8 x 50 19 Nm
F inishing work
Installing spring-strut swivel bearing


Installing silencer
Closing seat

33 35 001 Replacing swinging-arm bearing

+ 33 35 502
ATTENTION
Change of position, pinion cover/swinging arm.
Leak at pinion cover.
Avoid changing the relative positions of the pinion cover/swinging arm.
Replace the swinging-arm pivot mounts in turn; one end must always
remain fixed in position by the quick-release axle or threaded sleeve.
Preparatory work
Removing cover for silencer
Removing rear left footrest plate and oil filler panel
Disengaging spring strut from swinging arm
Core activity
(-) Removing left swinging-arm bearing
Support the swinging arm with scissor-type lifter (No. 00 1 571).

Slacken screw (2), but do not remove it.
Remove threaded sleeve (3) and bearing inner race (4).

Slacken screws (2), but do not remove.
Ease swinging-arm shaft (3) out just far enough to permit removal of
the left bearing, and use a suitable tool to press right bearing inner
race (4) into the bearing seat.
Remove bearing outer race (1) and spacer (2) with internal puller (No.
00 8 573), threaded adapter (No. 13 5 256), pull rod (No. 13 5 251)
and impact weight (No. 13 5 253).

(-) Install the left swinging-arm bearing
Replace O-ring (1) on spacer (2).

Install spacer (2), using handle (No. 00 5 500) and drift (No. 11 1 620).
Install new bearing shell (3) until seated, using handle (No. 00 5 500)
and drift (No. 11 1 620).
Lubricate new bearing (1).
Lubricant
Install bearing (1) and bearing stud (2), noting spacer (3).
(-) Removing right swinging-arm bearing
Remove swinging-arm shaft (1) and bearing inner race (2), clean the
bore (arrow).

Remove bearing outer race (1) with internal puller (No. 00 8 563),
threaded adapter (No. 13 5 256), pull rod (No. 13 5 251) and impact
weight (No. 13 5 253).
Remove shaft sealing ring (2) and install replacement.
(-) Install the right swinging-arm bearing
Pack new shaft sealing ring (1) with grease on the inside (arrow).
Lubricant
Install shaft sealing ring (1) using handle (No. 00 5 500) and drift (No.
11 1 620) just far enough to hold it in position in the frame section; it is
subsequently pressed into its final position by bearing shell (2).
Install bearing shell (2), using handle (No. 00 5 500) and drift (No. 11 1
620).
Make sure that shaft sealing ring (1) does not project at the rear; if
necessary press from the rear against bearing shell (2).
(-) Installing swinging-arm shaft
Lubricate right bearing inner race (2).
Lubricant
Clean and thinly lubricate swinging-arm shaft (1).

Lubricant

Lubricate left bearing inner race (4) and install.
Lubricant
Install threaded bush (3).

NOTICE
Make sure that correct tightening torque is applied, because this is how
bearing play is set.
Tightening torques
10 Nm
slacken
Tightening torque,
7 Nm
Tightening torques
Swinging arm, left, to threaded bush
M10 x 50 38 Nm
Install left bearing cap (1).

Tighten screws (1).
Tightening torques
Swinging arm, right, to swinging-arm shaft
M8 x 50 19 Nm
Install right bearing cap (2)

Finishing work
Securing spring strut to swinging arm
Installing rear left footrest plate and oil filler panel
Installing cover for silencer

33 35 004 Replacing swinging-arm housing cover

+ 33 35 504
Preparatory work
Core activity
(-) Removing swinging-arm housing cover
Remove screws (1), noting sealing rings (2).

Remove Bowden-cable holder (3).
Remove swinging-arm housing cover (4).
Remove seal (5).
(-) Replacing swinging-arm housing cover

Screws (1)
Service cover (2)
Seal (3)
Secure service cover (2) to the new part.
(-) Installing swinging-arm housing cover
Insert sliding sleeve (No. 33 6 788) in swinging-arm housing cover (3)

(shoulder to the inside).

Place swinging-arm housing cover (3) in position with a new gasket
(2).
Install sealing washers (4) and screws (5), noting Bowden-cable holder
(6).
Tightening torques
Swinging-arm housing cover to rear wheel swinging arm
M6 x 30 tighten in
diagonally
opposite
sequence
12 Nm
Remove sliding sleeve (No. 33 6 788) and install cover (1).
Finishing work

33 54 000 Replacing rear spring strut

+ 33 54 500
Preparatory work
Opening seat
Core activity
(-) Removing spring strut
Support the rear wheel with wedges (No. 36 5 521).

Remove screws (1) and remove spring strut (2).
(-) Installing spring strut
Insert spring strut (2) and install screws (1).
Tightening torques
Spring strut to frame and swinging arm
M12 x 45 66 Nm
Finishing work


Closing seat

33 54 006 Replacing bottom spring strut pivot mount

+ 33 54 509
Preparatory work
Opening seat
Core activity
(-) Removing spring strut
Support the rear wheel with wedges (No. 36 5 521).

Remove screws (1) and remove spring strut (2).
(-) Removing spring-strut swivel bearing
From behind, insert a suitable M10 screw (1) with washer (2) into
spring-strut swivel bearing (2).
Connect screw (1) to adapter (No. 13 5 256) and pull rod (No. 13 5
252).
Remove spring-strut swivel bearing (3) from swinging arm (4) with pull
rod (No. 13 5 252).
(-) Installing spring-strut swivel bearing
Position spring-strut swivel bearing (1) in swinging arm (2).

From behind, position washer (No. 33 2 534) on swinging arm (2) and
install spindle with thrust nut (No. 33 2 531).
B mark (arrow) to swinging arm (2)
Install suitable washer (3) and nut (4) and tighten until hand-tight.
Pull spring-strut swivel bearing (1) into swinging arm (2) until seated.
Tightening torques
Spring strut to frame and swinging arm
M12 x 45 66 Nm
Finishing work
Closing seat

33 81 000 Replacing chainset

+ 33 81 500
ATTENTION
Incorrect chain tension of a new chain.
Component damage
Use chain tensioning rail with basic size.
Preparatory work
Opening seat
Removing silencer
Removing rear wheel
Core activity
Remove screws (1).


(-) Removing chain and pinion
Remove chain (1).

Remove screws (2).
Turn locking plate (3) until the teeth are clear and remove.
Remove pinion (4).

inside.
seated
arm.


(-) Replacing sprocket
Replace sprocket (1); from now on it is not permissible to install the

sprocket with judder damper (2).

Install new O-ring (1) in sprocket (2) and lubricate thinly.
Gear oil
Castrol SAF-XO 33 11 7 695 240
(-) Joining chain
Seat sealing rings (1) on chain joining link (2), with the thick sealing
bead (arrow) toward the outside link plate of chain joining link (2).
Insert chain joining link (2).
Install sealing rings (1), thick sealing bead (arrow) facing out.
Position insert (No. 27 1 571) in chain splitting and joining tool (No. 27
1 561).
Position outside link plate of chain joining link (1) in insert (No. 27 1
575).
Position insert (No. 27 1 575) in thrust screw (No. 27 1 562).

Seat chain joining link (1) with insert (No. 27 1 571)and insert (No. 27 1
575).
Tighten thrust screw (No. 27 1 562) until fully tightened.
Back off the thrust screw and remove insert (No. 27 1 575) and insert
(No. 27 1 571).
Insert rivet die (No. 27 1 574) in thrust screw (No. 27 1 562).

Position insert with bore (No. 27 1 576) in the chain splitting and
joining tool.
Position insert (No. 27 1 573) with the square head (arrow) on chain
joining link (1).
Press-fit chain joining link (1) with rivet die (No. 27 1 574).
Technical data
Tightening torque 50 Nm
for installing rivets
in chain joining link
Back off thrust screw (No. 27 1 562), turn rivet die (No. 27 1 574)
through 90° and again press-fit the rivet.
Back off thrust screw (No. 27 1 562).
Reposition the tool and press-fit the second rivet in the same way.
Remove the tools.
Checking security of chain link

Check
Result:
Pin head not adequately secured.
Measure:
Repeat the process step and seat the pin head more securely.
Check
Result:
Pin head cracked, irregularly flattened or rounded.

Measure:
Remove the chain joining link and again install a new chain j oining
link.
(-) Installing pinion and chain
Install new pinion (4), lettering toward the outside.

Seat retainer (3) in the key seat (arrow).
Turn retainer (3) until screws (2) can be installed.
Install screws (2).
Tightening torques
Retaining plate to pinion
M5 x 12 5 Nm
Install chain (1).
the inside).
(arrows).
NOTICE


S ealant
Dow Corning 07 58 0 397 777


Tightening torques
M5 x 16 Tightening
sequence: 1st: top
(from front), 2 nd
bottom (from
behind)
4.5 Nm
S ealant
Dow Corning 07 58 0 397 777



side section (1).
preload.
H old left frame side section (2) in position with tools (B), (C) and (D)
installed.
Insert adjusting tools (E ) and (F) (No. 33 6 783) into right frame side

Install screws (5).
Tightening torques
M10 x 230, Screw
(mechanical)
M12 x 297, Screw

(mechanical)
Tightening torques
M8 x 25 - 10.9 22 Nm
M8 x 25 - 10.9 22 Nm

Adhesive
L octite 5970 83 19 0 404 517

the hole.
S upport the installed swinging arm, to ensure that ex cessive strain


Install spacer (2).
H old swinging arm (1) in position, noting spacing washer (2).
NOTICE
Install screws (1).

L ubricant


slightly to ensure that ex cessive strain is not placed on the retainer
(arrow).

L ubricant
Tightening torques
10 Nm
slacken
Tightening torque,
7 Nm
Tightening torques
S winging arm, left, to threaded bush
M10 x 50 38 Nm
Tighten screws (1).
Tightening torques
S winging arm, right, to swinging-arm shaft
M8 x 50 19 Nm
Tightening torques
S pring strut to frame and swinging arm
M12 x 45 66 Nm

(-) Installing sprocket and output shaft
Insert sprocket (3) into chain (4).

Insert output shaft (2) into sprocket (3).
Clean the threads and install new nut (1) and tighten until hand-tight.
Secure retaining plate (2) with screws (1).
Tightening torques
Retaining plate for grooved ball bearing to rear wheel swinging
arm
M6 x 35 8 Nm
F inishing work


Installing silencer
Closing seat

33 81 501 Replacing chainset (for maintenance)
ATTENTION
Incorrect chain tension of a new chain.
Component damage
Use chain tensioning rail with basic size.
Preparatory work
Removing rear left footplate insert
Removing rear wheel
Core activity
Remove screws (1).


(-) Removing chain and pinion
Remove chain (1).

Remove screws (2).
Turn locking plate (3) until the teeth are clear and remove.
Remove pinion (4).

inside.
seated
arm.


(-) Replacing sprocket
Replace sprocket (1); from now on it is not permissible to install the

sprocket with judder damper (2).

Install new O-ring (1) in sprocket (2) and lubricate thinly.
Gear oil
Castrol SAF-XO 33 11 7 695 240
(-) Joining chain
1 561).
575).

575).
(No. 27 1 571).

joining tool.
joining link (1).
Technical data
Remove the tools.

Check
Result:
Measure:
Check
Result:

Measure:
Remove the chain joining link and again install a new chain j oining
link.
(-) Installing pinion and chain
Install new pinion (4), lettering toward the outside.

Seat retainer (3) in the key seat (arrow).
Turn retainer (3) until screws (2) can be installed.
Install screws (2).
Tightening torques
Retaining plate to pinion
M5 x 12 5 Nm
Install chain (1).
the inside).
(arrows).
NOTICE


S ealant
Dow Corning 07 58 0 397 777


Tightening torques
M5 x 16 Tightening
sequence: 1st: top
(from front), 2 nd
bottom (from
behind)
4.5 Nm
S ealant
Dow Corning 07 58 0 397 777



side section (1).
preload.
H old left frame side section (2) in position with tools (B), (C) and (D)
installed.
Insert adjusting tools (E ) and (F) (No. 33 6 783) into right frame side

Install screws (5).
Tightening torques
M10 x 230, Screw
(mechanical)
M12 x 297, Screw

(mechanical)
Tightening torques
M8 x 25 - 10.9 22 Nm
M8 x 25 - 10.9 22 Nm

Adhesive
L octite 5970 83 19 0 404 517

the hole.
S upport the installed swinging arm, to ensure that ex cessive strain


Install spacer (2).
H old swinging arm (1) in position, noting spacing washer (2).
NOTICE
Install screws (1).

L ubricant


slightly to ensure that ex cessive strain is not placed on the retainer
(arrow).

L ubricant
Tightening torques
10 Nm
slacken
Tightening torque,
7 Nm
Tightening torques
S winging arm, left, to threaded bush
M10 x 50 38 Nm
Tighten screws (1).
Tightening torques
S winging arm, right, to swinging-arm shaft
M8 x 50 19 Nm
Tightening torques
S pring strut to frame and swinging arm
M12 x 45 66 Nm

(-) Installing sprocket and output shaft
Insert sprocket (3) into chain (4).

Insert output shaft (2) into sprocket (3).
Clean the threads and install new nut (1) and tighten until hand-tight.
Secure retaining plate (2) with screws (1).
Tightening torques
Retaining plate for grooved ball bearing to rear wheel swinging
arm
M6 x 35 8 Nm
F inishing work


Installing rear left footplate insert

33 83 000 Adjusting chain tension

+ 33 83 500
NOTICE
Chain tension can be adjusted by installing an oversize chain tensioner
rail.
Preparatory work
Core activity
(-) Removing chain tensioner rail

Remove chain tensioner rail (3), noting sleeve (4).
(-) Checking chain sprocket
Check
Check chain sprocket for deformation and wear.
Result:
Fig. 1: No signs of deformation or only slight deformation of the teeth is
perceptible.
Measure:
Chain sprocket is OK.

Result:
Fig. 2: Deformation at the teeth is perceptible.

Measure:
Replace the chain sprocket, chain pinion and chain.
=> 33 81 500, Replacing chainset (Billed as a separate item)
Result:
Fig. 3: Severe wear at the teeth is perceptible.
Measure:

(-) Installing chain tensioner rail (oversize)
To adjust chain sag, select the next largest chain tensioner rail
(number of dots).
Chain tensioner rails are available in 4 stages; the number of dots
(arrow) corresponds to the stage.
Clean the threads.

Transfer sleeve (4) to the new part.
Insert oversize chain tensioner rail (3).
Tightening torques
Chain tensioner rail to rear wheel swinging arm
Front, M6 x 40 8 Nm
encapsulated)
Collared screw at rear, M6 8 Nm
Finishing work

33 83 001 Checking chain for wear

+ 33 83 501
Core activity
(-) Check chain sag
Checking chain sag (without mark on chain channel)
Remove screws (1), cover (2) and gasket (3).

Check
Lift chain (4) and measure distance (A) between underside of chain (4) and chain
rail (5).
Technical data
Chain deflection max 15 mm
Turn the rear wheel and repeat this measurement at several points along the
chain.
Result:
Measured chain sag is out of tolerance.
Measure:
Adjust chain tension (install a thicker tensioning rail).
=> 33 85 508, Replacing chain tensioner rail (Billed as a separate item)
Install gasket (3), cover (2) and screws (1).
Checking chain sag (arrow mark on chain channel)
Remove screws (1), cover (2) and gasket (3).

Check
Push chain (4) up and check whether the chain underside reaches the wear
mark (arrow) on chain channel (5).
Turn the rear wheel and repeat this measurement at several points along the
chain.
Result:
Chain underside goes past the wear mark.
Measure:
Adjust chain tension (install a thicker tensioning rail).
=> 33 85 508, Replacing chain tensioner rail (Billed as a separate item)
Install gasket (3), cover (2) and screws (1).
Finishing work

33 83 002 Replacing chain

+ 33 83 502
Preparatory work
Remove the chain slide rail
Core activity
(-) Preassembling chain splitting/joining tool for splitting
drive chain
Insert rivet die (No. 27 1 577) into basic tool (No. 27 1 561).
Insert screw (No. 27 1 562) with press-out pin (No. 27 1 572) into basic
tool (No. 27 1 561).
(-) Splitting drive chain
Secure locator for press-out pin (No. 27 1 573) with hole over chain
rivet (1).
Press out chain rivet (1) with press-out pin (No. 27 1 572).
Remove the tool and separate chain link plates (2).
Take removed chain rivet (1) out of the tool.
(-) Checking chain sprocket
Check
Check chain sprocket for deformation and wear.

Result:
Fig. 1: No signs of deformation or only slight deformation of the teeth is
perceptible.
Measure:
Chain sprocket is OK.

Result:
Fig. 2: Deformation at the teeth is perceptible.
Measure:
Result:
Fig. 3: Severe wear at the teeth is perceptible.
Measure:


(-) Installing chain
Attach new chain (1) to old chain (2) with a cable tie (arrow), making
sure that the lock of the cable tie is facing toward the outside.
Pull new chain (1) over front pinion, cut through the cable tie and

remove old chain (2).
(-) Joining chain
1 561).
575).
575).
(No. 27 1 571).


joining tool.
joining link (1).
Technical data
Remove the tools.
Check
Result:
Measure:
Check
Result:


Measure:
Remove the chain joining link and again install a new chain joining
link.
Finishing work

33 85 001 Replacing chain slide rail

+ 33 85 501
June 2014
Preparatory work
Core activity
(-) Removing bottom chain channel

Disengage chain channel (3) from the holders (arrows) and remove.

(-) Removing top chain channel
Remove screw (1).

Remove chain channel (2).

(-) Remove the chain slide rail

Remove chain slide rail (3).
(-) Installing chain slide rail
Clean the threads.

Work chain slide rail (1) into position, noting the locator (arrow).
Secure chain slide rail (3) with screws (1) and (2).
Tightening torques
Chain slide rail to rear wheel swinging arm
Front, M6 x 40 8 Nm
encapsulated)

(-) Installing top chain channel
Secure chain channel (1) in the holders (arrows).

Install screw (2).
(-) Installing chain tensioner rail
Clean the threads.

Insert chain tensioner rail (3), noting sleeve (4).
Tightening torques
Front, M6 x 40 8 Nm
encapsulated)
(-) Installing bottom chain channel
ATTENTION
Re-use of chain channel after disengagement.
Loosening of threaded fasteners.
Renew the chain channel if it has been disengaged.

Secure new chain channel (3) in the holders (arrows).

Finishing work

33 85 003 Replacing chain tensioner rail

+ 33 85 508
Preparatory work
Core activity
(-) Removing bottom chain channel

Disengage chain channel (3) from the holders (arrows) and remove.

(-) Installing chain tensioner rail
Clean the threads.

Insert chain tensioner rail (3), noting sleeve (4).
Tightening torques
Front, M6 x 40 8 Nm
encapsulated)


(-) Installing bottom chain channel
ATTENTION
Re-use of chain channel after disengagement.
Loosening of threaded fasteners.
Renew the chain channel if it has been disengaged.
Secure new chain channel (3) in the holders (arrows).

Finishing work

34 00 010 Change brake fluid in entire system

+ 34 00 504
Core activity
(-) Changing brake fluid, front, and bleeding brake system
Set the brake lever to maximum span.

ATTENTION
Material damage

Screws (1)
Cover (2)
Support plate (3)
Diaphragm (4)
Draw off the old fluid and clean reservoir (5).
Push back brake caliper (1) by hand.
The brake pistons are pushed back.
Draw off the excess brake fluid that was forced back into the reservoir.
Turn the handlebars to a position in which the brake fluid reservoir is

horizontal.
WARNING
Brake fluid is hygroscopic.
Reduction of boiling point if stored in open container.
Use only fresh brake fluid from an unopened container.
Top up with fresh brake fluid to the MAX mark (arrow).
Hydraulic fluid
Brake fluid, DOT4
Connect the brake bleeding device to bleed screw (1).

Slightly open bleed screw (1).

WARNING
Air bubbles difficult to recognise in brake fluid drawn off by
vacuum extraction.
Air in the brake system.
In the final step, bleed the system manually (without vacuum
extraction) until the fluid emerging is bubble-free.
Continue bleeding the brake system until fresh brake fluid emerges
Close bleed screw (1).
Tightening torques
Bleed screw in filling banjo bolt/brake caliper, right
in filling banjo bolt, M8 10 Nm
in brake caliper, right 6 Nm
Repeat the fluid-change procedure/procedure for bleeding the brakes

at the right brake caliper.
Operate the brake lever to seat the brake pistons.

horizontal.
WARNING
Hydraulic fluid
Brake fluid, DOT4
Prior to assembly, remove all traces of brake fluid from all

components.
Diaphragm (1)
Support plate (2)
Cover (3)
Screws (4)
Check
Check brake pressure by operating the brakes.

Result:

Low brake pressure

Measure:
Repeat the bleeding process without vacuum extraction.
(-) Changing brake fluid, rear, and bleeding brake system

ATTENTION
Material damage

Screws (1)
Cover (2)
Support plate (3)
Diaphragm (4)
Push back brake caliper (1) by hand.

The brake piston is pushed back.
Draw off the excess brake fluid that was forced back into the reservoir.
WARNING
Hydraulic fluid
Brake fluid, DOT4
Remove cap (1) and connect the brake bleeding device to bleed screw
(2).
Open bleed screw (2) by half a turn.
Continue bleeding the brakes until new brake fluid emerges; top up

with fresh brake fluid as necessary.

Close bleed screw (2) and remove the brake bleeding device.
Tightening torques
Bleed screw to brake caliper, rear
6 Nm
Secure cap (1).
Operate the brake several times until the brake pads are bedded.
Hydraulic fluid
Brake fluid, DOT4

components.
Diaphragm (1)
Support plate (2)
Cover (3)
Screws (4)
Check

Result:
Low brake pressure
Measure:
Finishing work

34 00 033 Bleeding front brake system

+ 34 00 507
Core activity
(-) Filling and bleeding front brake system

ATTENTION
Material damage

Screws (1)
Cover (2)
Support plate (3)
Diaphragm (4)
horizontal.
WARNING
Hydraulic fluid
Brake fluid, DOT4
Connect the brake bleeding device to bleed screw (1).

WARNING
vacuum extraction.
Continue bleeding the brake system until fresh brake fluid emerges.

Tightening torques
Bleed screw in filling banjo bolt/brake caliper, right
in filling banjo bolt, M8 10 Nm
in brake caliper, right 6 Nm
Repeat the fluid-change procedure/procedure for bleeding the brakes

at the right brake caliper.

horizontal.
WARNING
Hydraulic fluid
Brake fluid, DOT4

components.
Diaphragm (1)
Support plate (2)
Cover (3)
Screws (4)
Check

Result:
Low brake pressure
Measure:
Finishing work

34 00 035 Bleeding rear brake system

+ 34 00 509
Core activity
(-) Filling and bleeding rear brake system

ATTENTION
Material damage

Screws (1)
Cover (2)
Support plate (3)
Diaphragm (4)
horizontal.
WARNING
Hydraulic fluid
Brake fluid, DOT4
Remove cap (1) and connect the brake bleeding device to bleed screw
(2).
WARNING
vacuum extraction.
Continue bleeding the brake system until fresh brake fluid emerges.

Tightening torques
Bleed screw to brake caliper, rear
6 Nm
Secure cap (1).

horizontal.
Hydraulic fluid
Brake fluid, DOT4

components.
Diaphragm (1)
Support plate (2)
Cover (3)
Screws (4)
Check

Result:
Low brake pressure

Measure:
Finishing work

34 11 001 Measuring front brake-disc run-out

+ 34 11 844
Preparatory work
Core activity
(-) Measuring front brake-disc runout
Raise the front wheel clear of the ground so that it can turn freely.
Clean the brake disc.
Seat dial gauge (No. 00 2 510) in dial-gauge holder (No. 34 2 524) and
install extension (No. 34 2 523) and measuring adapter (No. 34 2 510).
Position the dial-gauge holder on the brake caliper mount and install
screw (1).
Align dial gauge in such a way that the measuring adapter is in contact
with the brake disc close to the outer circumference and the dial gauge
is slightly preloaded.
Check
Set the dial gauge to "0".
Slowly turn the wheel through at least one complete revolution

and observe the dial gauge reading.
The sum of the positive and negative dial-gauge readings is the total
runout.
Technical data
Brake disc lateral At max 0.15 mm
runout, front circumference
Result:
Lateral runout is excessive.
Measure:
Check positioning of the brake disc/wheel rim.
Check the wheel rim for damage.

If necessary, check the brake disc.
Finishing work

34 11 008 Replacing front brake pads

+ 34 11 832
Core activity
(-) Removing front brake pads
Press back brake caliper (1).


Threaded plug (1)
Pin (2)
Brake pads (3)
Remove the brake pads on the right-hand side in the same way.
(-) Installing front brake pads
Note plate (1).
Install brake pads (1), noting plates (2) and (3).

Install pin (4) and threaded plug (5).

Tightening torques
Pad retaining pin to brake caliper
M10 x 1 17 Nm
Threaded plug (pad retaining pin) to brake caliper
M10 x 1 2.5 Nm
Install the brake pads on the right-hand side in the same way.
Finishing work
Bedding in brake pads

34 11 060 Replacing front brake caliper (without bleeding brakes)

+ 34 11 560
Preparatory work
Drain the front brake system
Removing front brake pads
Core activity
(-) Removing front brake caliper
ATTENTION
Material damage
Remove banjo bolt (1) with sealing rings (2).

Disengage brake line (3) and seal the openings.
Remove screws (4) and remove brake caliper (5).
(-) Installing front brake caliper
Secure brake caliper (5) with screws (4).
Tightening torques
Brake caliper to fork leg
M8 x 32 28 Nm
Hold brake line (3) in position and install banjo bolt (1) with new
sealing rings (2).
Tightening torques
M10 x 1 24 Nm
Finishing work
Installing front brake pads
=> Bleeding front brake system (Description in item: 34

00 507, Billed as a separate item)

34 21 031 Measuring rear brake-disc run-out

+ 34 21 774
Preparatory work
Removing silencer
Removing rear wheel
Releasing brake caliper
Core activity
(-) Measuring rear brake-disc runout
Requirement
No burrs or scoring on brake disc, brake disc thickness above
minimum.
No play in wheel bearing.
Raise the rear wheel clear of the ground so that it can turn freely.
Clean the brake disc.
Secure the dial-gauge holder (No. 34 2 524) to the brake caliper with
screw (1).
Insert extension (No. 00 2 504) with clamping bush (No. 00 2 506) in
dial-gauge holder (No. 34 2 524).
Insert dial gauge (No. 00 2 510) into clamping bush (No. 00 2 506) and
install measuring adapter (No. 34 2 510).
Align dial gauge in such a way that the measuring adapter is in contact
with the brake disc close to the outer circumference and the dial gauge
is slightly preloaded.
Check
Set the dial gauge to "0".
Slowly turn the wheel through at least one complete revolution

and observe the dial gauge reading.
The sum of the positive and negative dial-gauge readings is the total
runout.
Technical data
Brake disc lateral At max 0.15 mm
runout, rear circumference
Result:
Lateral runout is excessive.

Measure:
Check positioning of the brake disc/wheel rim.
Check the wheel rim for damage.
If necessary, check the brake disc.

Finishing work
Securing brake caliper
Installing silencer

34 21 060 Replacing rear brake caliper (without bleeding brakes)

+ 34 21 560
Preparatory work
Draining rear brake system
Removing silencer
Removing rear wheel
Removing rear brake pads
Core activity
(-) Removing rear brake caliper
ATTENTION
Material damage
Remove banjo bolt (1) with sealing rings (2).

Disengage brake line (3) and seal the openings.
Remove screws (4) and remove brake caliper (5).
Remove screw (6) and disengage wheel-speed sensor (7).
(-) Installing brake pads in rear brake caliper
Note plate (1).

Tightening torques
M10 x 1 17 Nm
M10 x 1 2.5 Nm

(-) Installing rear brake caliper
Secure wheel-speed sensor (7) with screw (6).
Tightening torques
Wheel-speed sensor to fork/brake caliper, rear
M6 x 16 8 Nm
ATTENTION
Material damage
Hold brake caliper (5) in position and install screws (4).
Tightening torques
Brake caliper, rear, to rear wheel swinging arm
M8 x 32 28 Nm
Hold brake line (3) in position at brake caliper (5) and install screw (1)
with new seals (2).
Tightening torques
M10 x 1 24 Nm
Finishing work
Installing silencer
=> Bleeding rear brake system (Description in item: 34

00 509, Billed as a separate item)

34 21 195 Adjusting parking brake

+ 34 21 779
Core activity
(-) Adjusting parking brake
Adjust the cable for parking brake (basic setting)
Check
With the side stand retracted, measure distance (A).
Technical data
Basic setting of Distance 56 mm
parking brake from
Bowden
cable
connection
to centre of
lever pivot
mount with
side stand
retracted
Result:
Result not OK
Measure:
Adjust the parking brake by turning nut (1); if necessary counter-hold

at the hexagon (arrow).
Extend the side stand.

Slacken locknut (1).
Tighten adjusting screw (2) by turning it clockwise.
Tightening torques
Adjusting screw to brake caliper (parking brake)
1 Nm
Tighten locknut (1), counter-holding adjusting screw (2) to prevent it

from turning.
Tightening torques
Locknut (adjusting screw) to brake caliper (parking brake)
18 Nm
Install special tools (No. 34 0 611) in rear-wheel axle, seating the pin
against the spoke (arrow).
Turn rear wheel (1) in the forward direction of travel by applying
torque.

Check
Technical data
Braking effect of measured at >180 Nm
parking brake rear wheel
with side
stand
extended
Result:
Rear wheel can be turned.
Measure:
Increase braking effect of the parking brake (slacken locknut and turn
the adjusting screw clockwise)
Tightening torques
18 Nm
Extend and retract the side stand 10 times, then recheck the
braking effect.
Finishing work

34 21 197 Replacing Bowden cable for parking brake

+ 34 21 777
Core activity
(-) Removing Bowden cable for parking brake
Remove circlip (1) and screw (2).

Disengage Bowden cable (3).
Remove screw (1).

Remove adjusting screw (2).
Remove the following parts from Bowden cable (3):
Holder (4)
Holder (5)
Pin (6)
Spring (7)
Remove Bowden cable (3).
(-) Installing Bowden cable for parking brake

Clean the threads.
Secure Bowden cable (3) with circlip (1) and screw (2).
Tightening torques
Cable (parking brake) to side stand
M6 x 16 12 Nm
encapsulated)
(Loctite 270, High strength)
Seat Bowden cable (3) in bracket (4).

Seat Bowden cable (3) in spring (7) and pin (6).
Install adjusting screw (2) and tighten until hand-tight.


Check
Technical data
Basic setting of Distance 56 mm
parking brake from
Bowden
cable
connection
to centre of
lever pivot
mount with
side stand
retracted
Result:
Result not OK
Measure:


torque.
Check
Technical data
with side
stand
extended

Result:
Parking brake not working correctly.
Measure:
Adjust the parking brake.

Tightening torques
1 Nm

from turning.
Tightening torques
18 Nm
torque.
Check
Technical data
with side
stand
extended
Result:

Measure:
Tightening torques
18 Nm
braking effect.
Finishing work


34 21 198 Replacing brake caliper for parking brake

+ 34 21 776
Preparatory work
Removing silencer
Removing rear wheel
Core activity
(-) Removing brake caliper for parking brake
Remove adjusting screw (1).

Disengage Bowden cable (2), remove stud (3) and spring (4).

Release brake caliper for parking brake (3).
Remove brake caliper for parking brake (3) with brake pads (4).
(-) Replacing brake caliper for parking brake
Re-use the brake pads in the new part, or install new brake pads as
applicable.
(-) Installing brake caliper for parking brake
Clean the threads.

Install brake pads (4) and install screws (1) to hold them in position.
Hold brake caliper for parking brake (3) in position.
Install screws (2) and (1) and tighten.
Tightening torques
Brake caliper (parking brake) to swinging arm
M8 x 25 30 Nm


encapsulated)
Pad retaining pins to brake caliper (parking brake)
18 Nm

Bowden cable (2)
Spring (4)
Pin (3)
Adjusting screw (1)
(-) Installing rear wheel
Hold rear wheel (2) in position and install screws (1).
Tightening torques
Rear wheel to output shaft
M10 x 1.25 x 40 Tighten in
diagonally
opposite
sequence
60 Nm

Check
Technical data
Basic setting of 56 mm
Distance
parking brake
from
Bowden
cable

connection
to centre of
lever pivot
mount with
side stand
retracted
Result:
Result not OK
Measure:

torque.
Check
Technical data
with side
stand
extended
Result:
Parking brake not working correctly.
Measure:
Adjust the parking brake.

Tightening torques
1 Nm

from turning.

Tightening torques
18 Nm
torque.
Check
Technical data
with side
stand
extended
Result:
Measure:
Tightening torques
18 Nm
braking effect.
Finishing work
Installing silencer

34 21 199 Replacing brake pads for parking brake

+ 34 21 775
Preparatory work
Removing silencer
Removing rear wheel
Core activity
(-) Removing brake pads

Release brake caliper (3).
Remove brake pads (4).
(-) Installing brake pads
If brake pads do not fit into the brake caliper, back off the brake
caliper:
Turn adjusting screw (2) counter-clockwise to slacken.
Clean the threads.

Install brake pads (4) and install screws (1) to hold them in position.
Hold brake caliper (3) in position.
Install screws (2) and (1) and tighten.
Tightening torques
M8 x 25 30 Nm
encapsulated)

Pad retaining pins to brake caliper (parking brake)

18 Nm
Finishing work
Adjusting parking brake
Installing silencer

34 21 200 Replacing rear brake pads

+ 34 21 769
Core activity
(-) Removing rear brake pads
Press back brake caliper (1).


Threaded plug (1)
Pin (2)
Brake pads (3)
(-) Installing rear brake pads

Note plate (1).

Tightening torques


M10 x 1 17 Nm
M10 x 1 2.5 Nm
Operate the brake several times until the brake pads are bedded.
Finishing work

34 21 301 Removing/installing rear brake disc

+ 34 21 772
Preparatory work
Removing silencer
Removing rear wheel
Core activity
(-) Removing brake disc
Slacken screws (1) one after the other, operating rear-wheel brake (2)
each time a screw has to be slackened.
Take care to slacken screws (1) only to the extent that when brake
disc (3) is turned, the screws do not come into contact with brake (2).
Turn brake disc (1) until the recess (arrow) is located over one of the
screws (2).
Remove screws (2) and disengage brake caliper (3).
Move brake caliper (3) to one side and secure it so that it cannot fall.
Remove screws (4) in the same way and disengage parking brake (5).
Remove screws (1) one after the other and remove brake disc (2).
(-) Installing rear brake disc

Clean the threads.

Clean the mating faces of brake disc (1).
Place brake disc (1) with sensor ring (2) in position, the shoulder
(arrow) is up.
Install new screws (3) one after the other and tighten until hand-tight.
Place brake caliper (3) in position.

Turn brake disc (1) until the recess (arrow) is located over one of the
screws (2).
Install screws (2).
Tightening torques
Brake caliper, rear, to rear wheel swinging arm
M8 x 32 28 Nm
Place parking brake (5) in position and install screws (4) in the same
way.
Tightening torques
M8 x 25 30 Nm
encapsulated)
After completing all work, operate the brake until the brake pads are
bedded.
When turning brake disc (3) make sure that screws (1) do not come
into contact with brake (2).
Tighten screws (1) one after the other.
NOTICE
Operating the side stand / parking brake can block the output shaft.
Tightening torques
Brake disc to wheel flange
M8 x 15.5, Replace screw tighten in

Thread-locking compound (Micro- diagonally

encapsulated) opposite
sequence
1st tightening
torque, 12 Nm
2nd tightening
torque, 30 Nm
Finishing work
Checking basic setting and braking effect of parking brake
Installing silencer

36 23 001 Replacing wheel-speed sensor, front

+ 36 23 601
Preparatory work
Core activity
(-) Removing wheel-speed sensor
Remove screw (1) and disengage wheel-speed sensor (2).
Release the sensor cable (arrows).
Release the sensor cable (arrows).

Disconnect plug (1) for the wheel-speed sensor and remove the
sensor.
(-) Installing front wheel-speed sensor

Insert wheel-speed sensor (2) and install screw (1).
Tightening torques
Wheel-speed sensor to fork/brake caliper, rear
M6 x 16 8 Nm
Secure the sensor cable (arrows).

Connect plug (1) for the wheel-speed sensor.
Secure the sensor cable (arrows).
Finishing work

36 23 003 Replacing sensor ring, front

+ 36 23 603
Preparatory work
Core activity
(-) Removing front sensor ring
Remove screws (1) and brake disc (2).

Remove sensor ring (3).
(-) Installing front sensor ring
Clean the threads.

Place sensor ring (3) in position.
Install brake disc (2) and screws (1).
Tightening torques
Brake disc to front wheel
M8 x 15.5, Replace screw 30 Nm
encapsulated)
Finishing work

36 23 004 Replacing sensor ring, rear

+ 36 23 604
Preparatory work
Removing silencer
Removing rear wheel
Core activity
(-) Removing rear sensor ring
Carefully clamp drive shaft (1) in a vice fitted with aluminium jaws.
Screws (2)
Brake disc (3)
Sensor ring (4)
(-) Installing rear sensor ring
Clean the threads.

Clean the mating faces of sensor ring (4).
Place sensor ring (4) and brake disc (3) on shaft (1) as illustrated.
Install screws (2).
Tightening torques
Brake disc to wheel flange
M8 x 15.5, Replace screw tighten in
Thread-locking compound (Micro- diagonally
encapsulated) opposite
sequence
1st tightening
torque, 12 Nm
2nd tightening
torque, 30 Nm
Finishing work
Replacing shaft sealing ring in swinging arm


Installing silencer

36 30 300 Removing/installing front wheel

+ 36 30 628
Preparatory work
Core activity
(-) Removing front wheel
Slacken clamping screws (1).

Remove quick-release axle (2).
NOTICE
Do not damage the wheel-speed sensor when removing and installing
the wheel.
Remove front wheel (3), noting spacing sleeve (4).
(-) Installing front wheel
Clean and lubricate quick-release axle (2).
Lubricant
Optimoly TA 18 21 9 062 599
Install front wheel (3), noting spacing sleeve (4).

NOTICE
Do not damage the wheel-speed sensor when removing and installing
the wheel.
Install quick-release axle (2).
Tightening torques
Quick-release axle in axle holder
M18 x 1,5 30 Nm
Tighten clamping screws (1).
Tightening torques
Clamping screws (quick-release axle) in telescopic forks
M6 x 30
Tighten screws
six times in
alternate

sequence
8 Nm
Finishing work

36 30 320 Removing/installing rear wheel

+ 36 30 629
Preparatory work
Removing silencer
Core activity
(-) Removing rear wheel
Remove screws (1).

NOTICE
Operating the side stand / parking brake can block the output shaft.
Remove rear wheel (2).
(-) Installing rear wheel
Hold rear wheel (2) in position and install screws (1).
Tightening torques
Rear wheel to output shaft
M10 x 1.25 x 40 Tighten in
diagonally
opposite
sequence
60 Nm
Finishing work
Installing silencer

36 31 851 Renewing front wheel bearing (wheel removed)
Core activity
(-) Removing left and right shaft sealing rings
Using a suitable tool, carefully remove shaft sealing rings (1) on left
and right.
(-) Removing wheel bearings of front wheel
Remove left wheel bearing (1) with reaction support (No. 00 8 562),
internal puller (No. 00 8 573) and support ring (No. 36 6 640).
Remove spacing bushing (2).
Remove right wheel bearing (3) in the same way.
(-) Installing wheel bearings
Clean the bearing seats.
Install bushing (1).

Introduce left bearing (2) into the bearing seat.
Install short spindle with pull-in nut (No. 36 5 552) washer without
thread (No. 36 5 554) and washers with thread (No. 36 5 553):
Washer dia. 47 mm
Remove the tools.
Introduce right bearing (1) into the bearing seat.

Install short spindle with pull-in nut (No. 36 5 552) washer without
thread (No. 36 5 554) and washers with thread (No. 36 5 553):

Washer dia. 47 mm
Remove the tools.
(-) Installing shaft sealing rings
Install shaft sealing rings (1) on left and right with drift (No. 23 4 550)
until the rings are flush with the rim.
Lubricate friction faces of shaft sealing rings (1).
Installation tool
Finishing work

36 32 501 Renewing front tyre (wheel removed)
Core activity
(-) Removing front tyre
Use commercially available tools to strip the tyre off the rim.
(-) Replacing rubber valve
ATTENTION
Re-use of tyre valve
Pressure loss in tyre.
When fitting a new tyre, also install a new tyre valve.
Use a suitable tool to remove rubber valve (1).

Lubricate new rubber valve (1) and install, using a suitable tool.
Care products
(-) Installing front tyre
ATTENTION
Component damage
Install the tyre in accordance with the manufacturer's instructions,

using commercially available tools. Make sure that the direction-of-
rotation arrows on tyre and rim point in the same direction.
Manufacturer-specific tyre mark for imbalance must be toward the
valve.
Check
Inflate the tyre to test pressure and check the valve for leaks.
Technical data
Wheel valve test 4 bar
pressure
Result:
Valve leaking
Measure:
Replace the valve insert.
Result:
Valve leaktight
Measure:

Adjust the air pressure
Technical data
Tyre pressure, front Tyre cold 2.4 bar
Check the tyre and make sure the line is at a uniform distance from the
rim flange all the way round.
(-) Static balancing of front wheel
Align balancer (No. 36 3 601) with knurled screws (1) and level gauge
(2).
Insert balancing shaft (No. 36 5 571) in front-wheel bearing and secure
it with tensioner (No. 36 5 572), making sure that front-wheel bearing is
lightly preloaded.
Place the front wheel on the balancer and allow it to come to rest.
Clean the attachment points for the adhesive weights.
Affix adhesive weights (3) opposite the heaviest point of the wheel.
Technical data
Permissible front- max 5 g
wheel imbalance
Balancing weight max 80 g
for front wheel
Weight must be
divided equally
across both sides
and weights
attached to rim on
left and right.
Repeat the balancing procedure as a check.

36 32 511 Removing rear tyre (wheel removed)
Core activity
(-) Removing rear tyre
Use commercially available tools to strip the tyre off the rim.
(-) Replacing rubber valve
ATTENTION
Re-use of tyre valve
Pressure loss in tyre.
When fitting a new tyre, also install a new tyre valve.
Use a suitable tool to remove rubber valve (1).

Lubricate new rubber valve (1) and install, using a suitable tool.
Care products
(-) Installing rear tyre
ATTENTION
Component damage
Install the tyre in accordance with the manufacturer's instructions,

using commercially available tools. Make sure that the direction-of-
rotation arrows on tyre and rim point in the same direction.
Manufacturer-specific tyre mark for imbalance must be toward the
valve.
Check
Inflate the tyre to test pressure and check the valve for leaks.
Technical data
Wheel valve test 4 bar
pressure
Result:
Valve leaking
Measure:
Replace the valve insert.
Result:
Valve leaktight
Measure:

Adjust the air pressure
Technical data
Tyre pressure, rear One-up, tyre 2.5 bar
cold
two-up 2.9 bar
and/or with
luggage,
tyre cold
Check the tyre and make sure the line is at a uniform distance from the
rim flange all the way round.
(-) Static balancing of rear wheel
Secure balancing adapter (No. 36 5 561) with wheel studs (1).
Align balancer (No. 36 3 601) with knurled screws (1) and level gauge
(2).
Introduce balancing shaft (No. 36 5 571) into the rear wheel and
secure it with tensioning device (3).
Place the rear wheel on the balancer and allow it to come to rest.
Clean the attachment points for the adhesive weights.
Affix adhesive weights (4) opposite the heaviest point of the wheel.
Technical data
Permissible rear- max 5 g
wheel imbalance
Balancing weight max 80 g
for rear wheel
Weight must be
divided equally
across both sides
and weights
attached to rim on
left and right.
Repeat the balancing procedure as a check.

46 51 050 Replacing rear frame

+ 46 51 563
Preparatory work
Opening seat
Removing right centre footrest plate
Removing hinge
Removing rear trimmer with rear-light unit
Removing number-plate carrier
Removing luggage-compartment base
Core activity
(-) Disengaging Bowden cable for seat latch
Disengage Bowden cable (1) from seat latch (2).
Remove the cable tie (arrow) from Bowden cable (1).

Work Bowden cable (1) through front luggage-compartment base (2),

noting rubber grommet (3).
(-) Removing rear frame
Remove screws (1).

Ease footplate (2) carefully aside.
Open cable ties (arrows).

Remove screws (1) and washers (2).


Screws (1)
Washers (2)
Rear frame (3)
(-) Removing front luggage-compartment base
Working carefully, remove (1) from rear frame (2).
(-) Changing rear frame

Removing seat latch
Remove screws (1).

Remove seat latch (2).
Transfer the reusable small items from the old rear frame to the new
frame.
Installing seat latch
Insert seat latch (2).

Install screws (1).

Tightening torques
Seat lock to rear frame
M6 x 12 8 Nm
(-) Installing front luggage-compartment base
Insert luggage-compartment base (1) into rear frame (1) and align.
(-) Installing rear frame
Hold rear frame (3) in position.

Install washers (2) and screws (1).
Tightening torques
Rear frame to main frame/frame side section
M10 x 25 38 Nm
encapsulated)
Ease footplate (1) carefully aside.

Install washers (2) and screws (3).
Tightening torques
Rear frame to main frame/frame side section
M10 x 25 38 Nm
encapsulated)


Re-align footplate (2) carefully with the Maxi-Scooter.

Install screws (1).
Tightening torques
General threaded fastener for fairing panels
M6 2 Nm
(-) Securing Bowden cable for seat latch
Route Bowden cable (1) through front luggage-compartment base (2),

noting rubber grommet (3).
Secure Bowden cable (1) with cable tie (arrow).

Secure Bowden cable (1) to seat latch (2).
F inishing work
Installing luggage-compartment base
Installing number-plate carrier
Installing rear trimmer with rear-light unit
Installing hinge
Installing right centre footrest plate
Closing seat

46 51 120 Removing/installing frame

+ 46 51 575
Preparatory work
Opening seat
Removing hinge
Removing complete tail assembly
Removing fuel tank with seat
Removing right footplate carrier
Removing windscreen


Disconnecting plugs of left multifunction switch
Disconnecting plug of right multi-function switch
Removing handlebars
Removing leg guard
Removing left brake caliper
Removing right brake caliper
Removing forks with steering-head bearing and top fork bridge
Removing rear wheel
Draining rear brake system
Disengaging rear brake hose from brake caliper
Releasing spring strut
Disengaging left frame side section
Disengaging right frame side section
Preparations for frame removal
Removing complete nose assembly
Core activity
(-) Removing main frame
Remove screw (1).

Remove holder (2) with brake line (3).


Carefully remove frame (3).
(-) Installing main frame
ATTENTION
Incorrect routing of hoses, cables and Bowden cables.
Malfunction. Component damage.
Make sure that routing is correct.
Consult the function diagrams and overviews.
Carefully manoeuvre frame (3) into position.

Install screws (1) with washers (2).
Tightening torques
Engine to frame
M10 x 35 38 Nm
Install screws (1) with washers (2).
Tightening torques
Engine to frame
M10 x 35 38 Nm

Hold brake line (3) in position with holder (2).

Install screw (1).
Tightening torques
Brake hose to main frame
M5 x 12 5 Nm
Finishing work
Installing complete nose assembly
Finishing work for frame removal
Securing right frame side section
Securing left frame side section
Securing spring strut
Securing brake hose to rear brake caliper
Installing forks with steering-head bearing and top fork bridge
Securing right brake caliper
Securing left brake caliper


Installing handlebars
Connecting plugs for right multifunction switch
Connecting plugs for left multifunction switch
Filling and bleeding rear brake system
Adjusting throttle-cable play.
Securing radiator
Installing fuel tank with seat
Installing hinge
Installing complete tail
Install the right footplate carrier


Closing seat

46 51 180 Checking motorcycle with frame- measuring system

+ 46 51 676
Preparatory work
Core activity
(-) Removing screw for handlebar attachment (for frame
measuring system)
Remove left screw (1).
(-) Checking motorcycle with frame-alignment measuring

system
Use only the frame gauge recommended by BMW Motorrad.
(-) Installing screw for handlebar attachment (for frame

measuring system)
Install left screw (1).
Tightening torques
Handlebars to fork bridge

M10 x 55 41 Nm
Finishing work

46 51 520 Replacing frame (frame removed)
Preparatory work
Removing bottom steering-head bearing
Core activity
(-) Replacing frame
Transfer reusable small items to the new frame.

Clean the attachment area and affix the adhesive type plate.
Dispose of the old frame in accordance with locally applicable
legislation.
Finishing work
Installing bottom steering-head bearing (inner race)

46 61 000 Removing/installing front-wheel cover

+ 46 61 500
Core activity
(-) Removing front-wheel cover
Remove screws (1) and remove wheel cover (2).
(-) Installing front-wheel cover
Hold wheel cover (2) in position and install screws (1).
Tightening torques
Wheel cover to forks
M5 x 14.5 5 Nm
Finishing work

46 61 008 Removing/installing rear front-wheel cover

+ 46 61 502
Preparatory work
Core activity
(-) Removing front section of wheel cover
Remove screws (1).

Remove front section (2), noting the locators (arrows).
(-) Installing front section of wheel cover
Install front section (2), noting the locators (arrows).

Install screws (1).
Tightening torques
Wheel cover, front, to wheel cover, rear
M5 x 16 2 Nm
Finishing work

46 62 050 Renewing number plate carrier

+ 46 62 508
Preparatory work
Opening seat
Core activity
(-) Removing number-plate carrier
Cut through the cable ties (arrows).

Disengage socket (1) for the number-plate light.
Remove screws (2).
Remove license-plate carrier (3).
(-) Replacing number-plate carrier
Remove nut (1).

Remove screw (2) with number-plate light (3).
Remove nuts (4) and remove reflector (5).
Substitute the new number-plate carrier for old number-plate carrier
(6).
Hold reflector (5) in position.
Install nuts (4).
Hold number-plate light (3) in position with screw (2).
Install nut (1).
(-) Installing number-plate carrier

Clean the threads.
Secure number-plate carrier (3) with screws (2).
Tightening torques
Number-plate carrier to rear frame

M6 x 16 2.5 Nm
encapsulated)
Secure socket (1) for the number-plate light.

Finishing work
Closing seat

46 63 003 Removing/installing leg guard

+ 46 63 991
Preparatory work
Opening seat
Core activity
(-) Removing leg guard
Requirement
Slipstream deflectors are opened out.
Remove screws (1).

Inside leg guard (2), disengage the locators (arrows) on left and right.

Carefully disengage leg guard (2).
Remove screw (1).

Disengage Bowden cable for stowage-compartment lid (2) from
steering-lock housing (3).
Disconnect plug (4) for the on-board socket.
Affix masking tape to the area around slipstream deflector (5) (arrows).
ATTENTION
Component damage
Carefully lift footplate (6) and remove leg guard (7).
(-) Installing leg guard
Requirement
Slipstream deflectors are opened out.
If necessary, affix masking tape to the area around slipstream deflector

(5).
ATTENTION
Component damage
Carefully lift footplate (6) and insert leg guard (7).

Engage Bowden cable for stowage-compartment lid (2) in Bowden
cable at steering-lock housing (3).
Connect plug for on-board socket (4).
Install screw (1).
Secure leg guard (2) at the locators (arrows).
Install screws (1).
Tightening torques


M6 2 Nm
Tightening torques
M6 2 Nm
Check that luggage compartment latching mechanism is in working

order and remove the adhesive tape.
Finishing work
Closing seat



46 63 004 Replacing cover for stowage-compartment lid, left or right

+ 46 63 507
Core activity
(-) Removing cover for stowage-compartment lid
Open stowage-compartment lid (1)

Remove screws (2).
Remove cover (3).
(-) Installing cover for stowage-compartment lid
Hold cover panel (3) in position.

Install screws (2).
Close stowage-compartment lid (1) until it latches with an audible click.
Finishing work

46 63 006 Replacing centre cover

+ 46 63 512
Preparatory work
Core activity
(-) Removing centre cover
Remove screws (1).

Slide cover (2) to the rear and disengage, noting the retainers
(arrows).
Remove cover (2).
(-) Installing centre cover
Install cover (2), noting the retaining lugs (arrows).

Install screws (1).
Tightening torques
M5 2 Nm
Finishing work

46 63 019 Replacing tail cover, centre section

+ 46 63 982
Preparatory work
Opening seat
Core activity
(-) Removing rear trimmer with rear-light unit
Remove screws (1).
Open the cable ties (arrows) and disconnect plug (1) for the rear light.
Disconnect plug receptacle (2).
Remove screws (3).
Remove rear trimmer with rear light (4).
(-) Removing rear-light unit
Remove screws (1).

Remove rear light (2) from centre rear trimmer (3), noting the locators
(arrows).

(-) Installing rear-light unit
Insert rear light (2) into centre rear trimmer (3), noting the locators
(arrows).
Install screws (1).
Tightening torques
Rear light to rear finisher
M5 x 16, Replace screw 2 Nm
(mechanical)
(-) Installing rear trimmer with rear-light unit
Install rear trimmer with rear light (1).

Install screws (2).
Tightening torques
M5 2 Nm
Connect plug (1) for the rear light and secure.

Secure the wiring harness (arrows).
Install screws (2).
Tightening torques
M5 2 Nm

Finishing work
Closing seat

46 63 030 Replacing windscreen adjuster

+ 46 63 710
Preparatory work
Removing windscreen
Raising windscreen holder
Removing windscreen holder
Removing instrument carrier
Core activity
(-) Removing windscreen adjuster with drive
Disconnect plug (1) for the windscreen adjuster.

Remove screws (2).
Remove windscreen adjuster with drive (3).
(-) Installing windscreen adjuster with drive
Install windscreen adjuster with drive (3) and secure with screws (2).
Tightening torques
Windscreen adjuster to fairing bracket
M6 x 16 8 Nm
encapsulated)
Connect plug (1) for windscreen adjuster (3).
Finishing work
Preparation for initialising/calibrating new parts
Installing windscreen holder

46 63 031 Replacing windscreen

+ 46 63 830
Core activity
(-) Removing windscreen
Remove screws (1) and covers (2), remove windscreen (3).

ATTENTION
Unsuitable windscreen attachment.
Detachment of windscreen.
Install only covers with large holes and the corresponding collared
screws.
if applicable, substitute collared screws for the raised-head screws.
(-) Installing windscreen
ATTENTION
Unsuitable windscreen attachment.
Detachment of windscreen.
Install only covers with large holes and the corresponding collared
screws.
Hold windscreen (3) and cover (2) in position.

Install screws (1).
Tightening torques
Windscreen with cover to windscreen adjuster
Collared screw, M5 x 20,5 5 Nm
Finishing work

46 63 039 Removing/installing windscreen holder

+ 46 63 836
Preparatory work
Removing windscreen
Core activity
(-) Removing windscreen holder
Remove clips (1) on left and right.

Remove pin (2).
Remove windscreen holder (3).
(-) Installing windscreen holder
Clean and lubricate pin (2).
Lubricant
MP 3 paste 07 55 9 062 476
Hold windscreen holder (3) in position.

Install pins (2) and clips (1) on left and right (short pins at front).
Finishing work

46 63 134 Removing/installing or replacing instrument carrier

+ 46 63 847
Preparatory work
Removing windscreen
Core activity
(-) Removing top instrument carrier
Raise windscreen holder (1).

Remove screws (2) and remove top instrument carrier (3).
(-) Installing top instrument carrier
If applicable, raise windscreen holder (1).

Insert top instrument carrier (3) and install screws (2).
Make sure that top instrument carrier (1) is correctly secured by means of the
locators (arrows) to bottom instrument carrier (2).
Finishing work

46 63 144 Removing/installing or replacing footplate, left

+ 46 63 997
Preparatory work
Opening seat
Core activity
(-) Removing left footplate

Remove body-bound rivet (3).
Remove screws (1), (2), (3) and (4).

Remove footplate (5), noting the locator (arrows).
(-) Installing left footplate
Install footplate (5), noting the locators (arrows).

Install screws (1), (2), (3) and (4).
Tightening torques


M5 2 Nm
M6 2 Nm
Install screws (1) and (2)
Tightening torques
M6 2 Nm
Install body-bound rivet (3).
Finishing work
Closing seat

46 63 146 Removing/installing or replacing footplate, right

+ 46 63 998
Preparatory work
Opening seat
Core activity
(-) Removing rear footplate

Remove screws (1), (2), (3) and (4).

Remove footplate (5), noting the locator (arrows).
(-) Installing right footplate
Install footplate (5), noting the locators (arrows).

Install screws (1), (2), (3) and (4).
Tightening torques


M5 2 Nm
M6 2 Nm
Tightening torques
M6 2 Nm
Finishing work
Closing seat

46 63 194 Replacing cover of fuel tank

+ 46 63 984
Preparatory work
Opening seat
Removing hinge for filler cap flap
Core activity
(-) Removing cover for fuel tank
Remove screws (1).

Disengage cover of fuel tank (2), noting the locator (arrow).
Remove screws (1).


Disengage diagnostic socket (1).

Remove fuel filler cap with retaining strap (2).
Disengage cover (3) from the locator (arrow) and raise it slightly.
Remove clip (4) and disengage Bowden cable (5), noting spring (6).
WARNING
Fuel is highly flammable and hazardous to health.
Risk of fire. Health hazard.
Comply with the pertinent safety regulations.
Secure fuel filler cap (2).
(-) Replacing cover of fuel tank
Transfer small parts and filler cap flap latch (1) to the new part.
(-) Installing cover for fuel tank
Remove fuel-tank cap (2).

Secure Bowden cable (5) and spring (6), install clip (4).
Install cover (3), noting the locator (arrow).
Install fuel filler cap with retaining strap (2).
Secure diagnostic socket (1).
Secure cover (2), noting the locator (arrow).

Install screws (1).
Tightening torques
M5 2 Nm

Secure cover (2), noting the locator (arrow).

Install screws (1).
Tightening torques
M5 2 Nm
Finishing work
Installing hinge for filler cap flap
Closing seat

46 63 196 Removing/installing or replacing centre trim panel

+ 46 63 856
Core activity
(-) Removing centre trim panel
Turn ignition/steering lock ring (1) counter-clockwise to release and

remove.
Open stowage-compartment lid (2).
Remove screws (3).
Remove centre trim panel (4).
(-) Installing centre trim panel
Insert centre trim panel (4).

Install screws (3).
Tightening torques
M5 2 Nm
Close stowage-compartment lid (2).

Install ignition/steering lock ring (1) and turn it clockwise to secure.
Finishing work

46 63 198 Replace mount securing fairing to frame

+ 46 63 858
Preparatory work
Opening seat
Removing windscreen
Removing instrument panel with covers
Removing battery
Removing windscreen adjuster with windscreen holder
Removing battery holder
Removing horn
Disengaging pressure modulator with bracket
Disengaging control unit with bracket
Removing voltage regulator

Disengaging ambient-temperature sensor

Disengaging plug for additional power socket
Core activity
(-) Removing fairing bracket from frame
Requirement
Handlebars turned to the left.
Mark wiring harness routing and cut through the cable ties (arrows).
Release the wiring harness.
Remove screws (1) on left and right.


ATTENTION
Hard or sharp-edged components.
Scratches and damage to paintwork.
Use a suitable soft cover or mask off the areas at risk.
Work fairing bracket (3) clear, noting both fork legs (arrows).
Remove fairing bracket (3).
(-) Securing fairing bracket to frame
Requirement
Handlebars turned to the left.
ATTENTION
Hard or sharp-edged components.
Scratches and damage to paintwork.
Use a suitable soft cover or mask off the areas at risk.
Work fairing bracket (3) into position, noting both fork legs (arrows).
Tightening torques
Front panel carrier to frame
M8 x 16 19 Nm
Install screws (1).
Tightening torques
Front panel carrier to frame
M8 x 16 19 Nm

ATTENTION
Electrical wiring not routed in compliance with correct procedure.
Open circuit and chafing.
Carefully route electrical wiring correctly.
Make sure that no lines can chafe or are kinked on installation.
Route the wiring harness on the right side.

Route the wiring harness on the left side.

Finishing work

Securing plug for additional power socket

Securing ambient-temperature sensor
Installing voltage regulator
Securing control unit with bracket
Securing pressure modulator with bracket
Installing horn
Installing battery holder
Installing windscreen adjuster with windscreen holder
Installing instrument panel with covers
Installing left mirror
Installing battery
Closing seat


46 63 212 Replacing headlight carrier

+ 46 63 712
Preparatory work
Removing windscreen
Removing battery
Core activity
(-) Removing headlight from carrier
Remove screws (1), remove headlight (2).
(-) Installing headlight in carrier
Secure headlight (2) with screws (1).

Finishing work
Installing battery

46 63 308 Replacing flip cap for fuel filler cap

+ 46 63 931
Core activity
(-) Removing filler cap flap
Push fuel filler flap (1) to the left and work it forward to disengage
(arrows), noting spring (2).
Remove fuel filler flap (1) from hinge (3).
(-) Installing filler cap flap
Place fuel filler flap (1) in position, inserting spring (2) into the opening
(arrow).
Secure fuel filler flap (1) at hinge (3) and close.
Finishing work

46 63 318 Renewing the cover of the storage compartment

+ 46 63 893
Preparatory work
Opening seat
Removing leg guard
Core activity
(-) Removing storage compartment lid

Screws (1)
Stowage-compartment lid (2)
Spring washer (3)
Pin (4)
Holder (5)
(-) Replacing stowage-compartment lid
Remove screws (1) and remove cover panel (2) from stowage-
compartment lid (3), noting the locators (arrows).
Position cover panel (2) on new stowage-compartment lid (3), noting

the locators (arrows).

Install screws (1).
Tightening torques
Cover to stowage-compartment lid
4 x 14, Screw for plastic 1.5 Nm
Glue the seal to sealing face (4).
(-) Installing storage compartment lid

Holder (5)
Pin (4)
Spring washer (3)
Stowage-compartment lid (2)
Install and tighten screws (1).
Tightening torques
M5 2 Nm
Finishing work

Closing seat

46 63 321 Replacing left or right rear trim panel

+ 46 63 896
Preparatory work
Opening seat
Core activity
(-) Removing left rear trim panel
Remove screws (1).

Work rear trimmer (3) up and remove, noting the locators (arrows).
(-) Installing left rear trim panel
Install rear trim panel (3), noting the locators (arrows).

Install screws (1).
Tightening torques
M5 2 Nm
Finishing work
Closing seat

46 63 330 Replacing side section of panelling on left or right

+ 46 63 897
Preparatory work
Opening seat
Core activity
(-) Removing left side panel
Remove screws (1).

Remove screws (1).

Disengage cover for fuel tank (2) from side panel (3).
ATTENTION
Component damage
Disengage side panel (3) from the locators (arrows) and remove,
noting cover of fuel tank (2).
(-) Installing left side panel
Insert side panel (3) underneath fuel-tank cover (2) and secure, noting
the locators (arrows).
Install screws (1).
Tightening torques
M5 2 Nm

Secure cover of fuel tank (2), noting the locator (arrow).

Install screws (1).
Tightening torques
M5 2 Nm
Finishing work
Closing seat

46 63 343 Replace inner cover for instruments

+ 46 63 907
Preparatory work
Removing instrument panel
Core activity
(-) Removing inboard cover
Remove inboard cover (1), noting the locators (arrows).
(-) Installing inboard cover
Install inboard cover (1), noting the locators (arrows).
Finishing work
Installing instrument panel

46 63 346 Replacing footrest plate, centre left or right

+ 46 63 790
Core activity
(-) Removing left centre footrest plate
Remove footrest plate (1) (noting the locators (arrows)).
(-) Installing left centre footrest plate
Install footrest plate (1), noting the locators (arrows)).
Finishing work

46 63 355 Replacing footrest insert, rear left or right

+ 46 63 994
Core activity
(-) Removing rear left footplate insert and footrest plate

Footrest plate (1), noting the locators (arrows).
Screw (2)
Footplate insert (3)
(-) Installing rear left footplate insert and footrest plate
Install footplate insert (3) and screw (2).
Tightening torques
Footplate insert to carrier
M6 x 16 5 Nm
Finishing work

46 63 356 Replacing footrest plate, front left or right

+ 46 63 993
Core activity
(-) Removing front left footrest plate
Remove footrest plate (1) (noting the locators (arrows)).
(-) Installing front left footrest plate
Finishing work

46 63 357 Replacing footrest insert, centre left or right

+ 46 63 513
Core activity
(-) Removing centre left footplate insert and footrest plate

Screw (2)
(-) Installing centre left footplate insert and footrest plate
Tightening torques
M6 x 16 5 Nm
Finishing work

46 63 358 Replacing footrest insert, front left or right

+ 46 63 514
Core activity
(-) Removing front left footplate insert and footrest plate

Screw (2)
(-) Installing front left footplate insert and footrest plate
Tightening torques
M6 x 16 5 Nm
Finishing work

46 63 359 Replacing left top side panel

+ 46 63 515
Core activity
(-) Removing top left fairing side panel
Open stowage-compartment lid (1).

Remove screws (2).
Remove screw (1).

Remove top side panel (2), noting the locators (arrows).
(-) Installing BMW badge

Clean and degrease the gluing face.
Affix the badge, making sure it is correctly aligned.
Technical data
Hold-down time for at room approx. 5 s
bonding temperature
(-) Installing top left side panel
Install top side panel (2), noting the locators (arrows).

Install screw (1).

Install screws (2).

Close stowage-compartment lid (1).
Finishing work

46 63 392 Replacing handlebar cover, bottom

+ 46 63 510
Preparatory work
Core activity
(-) Removing bottom handlebar cover
Remove screws (1) and remove handlebar cover (2).
(-) Installing bottom handlebar cover
Secure handlebar cover (2) with screws (1).
Tightening torques
M5 2 Nm
Finishing work

46 63 398 Replacing handlebar top cover

+ 46 63 562
Preparatory work
Core activity
(-) Removing top handlebar cover
Remove screws (1).

Remove handlebar cover (2), noting the locators (arrows).
(-) Installing top handlebar cover
ATTENTION
Kinking and chafing, lines and Bowden cables not routed in
compliance with correct procedure.
Malfunction
Make sure that routing and securing of the lines and Bowden cables
are correct.
Install handlebar cover (2), noting the locators (arrows).

Install screws (1).
Tightening torques
M5 2 Nm
Finishing work

51 16 041 Replace mirror glass

+ 51 16 541
Core activity
(-) Removing mirror glass
Without using tools, disengage mirror glass (1) from the ball head
(arrow) and remove.
(-) Installing mirror glass
ATTENTION
Lubricated rubber mounts or detent pins.
Mirror can disengage too easily from the mounting.
Do not lubricate rubber mount and detent pin.
Install mirror glass (1), making sure that it latches securely on the ball
head (arrow).
Finishing work

62 11 199 Replacing instrument cluster (without (testing software/programming)

+ 62 11 510
NOTICE
Do not, under any circumstances temporarily install control units from
other vehicles by way of testing.
The possible consequences include:
Coding data could be overwritten.
The control units could malfunction.
NOTICE
Before removal, test the control unit with the BMW Motorrad diagnostic
system and make a backup copy of the data.
Preparatory work
Removing bottom instrument carrier
Core activity
(-) Removing instrument panel
Disengage inner trim (1) from the locators (arrows) and remove
instrument panel (2).
(-) Installing instrument panel
Secure instrument panel (2) in inner cover (1), noting the locators
(arrows).
Finishing work
Installing bottom instrument carrier

=> Testing software (Description in item: 61 00 502,

Billed as a separate item)
=> Programming control units of vehicle (along with

testing software) (Description in item: 61 00 510, Billed
as a separate item)

62 11 205 Replace lens for instrument cluster

+ 62 11 505
Preparatory work
Removing instrument panel
Core activity
(-) Removing cover for instrument panel

Screws (1)
Cover (2)
Seal (3)
(-) Installing cover for instrument panel
Check seal (3); replace if necessary.

Install seal (3).
Secure cover (2) with screws (1).
Tightening torques
Glass cover for instrument panel
Screw for plastic, 2.5 x 13 0.3 Nm
Finishing work
Installing instrument panel

63 12 000 Adjust headlight

+ 63 12 500
Core activity
(-) Checking setting for low-beam headlight
Position the Maxi Scooter on a smooth, level surface.

Set the spring preload to the basic setting.
Apply the rider's weight to the Maxi Scooter.
Start the engine and check that the headlight setting.
Check
Distances:
(a): Distance between headlight and vertical surface
(b): Height of centre of headlight
(c): Distance to light/dark cut-off
Check the setting of beam throw.
Technical data
Distance between 5m
headlight and vertical
surface
For headlight
adjustment
Distance between Vehicle loaded 7.5 cm
light/dark cut-off and with 85 kg
mark at height of
centre of headlight
Result:
Setting for low-beam headlight not correct.
Measure:
Adjust the headlight setting (beam throw).

Correcting headlight beam angle
Correct beam throw for the low-beam headlight by turning right adjusting screw
(1).
If necessary, the beam throw of the high-beam headlight can be corrected by
turning left adjusting screw (2).
Finishing work

63 12 091 Replacing headlight

+ 63 12 637
Preparatory work
Removing battery
Removing windscreen
Core activity
(-) Removing headlight from carrier
Remove screws (1), remove headlight (2).
(-) Installing headlight in carrier
Secure headlight (2) with screws (1).

Finishing work
Installing battery

63 13 012 Renewing complete front left or right flashing turn indicator

+ 63 13 501
Preparatory work
Removing battery
Removing mirror glass
Removing backing plate
Core activity
(-) Removing LED flashing turn indicators
Turn the mirror base (arrow) until screw (2) is visible and remove screw
(2).
Remove cover (3), noting the locators (arrows).
Unpin plug (4) with unlatching tool (No. 61 0 326).
Remove LED flashing turn indicator (5) with cable.
(-) Installing LED turn indicators
Insert LED flashing turn indicator (5), routing the cable through mirror
base (1).
Pin the cable into plug (4):
Wire colour white or brown into slot 1
Wire colour blue or green into slot 2
Install cover (3), noting the locators (arrows).
Install screw (2).
Turn back mirror base (1).
Finishing work
Installing backing plate
Installing mirror glass
Installing battery

63 21 380 Removing and installing or replacing complete rear light

+ 63 21 502
Preparatory work
Opening seat
Core activity
(-) Removing rear-light unit
Remove screws (1).

Remove rear light (2) from centre rear trimmer (3), noting the locators
(arrows).
(-) Installing rear-light unit
Insert rear light (2) into centre rear trimmer (3), noting the locators
(arrows).
Install screws (1).
Tightening torques
Rear light to rear finisher
M5 x 16, Replace screw 2 Nm
(mechanical)
Finishing work
Closing seat

65 81 050 Replacing ambient-temperature sensor

+ 65 81 550
Core activity
(-) Removing ambient-temperature sensor
Disconnect plug (1) and disengage ambient-temperature sensor (2)

from the holder (arrow).
(-) Installing ambient-temperature sensor
Connect plug (1) and secure ambient-temperature sensor (2) in the

holder (arrow).
Finishing work

BMW - C650GT Manual13-15

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C650GT

BMW-Motorrad - 0133 - C 650 GT, K19

Technical data 0133 - C 650 GT

00 - General maintenance and construction groups

Designation Precondition Value Valid

BMW Motorrad, UX-VA-4 1/1

Technical data 0133 - C 650 GT

Designation Precondition Value Valid

Engine oil, quantity for topping up Difference between max 0.5 l

BMW Motorrad, UX-VA-4 1/3

Identifier for crankshaft-bearing 1 Bearing shell red

Mark for classification of the Mark I (inside): 1/2/3

11 24 - Conrod with bearings

B Production date, month

Identifier for balancing-shaft bearing 1 Bearing shell blue/yellow

Identifier for balancing-shaft bearing A Bearing shell blue/yellow

Mark for classification of the Marks on the balancing A/B

BMW Motorrad, UX-VA-4 2/3

11 34 - Valves with springs

Exhaust valve clearance Engine cold max 35 °C 0.28 +0.04 mm

- at engine 4.5 +1.5 bar

BMW Motorrad, UX-VA-4 3/3

Technical data 0133 - C 650 GT

12 - Engine electrical system

Designation Precondition Value Valid

BMW Motorrad, UX-VA-4 1/1

Technical data 0133 - C 650 GT

13 - Fuel preparation and control

Designation Precondition Value Valid

BMW Motorrad, UX-VA-4 1/1

Technical data 0133 - C 650 GT

Designation Precondition Value Valid

BMW Motorrad, UX-VA-4 1/1

Technical data 0133 - C 650 GT

Designation Precondition Value Valid

Coolant capacity (total) 1.5 l

Coolant, frost protection min −30 °C

BMW Motorrad, UX-VA-4 1/1

Technical data 0133 - C 650 GT

Designation Precondition Value Valid

BMW Motorrad, UX-VA-4 1/1

Technical data 0133 - C 650 GT

Designation Precondition Value Valid

BMW Motorrad, UX-VA-4 1/1

Technical data 0133 - C 650 GT

Designation Precondition Value Valid

BMW Motorrad, UX-VA-4 1/1

Technical data 0133 - C 650 GT

31 - Front axle, front-wheel steering

Designation Precondition Value Valid

BMW Motorrad, UX-VA-4 1/1

Technical data 0133 - C 650 GT

Designation Precondition Value Valid

BMW Motorrad, UX-VA-4 1/1

Technical data 0133 - C 650 GT

33 - Rear axle, rear-wheel drive and rear-wheel guidance

Designation Precondition Value Valid

BMW Motorrad, UX-VA-4 1/1