1111 12 13 16

'18, ;21 2,3,

26 31 32 33 34

36 46 ,51

52 61

63

page

MiaintenanCle and g,enera~ hints I ntroductlon

Engine

IEng i ne'·E~ectrilca~ Fuellsupply and adjustm,ent,s Fuell tan'k land Uln,es,

Exh.aus,t sys,te'm

Cllll.nchl

Drive :sha,ft Front 'fo,rlk St.eeriing

rear whee~ drive

Op ..... a.{1 00-0/3 '1'1 -0/1 12 -D'l1

113 OJ1

Hl, 011

18,-m1 211- OJ1 ,23,-.0/11 26-0'/1 31-0111 ,32:'~IOt'

33 0'/1

34 011

35 .0/1

Tr,a.nsmi~s.siilon

- - ' . - -

P'led,al, ,ass,emblly Wheeh~ and lyres Fr,ame

36,-0/1 46-01'1 51' ,-on

52, 011

611 0111

'62, 01'1

63 ":",0/1 -

Equipment.

Genera~ slectrlce Instruments Ughts,

S,ervice and 'General lnformatlon

II ntro (lh.ldioln • • ,. • " . • • .' • .' '. • '. • •• • • • .' • '. • • ., • a, , "' ,0 ., '. • '. • " "' co "' co "' co "' • ., ,. • co • • ., ••• P,a,ge 00 - Ol 3:

Ti[,h'~en h'il9 tom'lqu e ,ICC" B MIWalmld D'I N s;t,alnd~:s,., ,0 • • • ,0 co • • " • co • co • • " • • • • '. "' '. • • • • • • • , ..' OO~ 0/ 5,

Titgh~elfbl~i"Ig tOlr'Qtl>ll! ~u nUl!1;!lry for R 80 ,e; IS. .. . " . " . " . " , . . . . . .' co • • ., co • '. • • • • • • • • • • • • •• 00- fJl .,

Bo Its allild nuts, DUlt/J standard ,and classes. • . • , • 0 ,. • • • • • • • " • • , • 0 0 " • • • • " " • " • • • • • '. • .'. 00,- 01 :9 CO!i!Versi,o,1iII C1lnd Ico:mparison chalrt olf 'stalndard Ullillitsof dimensioniing .,. 0, ,. 0, , •• , ,0 • 0 ., ••••••• 00,- ,eVUJ Engiine oi'llfue,1 00 nsumlPtjoll1l1 - deteirmin~ng •.•.•.•.•.•.•••. , •.•.• o. 0 •• , ,0 0 " ., 0 ••• , 0 .,. 00- ,on 1 IEngine ,oil viscosiity diiaglram .• , .• ' .. ' .. " . ' ..•. "' .• ,. " ••• ' •• " ••••••••••••••• , ,0 ., , ••• , •• , 0 00- 01/112

,Engine oil c:ilr'QUit "! OIl,!, II! II!! t If! 'Ii It! 'Ii II ,i ~ 'Ii i Iii i Iii i t6i i iii • iii •• , ••• ,01 • '!' ! !!' ~ I' I! '!' I! !to II 'II I IE I Ii- i It! I' Iti I of; .' I. i' If! I'iti 100= 101/11:3

BMW 'sp eciial tcels, co • "' 0 " • "' co .' • .' " • " • " • • • • • • • • • • ,. • 0 " • '" • " • "' • "' • " • • • • • " • • .' • • • .' • .'. 00- 0/14

G,enera lteeh niCiliI daita. 0 " ,0 0, • • " "' " • '. • " • " • • • • • .' • • • "0 ., • • 0 , 0 ., • , • ., • "' • " • " • "' • " • • "' " "''' 00- (J1/J5

00 00 0091 IFwee dellti~ery i nsp,ection . . . ., .. ". .. . .. . • . .. " " . • 0 • 0 ., ,0 , .0 • • ., •• ,. •• • • • • •• • • •• IiJO-lJO! ~I

11191 h~ i nspecdo nat 1 000 Ilk m (6100 m m.) • • • • .' • , '. • " • • • • " 0 • • •• " • " • " • • • • • " •• ICIO-oot11l1 .~ 39 IBMW :S€!wvice Ibeg'inning at 7600 Ikm (,SODO mt) , ' •••... ,. ' •••••••••••••••••• OC!l~/23

1,4'91 BIMW insp!E!Ction Ibegl'illi1lnilng at 15000 km 1(10000 mt) .. ' .....• ' ..... , ...•.•.• OO-COl311

1'99' E.ngine inspec'tion aftl!rUlOO km 111600 ml.] •••• " 0 •••• 0,' • " • " • " • " ••••••••••••• 00-00/45

---- - - ---- - -

_"-~-I

11-- --- , _-- I

, -_' ---

---- -----

IL'C_J 1 "~l -=-_'I II

-------

00-011

Illnt:r,oduct,iionl

This r€i~ai,r rna nualon mi:CfQfmm w'illll 1~'N;!~lp to mSlkeSil! re that a II ,of t~,e most limpor~a f'll fe,pa i,r Oil nd service p:fO cedu res aJre carried O:lJIIt conrectiy. I:w: :s!nloulfl be lUi sed h!eryda,y li:lvsl1,op f"Oiremen Bind mechal' nks to sUlp.p'iement the ipract:k:a~ and 'ti~eoli1eUca~1 kJ~o~i'ld,edge' whi,ch~hev have .;!icqumwed ~n eurssrviee u,al~ning school. This wiU &\Ilf.l:n fUlnhew improiV\e! the' quaUty of serviee,

T!rJJ~sed i;t~on win be Ir,ep l,a(led wheirhl ,eha ngeso;r aOid i'~ iQ~'s(sl:lpp I,emenn) are neces$alry. IBoth t~,e hea cJ i figs alnd~l1i'ne JleFtine!fIIl~. Usts e,m COrlli1!elfll:iI:S wH~ liJ'alve the new 'edit.ioiflll da1ltE!'. Old mih::lrD~ilm:!l sheuldbe destroyed,.

Alii I pi~ctJulres and~ex,t:i Ire~~r~:o' ,iii motlorcy:d!e w~it~h stancilalF'lJI Of 'Qflugi naJ ~ 18 MW equ ipmem a ndacce:ssorrmes, and net 11:0 mOI~orcy,cllles ,convertedi I'iI some marmer or ether,

• lhe lit'!anu'all~ h!;Jlstli'ne Si1llm,e 9lroUlPsystlfl,m (00 . '. . '6,3 )as usedinfl:at ral~e :cat:al~ ogs.

• l~ih3'.a:n~lrngi ef pag;e l'lllIJim'ilelr'inQscyS1l:erm: ,e.g.

3,3 10

rl--------.~-\-S.~I"'b· .... ~._ .. 'lri~! .. ,In .. ~1

I Main 'gl~OI!iJP' 1 ... ' :tl ..... rc-

I

• ~I n ao:ditlh:m to' othe,r ~mp!o!1:a nit i:nfo,rm arUon. the necessary BMIW speci.alll 11:00 Is arel descri bed a nJd UiustJlood in 'GnJ!lJ!lp 00. Ilheir >alppUcath:mis (tes,cribed in repair 10:0 texts •

• ! Norma Uy a j,ob '!.ext w ill descrr~be the Irem,ova I ,olr d~salsse.mbl y procedu res, Thereare ap\plrolPria1.1e i nsta IIa1l: ion l1Iotleswtitl:en assembilly or i nsta II atkliill c81rillnOit be loomp I'et'ed in 'revene sequ,enoe,

R~palir ~nst.ruc~.ions; wiH also be plublished in ISE'Ni.ce i:n~o'r:matkm bulletins if neceSSiiPY. They win, ef CO!UiI"Se, be inu::b:J!ed in W:liie ne,xt ,edifliion ,of the microfilm. Wie also r,ecommell1d using Uile span~ part m~lc!'ofUms For adldi1l:iona I help,.

lalMW Nbtron',ad GmbH '& Co .e Service D~v:iskHii

f!l,libliiilruilr: BMW IMO:~O:~iI'.1d! G m:bH &: Co.

T rieb$tllf(;lI~' 32 BOOO MlJl1itch 50

All r.ijgh'tS ~'es~vedl.. Aeprrn'ts, 'translafiQi'iliS Q:r rJeipr<ujuctiOlrn;s" ,a~eln '~xtr.iilcti,ons" IreqJWlliuiI' wriUen 'cO:r:lj~,nt Q~'lhtl, ptltbl isher.

SUllb,ieo~: to printed errers <lii'l;d EHflgi'n.ee:ril'il,g cI1N3i~"tges. IPr:v!'!1ied ilm, WestEiln"l Germ:any

t

! II

:Eng~ne

ty I i ndeir heard n~ts (in 3s1e~s: 15/215135, N ml COIn! rod! bolts

Clutch housing 'l:nyowheeH

Nlu1l: em va Ive adjlulSil:i n9 $Cpew Adapter f,or calrbu:retor eon necdo n

IN 1'1 315+4 50 :12 11100 + 5, 20 ±.2 60

ft,llbs. 2'!J, + 3 36:!: '~ 7:2 +4 114 i ~ 36

IE nghle IE Ilectiriea~1 IE!quiipiMeniil::

Mou 1111[1 111;9 bo!~tf'Dral~temallo r rotor S(parik: plugs

25!: 2 20+5

11a:±'~ ~4 i" 4

leLxll1alutStSiy,slte!1ll

Sp[de,r n uts mOil" e:xhau S1I:: 1P!~p sa

:200 + 20

'Oll!l~cliil

Ch:I1Joh hOll.l,si ng cO'V~r

20 + 2'

Ma!MI~.~ 'flmns'rniss:iolfll lrarrllislJiliis~ion to ,e!l1g:ine

Oanmrh!:::" .

Ou~plllif ~iiange 'ltD, itlr,an:smi~ssj,cllnr Ol.l'~~:UJ1I1 shan iransmissilOlni 'COVEllr te il:lI"i'.In!im~ssion CSifie Nu~ I{wedg:e bo~id on kick sta rt li~er

Oilfi II~ew p Ilug

Oil dlr,a~n plug

33 UiJ 22'1.'0

,S

22 .. 5 31 2fi

24 ~4 1601

,6,

~'B,

:22 1'9'

IP:rOipe~lle:r ·Shaft Twelve-sidled head bohs

Frol'1ltWlrrleel fork

IFork:. 1b1li~c1ge mount;!ng bolts

Aiboorber mountJng 100111:5 ~n5liicile 1iuIJe ,Axile mol:.! nt~rng: bolts

Upl1e,f SliISlleif1!ision mOL:! nt

Omfmer pl~'UlgS

O~I~ d rai n pl.ugs

4(1, 35 114+2

1210 :9 ,8,

291 25 '101+ 1 87

,6,$

5;

S'mer~liiIg

'SW!errilrr!91 mount: 1Ci:!'!) nut :Si~oned Inuit

1210

withoU11: Iplay

87

1iO.61

00 ~,fJJ7

IRear Wheell Il}r~we! W!ltlii! :!iwl!ngh19IAfl'! INlut 0 n d rive pirn~io,"

lhread!ed ri fII,gi nf~ina I dlri~ve hmjls~ing lNjumsfor~i filIalil d riv,e housilnl,g COllller

OU I,ev,elll i rn~pecti,olliJl pi uQ on 1inal~ drive 1~lousi ng OU draiin IprnUQI ,orillf. na I dWmV8' hOlliJlsi ng

Sih,aft boiltf'Or rea r wheel !s.w~ng i.ng arm

lLiock nut fOlr w,ear wheal sw,ilfll,gilrngl ,arm s~aft bo It OU flller 'Il IUig (I I'l r,ear wheel swi.ngmngl arm

Oi I draiiln Ipl~ugl en realf wl1eel sw~lIi1glhlg ann 5;il,001<: absorbew r'Dci to Sll rilnlgS1l1'ut e'y,e MOl!li1lting In:u:t:s fftiVe:~ve~siaecJ) ~o,r ~imalll cilriv,e hO'~is~ng 11;0' rear whee'! :swi'nging alrm

.siPri ng stlwt mou nt~ngl bG~tsl

NI!1l! 11165 1'18

17,.7 10 2!5,.5 10 + 2

1100'" 20 jflilrrl!gerti~hrri: 1!5.1

15

65 43+5,

Blr.akes,

Bral!ie Ilih'l!:e to brake ma5il:er cy.II~Iru:ilew 8:raik,e ~I~ me 'to bralk,e ca I ipe~

Brallf;:'EI Illine m bra Ike hose

:8 + 2 :s +2 12+3

'Wheelis illiildlTiires:

.F rlctlon 'toir'qltlllE! olf wh~1 bel1lri GiIjQ wi,th spec::ifired tigih1leni!'!liQ 'tlolf(Jue for front w:heel~ a.x:!h~' nun

F rent wi~,eel st!l.!b axile nUll:

1F!:earwinee!, 111 uts

0.115, ••• 0.30 44+3

85

frame

f'rame rears;ection ;molJllllrillitting belts Kick S1I:allrild mO:!IJ,n1l:Iillrngl boilits

Si,pring stnrlt, ,moIUlri't~11ril,9 bol~ts

22+2 4,3 +~ 43+5

ft.llbs. ~ 19 s,!J 13

'7

1:8

'7 +- '~I 12 ... 114

11JJ 111

47

31 + A\

'6 +~ '0 w~ 9+:2'

0.1 ..... 0.:;2 32-+,2 61

u:;+·~ 31+4 ,31 +·4

10.£11

\

E,lngliilne Olil 'Viiscosi'ty' IOiaglr,a,mm Depending on Outsiid~ Temperatura

.,

I::

I I I

-20

I'

II

I I

- .... , I'" II

II

III

~~Qi

!: III

~ ,""n

II ~

! I i o

I

'10

I

I:

60

I

II

I

I

I

II

SA E. 10 'W ·30

II

Appliicatiion:

Brand lnIall'li:e hea.vy dUity om!!! o'f ,AP'I rGlSiS$ lf~cath:m SE Qlr SF for i ntlernal~ oombilll'stion ,engli,nes"

----- - - - - ----

_-~'

- -

11- --I

'-- .'~--- ------

fl__o 1= J -] ,_~l --, l - - II

-------'

1) Oii~ ilfill~~ I~UI II'!! ~ilp'!l1i] 2~ A~;se'r bOi1e '~O ,0il[1 pump

3) E:atc:m@liilpump

4) m!!~nib!.!itfion IPWI~$~lU'~ Ibore to mtc:r,o oilll fUter

5) Fii,herilli'l!!ll of .oil 'from oli.l1side to inside th'~w;ghHllwr

ca!1l!tdge

6) Bypass valw ~ dinml: flow with clo~£Jed fiher

7) M ainplr,eS~li.Ife bOf!E!

:EI)Aifiillflul,af b.ore i!l"ll CiilliiIl:s.tn 3~t '~laIU1ige

(2.15 rnm dial. boil's fer ,eill:rn~hcarft Ill!.! bric~tlug:r1111 9~ Pr!re.rfsuf'e bore' to, cranksh;aI~1: beari'll'liil ca,ps

'Ilu brl(l~lti,ofll of 'flrrll1l:t ,clttanblmlaf~ thrust Oearill1il:gl! '11 0) AJIi:III'!u~!![!r borefo:u crankshaft ben!ril'l!li~ l1I!J1d $.llifety valve n1~'

~ 1} Plt¢sS,>i,ilre, saf,ety vahle ~,opelns above 15 bar)1

112:1 F rent crankshaft bea'l!ungshe'lll wiMi'iJ o~tl~t$ to' rig'l1!rt. ('13) and l~eft. (14) cylin,dt=r tnill~di

1i:n IB,gr'E:;to I~]gh't c.y IlilirldelF head

~:~u!bri:cation ,of' mckslit OIrn!fl lbearill'llt9!! a ~d v~l¥e s,t~m$) 14!~' IB·g~,£!ro I~eft: ~y~,i~dl!r lii!eOid!

(11!u'Drtc3Itiol1ll olf MckE!irr' arrn ib.eariill\!)s :al1!dll'!ll~ $.:ooms) ~ 511 ,B.Oil'lI i~c,a;ll'd!;$haft:;to Ille'ft: o~nl~Qd 'beariliil,g

~ 6,~8(ME: ,10 Q~illpl~essu re switahand r,ealr It;r.llnlk~haH tt!1n.!$1!:

bearilliil!!li

~ 7~B:o(~:e incr,al'lkshaft~or.ighlt conrad bel1uil191 18~ O~I Pfllll~U rl!fiwit:ch

tEl) !QiI retu m ing via IPush rod liu bes to oU Pi!" :~O) (:ir~n'l«:iI$e VElUM ~jI'al\le

211 ~ Stab]1 iz~ng ehamber fe,r cran'kc;'Ise v'ent

2:2) IRelftj m bore il'!ll slabil.izing '~h,am beJr (1.5 rnrn d~iiI.,~1

1o.Bl1

\

BIMW Sp,ecial'Toolls

AU om the IB MW ~ecia I too Is~ wh leh are Ireql!IJ,ired mor eorrect ~selli'v;~ci ng a I'1Id repaifilrngl o,f 1tt1~e R 80 G is" are i IlustJr,aJtled aind dlescrilbed OI!1lIU h;efoll'owi fig pa;ges.,

A'ii members: of' i1t1he BMW Dlea~er Organ izalil:ioli1 ,cain ordell" the ~$i;pech:ll tools diilrectfrom the manluf,acl' turer,

CA RTOO l. Hla 1"16 :Schub ern A.lmt'led~Blreh m~StralrJ<E! 5, 8070 II ngo.l$~ad'u:

f'et; 08,411 16902:8

Oeal~lers in export eountrles normaUy send theilf erder:s: te the' B MIW I~ m:porter resp'olillsi b Ie 'for 'them. I n,Slr;I,eoh\:!iI, cases erders ,cou ~Id hese !'lilt d;ir,ect to

BMW' Mio1torrad GmbH &: (:0. De:pt. BIM·K,~2

I t is u nfo.rru.f'N3i1:,ely mot possible 11:0 ~sUip,pllly eusterners a nd pe(rSOlrills. whJo do not belong ;j;.0 the' 18 MW Dei3li,er Qrgalillizat:i~on, wmth 6M1Ws:pec'ial :trml:st.

OO-,O/l4

hnpact !II!lil,ndl'if!11

to kn,ock in wheel bearingl outer races Order INc. DO 5 51010

IIJ nh,iierSiOll puWller IK.Uli!c ke '111 te,

'W, pU!jl~ baJili bear~ng off of :i'nilput :S'~aif1!: ,!'malnu,ilIl!lltr,i!l!nsmission~ as weU-as, install, elrcllp in oollnljufil:ct.km wiltll'l assern b 1"1 51 eeves IN!o,. 23 2: 655/1 ~4 a nd Jnes~u re pad i'l'ld uded with Ku klk,o 116,fK

Olrde;r Nlo. 00 1 !!JOO

Internall puner (wiith adap,IerJ'

to, pu III II out whee:11 bearing outer races (Ira ,conjum:ti,on 'W ith support from. 00 8 560)

Order lNio. 00 B 551

'to P'U'~IIDut swing~n1,gl srm bealrbllg (in oolnl:junction wi'dl1 s~IP:Pclolrtfrom 00' 856(1)

Orlde,1" No. Ifr(ruk ko2113

IKuk1ko, IpllI!Ill'er

to Pili 111'1 bead ng shellsout ,of 00 ntrol Iii ead Ord'er IN 0'. 00 8; 5eO

001,8560 00 ~o./1,7

10.81

110600

1'111 SSG

" 1680

111890

GlfiOUlpl 11

H'olldelF

,(foIl" assembly stand 001 41901,

to, ta ka 'eng i ne or manuadl 'tran:smissi 0 nfnr dmsaJsS9m~ b~ i ng a nd eUiSle:mlbl~ i ng

Ord er iNo. 't 1 (I 600

IF j·xllire'

ittCl' I~o,oseinl ,sind tig,Mlen IPr'es:su Fe neUe,f vllve in ma i n bearblg cap

Oraler No. '11 1 1560

Adaptetfor Kuklk:o '17/K.

to, PIII,.IlI1 ma,in beai'in.g Call' on of front of ,engi.ne U iii conj lUI 11"1 etl on wi1lih bridge' fro m Il<.u kko 1 7/K)

Order Nlo,. 111 1 680

PreiSSliillre'lpad

to bel r pressu re :spffindlle ,of un iv,ersa,i ipU Uer K uk leo 1 7'1K when puilling off main bea:r'in,g cap on crankshaft

.order INlo,. 11 1: 6'90

00-0118

10.81

I

V'alive splriilflQI II~fter

to remove ,illing ~~lstaIU v,allve~ ,of a d~sa,S'sembllecl ey ~i nder he~c.i

Order IN Or. 111 1 '7~O

Malfldre!l~

to kl!llock 'out va I\le glu rdesfrom ICy ll rider head (8 mm va Ille Site:m d i ~.,)

QrdI~~r No. 111 780

,Mandrel

to knock va Ive Igu ~desi nllO, cY'~~'~der head Order No. ~ 1 ~ 7'90

P\UI~~e:r

to pullan ;I; i m i ng ciha.in ease cover Olfde r No., 11 '1 800

10: .. 11

1i1 iI ?50

111 '1l710

11'1 iI 790

111 8S0

n 1 8'80

--~

111 B90

1112600

I mpact mandrel,

to instaH radial oil seal in timing chain case Clover ~a lternater :sea I·~

Order No.1! 1 1 :B!JO

IllMp'act ma !'!Idlre~1

to install clutch hO'iJlsiilllQI end Iradial oilseall of crankshaft (in OOlrnjunct[on with 111 1 890)

Order No. 11i ;, 880

flU II-oult!puslil-illi'l 'tiD 011

fa,r mmcvall and installation of clutlch hourslinglend rad ~a~ '0 i I se~11 on era nks:lhIs'ft Un ccmjllQ nd ion with 11 1880)

Olrde'r N,o .11 1 .BS a

PlI!IlIlell'

to pull off timingllchain sprocklat 'C'1iI ,crankshaft. Shell \i'iJ"iil:hgroove (dupl'ElJX chain) is replaced by aluxi!i.alry she,ll 11 2'606 (folr simpillex. chatn).

Ord'er No, .. 11 :2 6001

112620

~----~~~-------------------

AuxiW!iaJr;jl'slile,111

to puU .off sprocket 'on crankshaft (simplex cliain)

Order Nlc'_ 1'~ :2 606

IPr-essH)1I'I bush

'to press sprocket on to era mI kshatt (ii n CiOlIi1I,j u rtetien with 11 2 163fJ).

Order N'Q,. ,! 1 2: 6201

Pressiing' ,on tool

to press sprocket on to crankshaft Order N:o _ 1 11 :2 ,63{1

11 ,2630

Press,j:l'11;g mand re I

to PI'l9!SS out main bearill'1;Q!s tin eonluaetlen with

1'1 2: 7HU -

Order No,,, u ,2: 700

111 2700

10.81

.'

J

11 2,720

112800

,-:~

,',~>'L,,'" '~ """Clr

',,'

",

,A;ss8Imbly tocO I

to, press mil1l,~U1!i be<a,ri ngs in 8ni1d out ef e'rl,ghlEli block Order NI('.I.11 :2 711<0'

"ressilngl mBrl1ldlrel

te piress ma i n 'beiillr~i'lliligs 'for cranlk shaft. ~lmlliO e:rI1lgl~lriI,e block OrderNiQ. 1: 12 720

lHIolch~ir

to Inol,c1c;llU.1ch hO'l.l1s~ing' (flywheel) when IOOISEH"lI'iIfilQ:ilIlrIlld tig!hte'rl1l i,rlg rnou nNng] bQ!~ts

Oir-der No.1 U :2 ,800

'o~ygoln he;ad wrerilclh

to loesen and tigihtelrlll 00 nrod bolts Order No. 1'~ :2 fM50

IP~s1:o1'i1 IfWn9100mp.l'iess!O.r

1:)0 compress p is,tolFll rings wlh en 9iti,lldmngl p lsrcns ~;mo cyUndeJs

lOw-dew No. 11 2' 905

/

Man.drell

to If.< neck out p iston pins Orde,r No., lW 2' 9!2![)

O~ I pre!s:!ll!llr,e testetr

m meaJSiliJfe '0 II p resSiU re of rliJlI'mJrn i riLQI e~lgliine in .a stat 10- Irrllaryor movin;g motoIH'~

Orrdler No. 111 4 0

11. ,2905

112920

Bro'llJp,a

p.re:SSilflg'O'~~ho~t

to p.reSi) off .al~tlernatoir rotor Oro er No,. 1123 eoo

IIgl'lli1l:Iiolfiti m i ngl test'er

fair gt:a:UCi.lI~1 tssti n9 of 19 ni1l:i(m~i m i ng a ndeheck i"9 function 01 Tel iglni:tiolliil box

Order No,. 1.2 3 6;50

SYl'!cih~on,i'Z!el!'

f,or sy.n.oh !ron iz i ng csrbu rete rs Order No .13 0 700

OO·~·O.i.24

Gro:u'p "8

Exhaust wlflene!h

'to' illoosen andl tigh,ten exhaust pipe nuts Order INiol. 1:8 0 BOO

Centerilngl mandn:d

to center cllutch dirj,l;i'j1l pilate Order IrMa. 21 2 1660

'80600

-

._ ..... '

,

- -- - - - - - --- -

_-~_I -

II, - __ __- -== I

----- -_--

L'i~J-:1 ,_~[ ~I - II

--------

1(Ull

212610

.1830

Pl~ess:i ng·,off too,l

no presstra nsrn wssi:orll carver off Order N (I. 23 1f530

I mpa~1:· lllIillfidif'ell SI!i1ili s~eeve

to knoekl n nu:Ha I oil seal II; of ~ilri!,pu'l;siil!i91fi1:

Order Nlo. 23, 1 660

)

,.......-----~~------~--....,~ Ho,lde:r aln:d pu~~eir

to remove! ~lran'5m iss[o n outp ut flalliilg:e Ol'ldeir No .. :23 1 700/7 ~I 0

23 ,. 700./71.0

Impact too,ll

110 :lknock ~n radii iill I oi II sea I ef tra nsm i sslon cover Orde,r No. 23 1 760

Speci;al p,u'elfi

for rem ova lafcilrcl~ ipo nspdrnglstlfut (GroljifJ' 33)

Order INo. 23 2 lOO

~3 ·2100

.A:ssel1 bWysilehes

for removal and ~ns.t.anatiiion o,f ,okcUp eni nputstlla~t (presS!JJ1'I9s:I'9ie\i!"E! om ittiecl)

Order IN (I, 23 2 1650

PreSSllitre sleeve

fOlr re:moval~! a 1iiI:d lnsta lIarti,o,~ of ci~ol i p on iniP~lt shawl

Un 'DQnjUIiiI~ion with :2'32' 6,SO) . .

Order No .. 23 :2 6,s!S

Maister g:aiuge

to space'~ra:nsm iss IIQ n shaft when agsembl~ i f'IIg tra nsmiSiSkm

Order :rNJ o. 23 3: 16~O

1 I I

II

2611 7DlJ

.' .. ~

~j

. fl ..

31 46€Hl

a~-Olaf!

GrDLIF 26 ~~ . p

As~emlb!ly fixture

fo'r remova~ arlid ~nst:aIIII;;;!1tion ef tors~on damper on propeilile r shah

Olrd~er No., 2161 jl,[)O

!CUi!M!PS fiorf,Qlrk: '1iube

"1:0, clamp front wheel~ork for d i'[;1Issem b Iya ~d >8isslllmbly

Ordler No .e .31 4 160·[1

StJee~r'UlI~ers:

to check fork tubesfcr deviation 'flmiM palraU,el Ol'!der N,o. 311 4 16:20

,I, mpiillot mn:alndre'l

te kneek seal s mlll'il:ofio!rk 'slide ,til! bes '(u pped Ordl9<r N,o. J~ ~ '6,50

AS5e!flliIbl V s~eeve

tiO com pre~ pi dO n rmngls 'fa rinSil:a llati 0 f'I of c.om p lete de mper iin stilind itJube:

o rder N(.I. 31 4 7.20

IC:CHlp,1 ~filgi nill'n;!lI

toen la~ge' SUllpport ar'esl for plI!Jm ng out steering head bearing

Order INo. :n 4,800

Spl,oor

to P:1lJ,U in stesri ng hea d beillf~ng (i n conjl!lJllnC'~ioll'1 wwth s:phldll~e of frame g,aiUlige 46, !J 600 ~

Ordeil' 1~lo, .. 3:~ 4, ,8;2[1

114800

31 482:0

IHle')llB,g;OIl1 ,rling w~e!i1Gh

to '~iigl~l'~e,nI Ulp'plU· :spri'ng mQlMlIl~a:s; w,e~li as ea,1) nut on uIPpe!rf,ork, br iage

Ow:c1el!l' :Nlc'. 3:1 4 ,81~Qt

'HUll

3:3'il60

331610

•

oo·~o/a.o

HIQ,Ider

110 ta:~,e f~lnI'8 i d riVIE! housl ng mol' d isassemb Iya Iiild assernbl V (i n eon] 1lII,IiilICt.i'Q IilIW'i't h assemb ~y sta nd 00 1 4,908ind 3:3 1 6,10~,

o rder No. 33 1 600

AUtx;i I'iiary hoi de r

to italll::.€ f ilnlll1Jli driVE! h!ousi ng IOf 1!1 80 G./S

1~~11i1! ,conjunc'~ion with 00 14QO and 3:3. 11 (50011

Order No .. 3311 6,10

IR: i no wrench

to loosen and :tighllen twe!llve·'sided mt!lu'ts en 'final. d rhi/,e tnQusinglsw~lrngl~ngalrm i'lange

Order No .. 33 1: 6:201

IHollde'r

to loosen and :tighten nu'I: 'Drill drive Il inion 10 rder No, .. 33 1 fH~OI

Spec is I Wr,e!l"lUl;lh

'W loosen a~d't]gMe:!i1! thr,eadedi r~lnQl (drive p~ni,ol~') Order No. 33 1 7C10

~ mpact 113.ndi!'lel

~o knock in radial~' o,~11 seal (drive p,inion tnn3!glcied rfog) Order No .33 1 '750

ltilple-l811l1liil lillJl:llew

to pu III oU bia II bea ri n:91 on If i.ng: 'gear Order N,o .. 33, 1 830/307

m!ilO pact Imandlrell

to knock :r<'ld ial~ cdlli sealll i nto iii i f'l:al~ drive housi ng clOver o rder No. 33 11 8!r50

a~ '1100

10.131

00 - 0/311

332800

33 2 illO

Fin:a~ driiVe gl1UJige:

to, measure backlash Order No. 33, 2 600

Anest

te lock i[J:r ive pinion Order No. 33 2 6;201

Cllamp

fo!r d~sassemblv and ,aJssembly' of sprin.g strut Ora er IMol. 33 ,6 6:00

00-OJ32

10.81

G.rDUIP' 36

IBarualru::e.r

f,or bs land liIigl w:h e~~;sa:s W~ U as m.€'asu ri n9 la.1I:et8J~1 and Irae! la I runout

Ofch1l,r No. 36 :3 600

Ba,lance ihotldler

for rear wll1,eed (~n (lOIIlQIu.~,ctionw~th 117 rnrn d~la. takeUPI slfu!iITt from 363 600)1

Order IN o, as :3 60S

IN! ppile wreifilclh

1iO reel ~ n whee!:s Ord!lW N,o.3fl 3 8ifJO

Tml ()Iffse1l: gaui;e

to me~5f!.!re moe ('Jff~5et difference betw~ell1' front wtheetlt and peat wheel

Order No. 36:3 900

363808

363800

36 S 90()

~--------------------~---

10.81

-

•

"_

•

36,3907

465600

StOIPS foil" toe offsetg811!Jge

to det,ermine toe ,offset Un conjunotlon with 3639001 OI!1'de'r No. 36 3 907

IFlrame g:a,uge III

to check frame fnr dlstertlon in stee'ring head area Order N,o. 46 6,1600

Fnilme gauge II

to' eheek frame tor dlstorrion in :swinging arm mount area

Ordelr No. 46 5 610

00-0'/34

UUI1

mm

2

Ili mensliols and Welig:hts Max. ~jelil!;r~1h

mm

mm

mm

MalX. heig lilit without mirror (motorcycle IUIWI k)aded)

mm

111 ~o (4:5 .:275 "~i

mm

G,ro'l~md ,c1h!lalralnce with load ~r'idler weig Ilhllg 715 ikgJ16B, ~bsd

mm

mm

Wemgh1l: (yf readiy~1I:o-ride m()~iOrcyc Ie wi!ti~lfiliJlllll ~u,el ta'illn k :aWld tnols

(mN curb weighr!:)

IPiermiss:ib~e 1I:o"~a I we ig bt

=curb w,e~gh1l: ... weigiht Oi~ pef:oons a,r1td hIJ,ggage

39B, (87'"]' l'!:Is.)

I~owe'r weilQlht. ready"tlCHidie +15 kg (116\5 ~ibs.) Irmder

kgJkW

1.(J!5

~ermissib Ie wheel liloald Frr'olrl;l!;w~lth2'.1 b~r ll:reSSl!.!lf'e (30 psU Rea r with 2.,2 bar presSiU re (31 psffi)

kg ""g

1 ,8: (392 Ilbs.) 27'0 (,!:I95 lIDs.)

OO~O/35

,Motlell

jiir!1e rirnrfl,attiiolil ,preSSlrre Pl'lesSlll~eiinl barr fol!" co,ld tires

Front Rear

IIIif! portanrf!

Clneck forr correct 'ti ra tread depth ea II,ed fOir by legl~;sl,m:ioliil:!

Reoomme:mided m[nimum: :2 mm I~p 10' 1 :30 km/h (80 mph) 3: mm abo\i',e 130 km/h ~80 mph)

o ne fierson 1 .'9 1(27' psi;) 1.8 (216 psn

Two IPersom 2.,' (30 ps]) 2'.2 (31 psi)

CapaltilUeS

IFu@1 'tank - ·~9.5 Htenof which 2' I iuen~ ~n reserve

Engine' omlll ·~2 ~tr.+ O·.2~, ltr, when Irep'l,a,c~tngl oU1IiUltter

Regul11arli grraclre 'gasoUnea;Qo. DIN 51 600~ m~n.S'n RON or :82. MONI

Bra nd na me heavy d ~Ity '0 i I fer i nternal cormbust ion ,eng i n€Os,see' page ILIO-On:2 Tor o,m g:rades.

B,ra nd na me' hYPC'~id gear 0 ~lll" .AP I C lsssif lcat ion GL5

,aibove5° C :=; .8:1\1: 90

bel,ow 5° c .::;:. SA E, so

Te~escoiP·e fork - 0.22 .:1;. 0.01 In. per fork member See pagel 3.11 ~l3 f,or el i 9lrades,

Trensmlssien

Rea·r wi1lee~ swinghilgarm firl1'il!iill drive

{I' .. SO ~Itr. 0 .. 15, ltr, 0,35 ltr,

Brakes - 3p"prf(lX. 0.3, 1"I;lr .• (,nlIew f~mng wUh DOT 4: brai~e fl~u~d "SL"

b~eecling)

service land Gener,all Iinforrrnatiion

IM~od'e~

IR ,80 GIS

ICspaiciiUes Flue'l tank

~ 9,,5, Ur,ers, of whi,eh ,2 I irt!ers,j 111 w,eserve

EngineoUI

2 ltr, +" 0.2:5 ltr,

when re;p~aci ng oU ~ i Iter

Tlransm i's:sio,n

R'!!iali' whee,1 'swinging arm IFinal1 drive

0.80Iu. 0.15 ltr, 0.35 I'tlr"

Regular ,grade gasoline ace, IOI,N 51 600~ mi:n. 911 RONI or 82 MiON

Brand name heavy duty o,illf,o'f' int,ernal c:omlbust~on eng i nes, see' page' 00--01/1':2 for on gndes,

.~.

Br,and mam.e hyp,o ld Qie.1Ir 0 i I. AP'II elassif~catlon Gl5 abcr·~e BO C "" S,AIE '90 be,I'owEi,oC := 5AE SOl

Telescope forik.

0.2:2 -+ 0,.01 Itr. per focflk. rnern beli

,appr'ox. 0.3 I,tr. (new' f~rm n9 w~th blleooh'll\9~

--- - - - -- -

_-~'

11---, --,

--_ ---

---- ----

II__I [_ J J ~ I :=_'I II

-------

101000 '1:39 BMIWServi,ce 8'1: 7'5100 km (5101010 miilles) and 150100 kml (10100101 m,ile)lrntervals,

.~. (;ihliillng i Ag Q,m i n e,m1g~n,e snd o,i III 1ffUi1leilf; Irepl.ac i rll.g on 'fiil1I:lllifi canridgE!

2. Lullr~catlng bealrhitgls of Fe,alr whee~ swifilSl~nglarm .amil cllutlCh cable ni!pple

3. Cleanilrilgl csrbu retO'r f lool~. hOiUlsiilnlQI

4 .. Tig,htlen Iriligl c:yl ilrilder h~ds; adju5tmlilgl v,al~ve play 5.. Cil'ileck i n9 spa rllk p hiJ.gs

16. :Synchlron~zi ng calrbu r,e~ors.: adjustinlg cabilies

7'. C:heckiogf.l::h:=aning oil pafil/:s!~rjd g,ij,ard ,calVity and cylinder ,cooling filils 8,. IFinal inspecmion wUh 1I:r.alffric lsa~ety il:est

010 010139 BMIWSi!! tV iii::;!! all: 115100 km (5',,100 CI milh!!'s,) and 1,5DI!lOlkm UO.I!JiOOIlilllile) Il1Iter1!lails:

1. C IiIlang i"9 OU iilnE.n9 i file a!lld OUFHlter;R.epl:aciin,g

O~II :1" i I:te:r CartJr~dl!l;e

Engine at oper,n;in:g t:empera~ml@" F~lrst replaee oiillf:jil~eil" car~rlidg,e.

U~8;1 M@idel: Aem,ove e ~d c·O!l,I'er (nwi1l:h bot h a-rings ~.315)~ii1d steel welsher (4)., flil U outfil lieF ea rtridge f2'll wi'~h w ir,e hocks. I nsta U new'fUtier c8Jrtrh::lg'E! with ;mew O'ring:s and paprer gaslJk.el!. UJI).

119182 Modell! R,emov,e eind cover with O·lrmlng (5). IP.aIi1;S 1,3,4 and 6 a~omitt:ed in co,mpalrisonno 198,1 modet Pt!III~ out f~!i~ler e.alrtrklge wah w~.re hooks. ~ nstall W1IIe'W mtle~ ca rrridge wi~~, '!I~led sea Is.

Imporfantl

When u s[ng af i lter ell rtrici!ge w~t:ho ut gh.H;ld sea Is, t~,e Q·,ring~s, n /3:] shown ,above must be' instaUed ,a;g8!in ..

U:nSCl"lew Glim drain p'~ug ()rrtl rear ofoil panancl dlraihloldl ciL

Addlln,e;w oil.

See' Speciifi leat ions for 0 i ~ Qr.8,de s a nid \!I.Q ~u me.

Check 0 i I ~e'lle!11 whh alnl inserted ~ notsorew,oo ~ 0 II dipsth:!k, ccu'l"ecting tio "!MAX.'" rnarkat most if nec€<SSSllry .•

Amoufillt of ell between M I Nand MAX maiwik:s; ~

0.85, hr •.

10.61

OO~OO/26

2. lu brica!l:~n,g IBeawh'll!;!ls ,of Rear 'Whee I ,Swilf'lgih'lQI Alnn

and Chll!l:c:lh Cable N i Plpi!!:=

Pry ,off left and rl;ght caps. Lubricate' bearings on both sides with a grea'se' gUIlill fittsd with iii tapered mJzz'lle.

Importaml

EXCle'ss~l.I'e' I ubrieati ng p ressure eo'u Id d anuige sea is, or press gaskets off oith ek seats,

Lubr icalte bel ri ng su rfaces o,f 'up,pe r a nd lower clutch ,ci;lbl e n i ppilies wit hi oH,

If necessary, remove shaft bolt f,or clutch handlever, pullll,eve,r out of gluide and turn 180'\

3:. Crueanril!l1l!1l Carbu re,!l:a,r IF h:Ufrl:: Hh:lus,il1lg

Talk,e o,ff spri'l1l,g c,lamp on floillt hous,ing olf both carburetors toward rear, Herneve Ihousing.

lOrain and clle:an neat houshilg,.

4. Tiight~l'IIill1;g C~dlwll'l delr Heards.: ,AdJ usrl rngVli;llhll':e' P laiY Take cff left ami right cyHl1de,i" hea,d 'covers after run:scfewing one cap nut and two nuts, ons:i'des ~arrowsl' of each co¥er. CSltreh E!'sc:alP i 1ii191 en.

I n'Sta/JatiofJ':

On,lv reuse gilskets when in pede,c! eonditionl

Unscrew spark IPllugls.

1 {Ull

rig hH9'fli the ~OUf ,co naif nuts i;llnd two hlexagon nuts SIC:. 'OOrdi,mJgl to t~;gh\t:eliil i n9 order plan,

TightlEm i ngtol'iqu,e :.see pitlge 00 -on.

Check val've p,l,il!i''i on as'~o,pped" 100 ld eng liine' with .a fIEi;e'I'er gal~l91e blide insertad bMweenrhe V,8i~II\I'e stem ,andl reeker arm.

Th is trequ ~Ir'!es oran k itl:'1lQI eng i ne ~ atll p 1:5:tO ~I o~ cy ~ i ncle'f bel ng aci,~ust~cI is in compr:essh:m iOC- both v,81111ves atre c ios!8o !

If necessary •. cerrect valve piay wi'th 1I:ii;eadjus,tijng' SCf'ew ,alfte,r u nscrew~nQ lock nat, 1'19 tnltEl!' lock nut again.

R'echeciik va~ve p!llay.,

See pase 11, -1Jt14lf ·of ,[] rOI!:,! p .~ lforspecimie:8tiom;.

51. rCh,ecl!dng Spark IPhJgl!i

Check ,e~.ectro,de ga,iJ w~lth a mee,l,er g:a,uge b lade., eerreet~ng iii necessa ry by bend ing i1!n,egtrQlliJ nd electmde 'to' distance A ~ fU5 "*' r[).11 mm.

I nSfallati'On;

G ivEl spi1illrk. p~ ugs· threads a Ug!lhrt coat of 9 raph ite grease b~fore inst:alllli~'9I.

6. SYIn:ohtr'otni,zin!1 CSl'1bl:ill'ietJDw.s; Ad~li.Isti 111!!!1 Cab les lmporta.nr!

Catriout,etorshlllve been detached on cyHncler hleads and shown~rQ:mthe 'SidetJo improve clari1l!yI

Ad~ust icHe speediwi1l!h ,engine 'wJfming ancl having ope~· aHngl teflflpe'ratulfle (8Ct' Coil tlempers:tul'e') and thmnl,e '~wist ,gri p closed,

u

,L- ~--~--------~~-E8tQO

1 CI.iI3'1

CO -Oll/27

E8113 ,014 IDOl ,_ 001,218

Adjus~ threttle eable p,lllay tc 4, mm at fiirst to' preIV',ent throttles, from "seizing;' en the cabl,es.

Adjiu~st c:ho'k"e cabl~e:s: tha't ,ohoke ~ even (anow) are pressed i n~c, thai r f i na I pooi't len w,~,en ehoks ,00 ntrol is, s,wit:c:hed riff.

M.alke' basic: ~setting 01'11 both earburetors wiith idle rntx'tulre eentrel 's.crew (1) and tbrottle stoll screw (2') as fellows,

Screw in mix,tJu!',econtl'loi sorew ,ag;iil'llst :s,to;p carefull~y and thelml. teesen by the' eerreet numbelii' o,~wms ('see Sp ecirficado ns]. 'Screw 'i fill stop, :s:c:rew far ,enOililQ hi tha'll:.

it just 1!ouches.~lhe thll"ott~le' Ileverali"ldt~i'Hm scnw ~n 'orne flllilitu rn,

Use tester, B MIW No. ~ 3: 1[1 '700., "1:.0 sy U'!I,ch ren iZeC8jbu· nf~on,. Connect rubber hoses o,'f; 'Uls:iler ,0 n pent i nerrtt vacuum eonaeetlons of carbull'etors (arll"owl, ,arher Ire· m nvi no p11uQIS.

Tum thli,ottll~e stop screw and idle mixture control sor,ew altennartely IUlntii call1'bur'et.ors are 'synchr'o:nized, . .Ad~ust max~mum speed withfhe control 'screw after each stop S:Cf"l~ adjustment.

See Ipage' '~ 1~Ol3 ,of 'G roup 11 fOlr ~d II~ speed.

flo QS~ eligl~irrnesiPeed 81 ig htl Y w~th t:~e throt:det,w uSt glri p 11:0 .ad,~UiS:t the '~hm:ttle cables. Ad~U5,t threttle cabi:es

w~it had] ust i!'l!g screws (a,rrow) that merClllIliry g,a Mlges. :1 n 1lieste r show the same ~evel.

.,. !Chll!1!ck~n!!I OU Panl{Sldd IG'ual1ld Cavity ,aId tyl illll(!!e!!' Cooili Ilg] R j bsf'oll" Diirt. Cllean! IJ:!QI if Necessa ry

Oil pans1ki:cI g,u'aro can be remor\ll',ed aher UlnS'I':!rewing fou r he,)(®,golfl head b a lts,

8. fililla'lllns:p8C!'j,C!1l'I !N!itli:l Traffle Sai~,ety lest

Condition 'U!Sit~ w'heelllS6Ilnd tires, tlre infrllation prnssurre- ~81e: Specifk:a1l:ions.

fu netlen tsst: hi ~gh beam, k.'lw beam, piliIlrki ng ~ igli1t,. St.op: I~ ig nt, license ph!ltiE! i igllt. tu frr!l s[glna I s, h i:gh baa m i ndi· cater lamp, batt!e'fY rchal~,ge lndieator lsmp, ~dle speedarnd oUpWies:sure indl~cator lamps. hom, specia~ equipmell'll'~ i'f appiic-ab~e.

CIUUCil!lj. 51l in., steed.n!91, foo'l: a nel ha n:d-opera1led olralke:s, lnstru m ents (test dn!ive if neCles.S!llry).

l.eektest: eng~ln e, nanism iSS[Oirl!. rear w~rH3jell ~i ~':I:g~rng srm j.fi.na.1 d riv'e housi n,QI. te~e:sco,pe mOrk"fuel :sy:s:rJem.

010 00 '14,9 B,MW Ilrnspe,c'ti,onl ,afti8'rr 15 OD,D km (,110'QiOO miille,s), and then 150100 km (1001010 mile) Intervals,

11. 'l::llhan,giing 'oil in ,engine and oUfilter: rE!ipl!acing o,illifilter cartri:dg'e1

:2. (:lnarHJing oil ~liiI,~ram:missi'olli'll -

,3" ella ngb1g1 '0 i I 'in rea r wheel SWblQ'i:ng arm

4,. Ohanghl!91 oil 'In final ddve!

5,. C,hangi!il,'Q1 oll in tieleooollD'efork

'tt Llibriicat.iing ibeariilllQs, of' rear wheelswingJng arm and elutch cable' n'~pple.s, 7'. Replacing air filte1r ca,lI'tridige

a" CI,ealniniQl carburetor float housing 9'. CI,ealning fuel valive:

10., Front wihe,el: Chec1lidng beall'~lI1g pla'y" iinsplec~ing lbralk~' !part'S, 11. IFI,ealll"wiI'I eell: Checil;dngl 11: i I I, P lay. i nspecH~!gl b,ralke psrts

12'. Check~ngl~djusting clutchplav - -

13. Chec'ldng/adjusting dead 'trallel ef rear wll'u!E!I: brake

14. Tigh~e ii1~ng, cy I i nder heads:; ad~u st i 11'51 va IWi!! ptalv

15. ,Re;p:~acilrtllQJ spall"k !p~ug,s

16. (:[l'lecki'ilQl/adjU:!ldng: iglnitiollill t:iming 11'. C!l1eckin.g s~ee'ring bealr'ing phil,! '11,8.Adiusdngsw~liIgling arm bealring Iphw

~9. Check i ng/oormC'~ i li:g bratke fllu lid I,ev,etl,; check ~ng b:rakies for Ilealk's

20. SeN~:chlgl baU'i.fY

21. Checkingtcorl'lecting tigihlt,ness of boillts: and nuts; 22 .. Synchmnizin91 C8'iI"bl.llll'leto,rs,;: adjusting cables

23. Chec1dnglc'leanblQI ell pan/'s!k~d Qluail'd carl/~tv and ,c:oolling Ir'jbs 'of cyil'il1lders 241. F~lI1!al i'liliSpec~iion w'ith 1I:iraftic sa.fetvtest.

'10.81

- -- - - - - - --- -

_-~_' -

II, - __ __- -== I

----- -_--

L'i~ J -:1 ,~~l ~I - II

--------

0000 '149 BIMIW II'fIIs1pectiion A.fter 1,50(10 'lu1I1 '(10~OOICl tiIii:i'les,) an dI Then 15100 k,11l ~ uumo mwWe:) Illf'llt:ervah

1. Changling on in E,f!!line! ,and OU Fwllt,er: Re:pllactng

Oii I fUter Ca rtridge

IE n,gli:rle' at 'ope:l'iF.I'ti no '~,emp eratu re.. 'F i rst rep ia~ ,0 i I .~ i l:1i:et ciilli11I'idg,e.

11.91811 Modell~ IRemQw end cOover (7l1 with both a-rings (3/51' all1d 'steel w;8'siler (4), Pull out filter cartridge (211 'W ith W~fie heoks, I nsta II newfi liter cartridg a with new O·r,iil1i9'S; oEHII,d peper gas1ike1l:, (6'1.

11'99:2; Model: R'6:mave end cover with, a'ring US,). Parts 1, 3,4 and 6 are omnted in oompafison t'oU[181 model, IP'ull eut filter ,cartlridg,e with wire hooks. lnstell new fUter ,calr~r[dge 'With g'lued se,~ls.

imporl;{fJ'fuJ'

When u!I,ing ill filter cartridgle withollJt Qllued seals" the O·rings (1/3,) shown abov,e must bft lnsta Uedaga i r:II.

:Uscrew (1]1 dlr,al~fD p I'ug em Iream- ,of aU pa l1'li1 ,amq(j drain o~,d oil ..

Add new oi I.

See Sllec~ncaltiofls for oU g.rades and volume .e

Chocik, 0 ll le\Ji',e:1 'with ,!:!'n i nserted (nolt sC~e\iVe(n ell d i,p' stick, oorrec,UlI1gl 'to ;'MAX·j mark ail: most if necessary_

Amount o,f oil between MIN and MA.X marks '"

0.85 ltr. '.

- -- - - - - - --- -

--~-' -

II, - __ __- -== I

----- -_--

'-'I~J -:1 ,_~[ ~I - II

--------

:2:. Cha!filgiing I()iii~ i III Tram,fIIiI iss~ofil irslnsmissi·on at o'pe;~at~Ir1!.gltemperalture. U I1screw oU d1ral~:1i111 p,1 ug.

R em ave ,0 i I fM ler Ip ~u,g. Dra [n 'Q 101 o,~it

Add l'iI,ew ,oU.

See Spec~fi cath:ms·folr O~I~ grades iii nd voll!lame .• o II ~ evel reaches law,er ,edge ,Qf fmer open i ng.

3. 'Chaln,gffirn.g OU li'l1l Aea!l" Wheel SW~!i'lglii!i'lgIArliln SWillfDgillfDgalrm hoas ilrllQI halS apenu: i ng~emrp,er;atu r~" Unscr~w on drain ph~.I9.

Then nltliTle~e ell finer pl~:g. !Jir.ain o~d oil.

,Add 1118:\1\1' oil,

See Speciiicflltk:llml'S "for ell 'grades; and vollJllme.

rC:~,ecld ng oU !.evel: glu idle malndf1elll i nto 'oil nUer bon: afil,d move aga inst e hlJUch be II heusl mg. Mlail'il.dlrel !WIU s~ be cGaltif.ldw~:t.h 0]1 up to a heiglht e,f2 mm.

,4. Cll1al!ilgwlI1.'mI Oii I j;l'iIf i na~ Drive

Final dr'f'lle at operatingl temperature.

Unlsc,r,ew oU drain pllug ~1l and '!hen loUfiUelr~bleed!er screw (21,. Drain ollid 'oil. Add new oll until l~eVlel

res ehss 'i I1SP eel len bo rEI {3:} ,

See Specirficaltklln:s,rCrl'" oU grades and volume.

5. Changi ng OU i III l"e:le.seope IForik:

IiJInscrew dr.aJ~n plugs 'in bottem olf· slide tubes. i n5tallation;

Jight1en drain pl,ygs, cal'ef:ully to avoid damaglingtihe thr,eads!

U f'IIS;C rew IU Piper v iller pi Jjj,gs '1.0 d i SlChar-gle the iI1o,r'k 'tubes. Drain oil whli'le moving telescope fork down end up (5, to] (Ii ti I1l'h'~S II, Add ~'eW o,i L

See Plag€: 3,1 ~OJ3 ,of GllI"OUP 31 for oil grades and v,olufII11e.

Impo'fTam:!

Brll,eed 'shock a bsorblusaUer HI,I i n9 te lesco pe 'forlk by movil1l:QI up and dOWlfl1 (5 to '~I 0, '1times~ - 'full abSOfib i 1'191 f,orce must be nodeed!

--- - - - -- -

_-~I

11---· --I

--_ ---

---- ----

II__I[_J J ~l :=__'I II

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00-00136

15 .• il..ubiriealting Bea rings olf Reali' Wheel S:w~nl!lliing Alrm

illl1Id Ch.ltcih Cabl'€! iN iipiprnes

Pry ,off left and r[gb~ plasUc caps .. ,L.ubdca~e .ileal~hlgls o'ml both sides wi'l:Wna 9 reese gl~ nfiued VIi' iillhla tapE!ned no!£:.zlile.

Imponanr.t

1E..x:cessive II!iJbriCin.i ng pressu recoiU '~d damage seal Ills or press. 9.a,s:kl~n;si off ·crfthei r seats ..

Llub{ic:a.~e bealrirll,g sl:Irf'aces of uPlPeralm!d I,ower clu1tt.dil! cable n i!pp,hlS wit ~I ,0 i I. I f IIn~ce&sary remove Shilh bo I~ wo'r clutch hand I eve", pu n lever eut ,ofgu ~de i~lli'ujl 1!:U rn

~80o., . -

1. Re:llllacii!l!gAir fw Iteir Calrtflidge

lift up a i r el eillniifJf LIIlppeir secthm after d lseen l1Iect~ill'lgl fOfl!.lrspr~;lilg holliders and pun IOU1tt air fnt~r ,calrtlF~dge on s]d,e UefH.

I n.stallation;'

Note ~ ns1ta II ed ,polsiil! ion of air m~e,~ cartrtdg,e ~ lieuellril~g in "rear' dlreetienend alrr,ow maril!;: .. TQP·· ..

fk Cilearn i nQI CaIF'b!)!!.re'll!olr IF.I'oall IHGli!!liiin.g

Take ,off ~pr~ng ,cil!amp ,olilfloa~ hOtllS~dngi ,o'f both csrbureters 1ttowardreal~. RemQve' ho t!lS~I!ili9I.

Drah'lllawnd clean ~ 100~t hoU'si I1g.,

5t II:: 1€!iI n~li1!gI !rue:1 Vallve

IRemovE! fi l:telr screen from ~ue~ va Ive by loo;se:~:~ iIiIgi coup Ung nut 0'1'11 hose .!lIcla:pte<r and pu ~IU r:ligl screen out Q,f \faIVi~ hO:lI!ismng.

10. Fm'\OIfl1l: Wheel:: Checking WIi'!le,eIIIBealrinl!J "181'11' ii,lild

~ !fI!ipeC1l:~n\'!.!1 Bl:'al~e IP,aJrts

R,emGVieandi ~~staJ~ I f\~o nt whe,e~, 36 30300.

C:ileok whee I beari:ng p ~ay (%dctmcn 'itO.rl:'llJle L adju sri n:g if necessal]:"y~~'3a, 31 3,71.

Check brake dlscfer wearal!l1!d thickness of: bfaike pads, r~p[alc~ll11glwar'~lldalmagled 1;.:lii31I'11:S ~f I~ 80essawy ~ ~.

We-a ~ I i 1m ltsisee :page 34,~1[)11.

1,S

11,5

~ 1. Rear Wl:1eel: Ciheckirng Whee:1 nl'll: Play land IlnspeC1l:&

ing IB!i'al~e [Parts

A,ea r wheEl I !!j,tandls TIr!1=e .• PI~ace :SI!.,! ~Itab Ie maglnet sta nds on muU~ eram:i, .iilIppl[iV d ia Igaug:e l!fl holder - cHar~ g·a liIge teste~i:s (lin outermost Ir~mflal1lgleedg~!

'Jnt wh~el past tbe periP'(ilnd~lcu ler - max. tii~t pl;ElY ",. fL5 mm. If neoessary repair beald!l1!gSi~~.

R,emo~afld hil,staU fE!iII r wheel 36, 30 120.

Clle-a n bralk,e dru m am d slhoes; giv,e bralke cams ,al :~ ig!ht eeat of gr,eaiSJE!!,

Check bra ke d fiIiJ m '~or wear,. glr~ ~:diIi;9 iifn,ecess;a ry'* ). Check. lthi,ck1fl es'S of pads, relP~laci 1"19 bra k,e shoes ~f neeessa ry * ).

Padt.h~dmess C8 n b echeckedthroug!h 3i nspect~on hotes,

Wea,r Umi:t:s: see: page .34--0/1.

CO·~OOJ31

11,2. Check.i Igl Adjus1l;~lRg Clul~cl;1 Plary

C ~utch p~ay 0111 h'ana lev,ersho'u,!~d be :2 ± 0.5 mm. If l~ et, ad~ust:

.' Unscrew ~OCI~. nut (1) of cableadju:s:t:~ng' screw, • Tumarcijust~I!I1gl screw ~21Iuni1:il " • "

• .,' di:stiil!nOe ~ 'C:'" ~ 201 i" :2: mmis, reachedc n trans" rn issio I'll el~d el U'~ch I~Elv:er (lif.lIV.fr ~lI'!cUlliiled a beet 4,.0 towalrol read. I,ig i1ltiEln h.'lck fal.l!lt ~ 1 ) .

'.' Unson'3:w loclk rllut"A" of transmlsslen ,endl ad~uS'6ng screw .

• !lUffill ,adJustml~gl~crew ":9" until clutch hawad I,e\l!'er pi,ay ms :2 ± O,~5 mmand 1:ig hten I,ock nut N A",

~3, IChecilc.ii!ilgll AJdjlUJSiling [llead1i raiVel: o:f IRealr WheeW

Bra'kie

BW,;ilke! pedia ~ s:hou ~id not have ma:~e d e8id travel tha n 2'5mrm.

AdjuninQl; "furrillt:humb air hex!ill:gcm nut on pu~111 rod cloc'k.w ise u nt i I rear Wllh!~e~l ,~IU:S!. beg i ns te brake. Th,en tu flril back by ate 4~u rns (~libra:ke' ped,all~ Uaive I ef abolU t 25 mm I,

- ~ 410 Til9I1:l'iielil i!'llg 'CYII ind1el' Headis; Adjlll~~n;g Vall:ve IP~ay Talk,e oU le1ltalrn;d Irig ht cyl mimi der h,e.ad eeversafter unscl'1ewi'lrniQi ont'! cap- nut and t.wo nuts on :sides (.a,rro,w!d o~; eaeh OOVEl,r. Coate h escap,ingo i I.

Ins'l;a.JIatiot1:

O'FII~y' r,eUilsegasl~ets. whef~lii\1ll perfect cond'irti:on~!

U n~rew spark p 11u:gs.

Tight'im the ~ol.!lrcou.i3Jr nuts !1111td two h exagon nU'~s ac,coOrd i 11191 to t[glhte nll~ng ,ordeil' p,lan.

ii:ghten i ng tOIIi',C!IIJ,U!!: see page' oo-an.

Check v,al~'Ve plh~V 01111 /3IS'i1:oppeid" oold e,nI!9Jwne with a feel,er gauge b~'a:de' inserted brer~ween the vallve' stern and! rocke:r srrn,

This IreQuiilres cranking engine' untll pist'on of cyillinder being adj:ust1oo is at com,pr,ess~cm TDe - both valves ClWte elosedl

Ilf' neceSS<a'fV; 'OOlrf1!ct va h"e p,l,iilIY w~th the ,adj Ulisting screw ,arfli:eii" u nserewl ng I,ocll< nut, Tighte'il Illo,ck nut again. Fh~chec'l!c 'lIal:!Je p~ay.

See I:'lag,e '11-'0/4 ef Gtmup 11 '~o:r specilficath:ms.

'115, FI!ep'l:a:c~lilgl Spark, Phll!,;)s

B'erfore' i nsta !ling new&,park pl11ugs eheektha ilr e lectrodie 'gap wlith a feeler' gauge blade'.,CQ'I"f1l2icting by 'bending ,ground ellect:rode tc dI~stance,A -= 0.6 + 10,'11 mm U neeessary.

See page' 112-10/3 for ap,proved' spark p ~ugs", Insta#atlon.:

'Giv.e s:par!1i: plug threads a Illight eeat of graphite Qlrea:se'.

'Ui" 'C:heeI!cJnglAdjustiilng, ~,gl11i1l:li'DIf:I 'lIming lmportantl

N,evef touch pOlwer c-lJrry'iing parts o,f a hiigh voh:age 'tnlliilsistor igniition systen11 whil:e e:ngin,e is Irunrdng -

DAIN'GERf .

S,'tati,c "lEtS,I:,

TSlke off e ngl,ne' cover after loosenll,ng bo,tih soC:k:et

head screws 11:,srrows)l. .

~ ~~ __ Em00043

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II, - __ -== I

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L'I~ J ·:1 ,~~[ ~I - II

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'10.8'1

o i:scon neet 3·p,in p.IUl!]lla nd cO:nlln,ed; ign hI: k'llr!, t!eS'~e'r, BMW 1~lo', 12 3 650 •

. Note:

1~:emovewil'1e 'c~ip o:f phl!g cOlrllnec'tion!

Crarnk enginer om wh ieh spa r!k p,lugls have! been rem oved, ,c~iockwiSie (OPiPclSi~e '~ONlialf\d dlirecth:m) on seeket ,i1Jlead boH ussdte mou nit tha Oil 1:t~n1!:alt!Or rcter, or cralill k engmnS! 51 owly wi1l:illlhe kiclr<; sta rter,

Cenltier wl1 i1l:ieS~rmple 'o~~I~yW:he,elll ma'rk"S' ,. mll.!st be al~!9n.oo wilthinsp!e,otiol~1 hela ma,rik on Ei'!1i,gi,rne block whelml diode o,f r'Qllrlllitio:m11 lies~,e,r I igh1l:& up ..

lf n@£le-sury ~ 'tlUlrll igln iii: ion, box ;alf~e:r loosen ]I~gl the'

rna nJillrIi"t I rugl bo Its Ir,arrows~. -

., Clockw:ise = "ratsrd"

• (:oullrrli1l:en:lockwhifi!::::" "adva rillce'"

Dynalm~c 'fe!St.

CO:lfi!m!C!t. s.troiloscop e Ja mpacco,rd i!~,91l.lo '5'l,! ppilliool i F1~ S'~Wl:lct ions I~trigig:er ,c~1 ilP on IfWg:hit ig fill~tmcm liNd). Stalr~ Ilmg,i net a ndacc€!llera1tte' 1IiO ~peecil o,il 3500 rpm. When ,al~miilli1gl lila mp' (I no lu't1ch ho Ii,J!IS~lilg' (~lyw~lee~) the wl~,rlt)e dot "F" must ,i3lllpear in the in:speiG~i,oln hollie' (fuU ,fliC:hfil nell! ig,ni1U Ion) .

To check the advanoe [gll'l H.iol~locmtn:;l,1 the aiCIjlliJist.i no whee·l(tf the strobo'5co'pe lem p must beturnsd u nti ~ the-Till C'~ mad:.aJp:pearsi.lhe e1fffective contre i .ang le can !'!lOW be' 'read ,on, the 1011 mp's sca:1 e.

S!s;S' :page 1,2-0/3· of G.f\QUI!P 1:2 fo.r spedf iOi!!ltions.

. -

WH.1'm fllli1Qli ne ru nlli1 i ng aticUe sp tied O~'50 :d1: •. ~ 50rp,m) the CEl:n!'UlfWhi ~itie .fitr~pe of Hywheel ma rk "'S" must be

ill I igJned wUh lth e ~nspection ha,l.e m~rk. I·f stiilPe is bebJ·w eenter, ~g IfIIlitio!~ tl m i ng ls rMarded toe much.

If stripe is alOOIl"JiiE! ,cen~el'. 'timi~n!Q1 ls advanced tee m~Cirn,

l' . (:Ileclic i rng S·tee!rlin:~ IBeall'iill1g PtalY

W.n.en st!~eri!,!!g tH~i1!'ring adjustment is correct, the handlebalro~ a JiM::keci up motor,eycl e should sl:o,wlly "f:an" flr'o:~ '-:s;traigtiJtaW'iea,d IPosiiti:on' 'lei' the !f iglht~1I:<lIp'.

Adj ust :s,tleerl 119'_' hS;ee3:2~ 00 4f5~.

1 a:. Adj lIIs:tiing Swhl!.~hlgIA!T'Al BNlriing Pl1ay'

Pl~y oU caps 'DIn! $,w~ng I ng arm ilea ri ngs. Unscrew lock nuts on len 81nd ri,ght: beari n9 bo,l~1!i ~.~rrO'W). To, ha\lie COn'leict beari ng preload t~:9lh1!e'~1 both bealringllboH:s;~o' 20 Nm~ loesen .ai9lali~n Bind tigh1l:e~to 110 + 2 IN m.

To~que 'lock. r:lutsto 100 + :2~O Nm (w~thoIJ1I: turning the, be~ring bo 11ttS~.

Tig'~lt:erniilrtl9~O rq ue: see pagla Oi()~/a .

. Impo.r.rant!

Dis>ta nee "a" fromfir·ame em both :s:idesof the r1ea!r whetHsiwiingil1gJ airm muSil;. be ma'intained whelli1 ad]'~st.ing t!~,esw~ng i ng aem be'S r i 1"1;9 p,l ay.,

'10..81

O(]i~·OOl41

" fi.l Che,cldng/(:!Orre~tiingBrake 1F~!Jj i:d L",e~; Ch8ck~n,g

161f,~kesf,or llea'ks

,9 ra'~e filiu k:l ~.eve I h1 'tIra'ril'51palren1l: tia~ Ie; on riglhr ha nd~e· bar shou lei reach to 'top 'or "MAX;! malr!k. 'Correct if' neci€'ssary.

I Q add brak,efl.u iel 'un:sc,rew 3 Ph i U ips screws and take ,oiff eover with ,g8,sketa'rild d ust cover.

SElie 8:pec if]cat ions for bra,ke' Uu id typ,e 31i11,d VOl lu m e. Cheek brake Uneamj braik:.e :~,Qse for COff'l9Ct routing and leaks,.

Irnportantl

IRep ~ace Dlr,8Ik,eUlJIl id crt least an~~'al i Iy for safety !

See pag:e 34-00l1foradd ltiona l l U'lIlformat ion,

2)0. Servh;irng Baner\!,

'" R emove :sel1l~ i:l'fllElr 1'iE!I,eas~ng ~Iock .

., 1[)'ii8ocHlll1ec~ baUery s~raps and ts ke off' battery cover.

• Pry oft six pl.ug:s, onn!Op, ef baneil'Y' with a screwd river,

'. I f acid I'W@i~1 latco law, edd dI ist:i Uedwa'I,er '1:0' ral~se I,eve I ~.o, malrk O'f '6· mm albaVlE! upp'er edge of p l.altJes. '. If In6ces1l1::llry dlea n al~d drv~o p crf battery a nel

I ubrica1!e bauery end poillas with acidlprotectio n glf'ease (e.g .. BOlsch Ft 40 V~ ) ..

211. ICheaklin,gICotir,ectrlflgl TigMness ·o,f Bollt.s <llrndi NllIJts

$tJub ax Ie nut i.lllilId bo lts (Mro nit wheel) jw~:eelll 1i1l.iJllts (rear whee ~ L front: sind rear e:~glwnre' rneu nts, kJck :sta:mid. upp€!;r and lower Sprillill'l1ll s1:rut m au nts, hose elern ps Olf'! ca rbulr,etors a swell aJS 0 n d l:IIst 'CO\fEl'J'S o'f~e'I'esoope~olrk and propeller sh:alf1l:.

Tlg hten il!l1!Q terque: see JJ!11:tgles 100-017 and 00-0/:8.

00-0014.2

22. Syrnctl ro,rIilli:zilng Carbru re'lio:rs; Adju5:i11rnng Calbl,es Importantl

C.arbiUlI'le:tors ~i1\11e been detached OlrncyHnder headsand shi:own fn:l<!Wlnh,e!iide' '~O mmplrDV'@: ,c!liillri tv ~

~

AclJ ~Ist i d~espeed wi:th III nJgl~ine: ru iii ni~ln,g! aJli1d i~ aJvli'rngl Clip· erami m,gl 'tlEi:mp eratu re 1~:80o Co ll '~em perBlt!Ullr,e II and l,hroniie: '~,wist gr~fl etcsed,

Adj IlSt tin rOUI~e c:abille p~;ay to 4 m m a'~ 'Urst to prevent rhrrouies'from "se'iz:i!1,gi" enthe cables.

AtUust choke cables tlhiilU, ehoke levers (a,rfIow) are pressed i:nto~,!iullmF fl nal pOisi1t ion when c hiro!lI;'e contra:11 ~,S!iw~,tched oft

Mii;like ibalsi,c S!8<nilrllg on both c8Irb:unet.oF'S with idl~e mlxtlJlr,e corntr<C.l1 screw U ~ and throttl e st,op :sorew (2:) as fo ~ ItCtINs,.

Screw iin mixture Ico,niil:lrol screw agaiinst st)Q(l' Icaref~ ~Iy antd then I~o osen by tbe eo rreet nu mlber 'c.rif tuens bee Specif~cathU1iI~d. Scr'e'win sto,p :sc'rew '~a,~ erlloulgh~I~'alt

lt jr~ISiI! touches theth rott~ie I,ever am:~ the rnl screwi rill ,one full turn,

Uise! itestti'r. BMW No. 1:3 0 '00.10 synch ron iZ11iI car,· IbUf!n.orS~. 'COnl~it~1 wbber htosescr~te~,e'r on Iper! i ne~li1Irt vacuum co nnec:fiem e·f carbu fle'tors Ifarrew)aft.erre· moving plugs.

Tu mil~rolt1tl~e' stop,SiQrew ami ~ci Ie mi>ru!re ICO r1lt'ro,1 scr,ew ,al~tiernalt.ely until ee rlburetors a,nesynchrol!1lli lied. Adjus.t ma:ximum speed whh the control :screw arneiii' eac',h S1i:O p screwaJdj IJISit mel!1l:t.

See page .~ 1 -'0/3 o:f Grlou p 11 mer i,(HeSJpeed.

E8'I 00 044

iBo·o:s:t e'FI!g~lne speed s~ ighU y \IV ittl the~ihrrot,iI: letw lst ,grip ~o~dJu:st the throttle cables. Adj'll,llstthrott.le cab'lles wllth ad]Msting sc!~ew:s (alrrow) that. mrercrury gauges, in tester show 'the same level.

23. ellu!!okling Oi ~I IPanlSk id "'~ uard Ca!.lityand Cyllinder CooWlinQ fUbiS~O'.r Dwwt~ C!lei~ullil!'llgif N,eGesS<1ilry

The 0 i I pan skJd gua ra ,catr~ be rernoved ,affia r u nserewi li191thefolJ f i~,exagoi!i1r hea,d bol1S.

:24., f~tn:aJll 111'i!!;!p,e,d~ol'il with fr·afifh;; Sdety T €'Jit

eo mid it ion 'test: whed!land 1t:~I~eS, tirei Ilil·flsrt i,Q'lrnr 11n!S~Mifie -see Spedf~ctlt ions,

F u nctientest: hig ~I baa 01, low IJrea m, pa rking If:gi~~; stOlP Ughil:, lleense ph!llie Ught,~u rn s~g~a,~;s. ~rf:g h bearn indicator lalmp, bauery chalrg:eindica1or lamp" ldle !;peed aad oil preSS~lfle ir:li('Hc81t;or ~amps. hem, specia~ eq Ui ipmlllnt if .a,ppri icab! e.

e ~utc'h. sh iih" ste;!!r~ n9. f001 and hand-operated brall;i: ss, i nS'ttru me nits;; (test dr~ve· if nE!C!8'ssary).

Leak test: !E!·n.g~ne,. transrnlssien, fe0rr wheelS'IJVinging arm, fina~ dwfrve! hQli!IS~f1g,. teh'!'sco,pe work .• ~ue:11 :s·y&tem.

00-00.144

10.131

E ·

1·····1- _ .

I lnglne

---- - - ---- - -

"-~-I-

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" ---

II-~F-J I "~l- -;j - II

----

1'1 IEngiine

Sp'ec~~ica,iI; lens . , . .. . • .. .. . .' . ., . • . . . .. ., .. . • a • , " .'. •• .' " , • • • • s • , • •• a • • • a .., P'aglE! 1 ~ ,- 0/3:

n 00 0319 Comp,l!'eSS;iOf~,- check • , • . • . • . .. • . . • . . '" . . . . . . . . . . • . • . • . I. •• •• • • • • ., 1 W -00/1 1111 lOa o.~a Eng i ne- remolve a ndl nsta II, ., .. •. . • . " . . ,. '" , . " . • . •. • . , .. .. ,. . . •.•. 1 ~-O() 12 1,11 ~ 11 O!)'O Cylinder ,~ remove 1i3lril,d install ., " • , " •• , •• , •••••• " .•••••• , .•••• , •• , 10.. 1 W -111/'1 11 'll 12: 080 Cylinder head - remove a no i nsta I~III.. . • . • . " ,. . • .. .. • . •. • . . . • . • .. ., .0.. 1'~ -112/'1 111: '112:51'3 Cylinde1r Ihea:d- dtsassernble and :8iss.emIb11Ie and glrind in valves, " . " . " .• , ... ,. 11- ~ 2/3

1, 11 11:2' 5el,l Va Iv€ guides - rep lace" . " . . . . . . . " I. ., • • I. " I. ., • ., • ., • ., • ., • • I. ., • 0 • " • I. , • • • • • " .1~ -12/:5

l' 11W 4f 060Ti m ~n9 carse cover - remOVE! and i ns~a II. . . .,. , . " . " .•. " . " . " . I •• " • • • " • " • • ,. 1'~ - 114/1

111 1141 11 5ffi A,aid ialll 0 ill sea ~ for cr'a nlksha~t h::'~ut(; hi erlld) - rep lace " • . • . • . • . • " " . I. ., • ., I. ., I. ". l1-M12

111 '114 165~ Radicalll 0 ill seal for cranlkshan (allllt:ernator end) - replace " .•.•. , .•. I. • • • • • • •• 11-1]4/2

nt!l11 OlE ngi rile verrt h Q'se - I'le;p lace" I •• , •• I. " " • • • I •• , • " • " ••••• " •••• , • I •• " • • • • • • • • "'. 11- mn

11' :21 001 era rillkshaft- rep Is ce. "' . • . .. . .. . . .. • .. .. .. . ., . .. . .. . .. . • . . . • . .. . .. . .. . .. .. .. . . . . 1 1-:2111

1: 1 21 53:~ Main b earl n9 bU5h~ngs - m,[O lace ... .. , • . • . .. • .. ,. . .. . .. . • .. • . "' .. ... . • .. .. 11-:21 /3

'11 2'2 000 Flywhee,ll ~ remeeeand insl:aU I(clutc:h lhio!!iJsing:) •. , ..•. "' .•.•..••••.• , • ,.. •••• 11-22/'1 11 24 000 Conneotingl'~od ~ rerrl!Clve and install, , •.•...•. , ..•.•.•.•.•.•... , • , .. ,. 11-24/1 1, 1 ;2'5, 000 Pi:StlO~, - IrenrH)Ve a nd inSl;,a.iII" .• ., .. ..• .• • •• • ,. •• •• •• •• •• • • • , 0 ., • • • •• •• • •• •• 11-25l1~ 11 31 06 ~ Set 'OT sp rockets - rep laee, . • . " .... .. .. . . , • •. , . • . • . • . • .. , • .. .. . " • 0.. 11-31 n

11 34,51)4 Val11lve pilla\{ ~ ad~ust., • , • , ••• , •••••••• a • " ., •••• " •••••••••••••••••••••• , 11-..:34/11

1. 1 4; 1 000 au pump, - lrem ove and' ~,n stPiU ., • , • . ., • . . ,,, •. a •• • • • • • •• , • • •• a • , s • , ., 11-4111

IE: ngi iiiUlI -, troub lashoet , . . . " . " . • . • . . . • ,,0 ,. •• .' • '" • '. •• • • , ,. ,. .' • , • • • •• 11 -42/3

4\ stroke oppo:sed cy!'~Ii1:de!l" e'ngiililu~ with V-suspended valves

2:

CyUnde.r arrangemenil:

0.83

78S co

j'iQ7,.5 ec

8.2 : 1

Max. CQrlst:a ntSipeed

I!dlile speed

950± 1 50 rpm

Ma,;'::. eiU1l:g1~nles:peed dud 1iI'!]1 break "I~ ~I up, '~()i '1 000 .km (.600 mil i I,es) ~IP!O' 2000 km ~ 1 :2!QO m m~les~

D inectk.llli"l ,of rotallioln

410001 rpm 41500 rpm

1I7.~ meter:slseo. ail! '7250 rpm

Corn proessiio'f'l p'resslIIlf,e ~. good ~·~ormal ~·poor

above! :9.0 balr (~28 psi, ~

'7 .5,tc) 9',:0 ball' 007 't.O t28 psl] bel~o,w '7 J3, bar ~ 1 07 psi)

1",e.st~Ag mnstmC1:.ions for c~)mpr,ess ion pli"8s.:sure ,~,mat'Or,cyde withstalrter)

F~lelll

see ~'1 00 1~]39

IR'egu la r grade gasou,ne DIN 511600 octane ,811 least 911 (iRONI) or 82 (MON)

1~'Ofmalf:lJIie I ro~rSu mp:ti'OIIil 201.00. ~) IN 7'OOJOat 111 10 Ilkm/l~ (68, mph)

Engh1el liLIIIbMk'aJliiolll: l!Uib.rh::at~n~1 wSitem

1 .5 bar (211 psi)

O~ IPI'18SSlJIWlsi niliica1to,r la1mp comes Ollnl with presslJIl:'le below

Elngiine

R' SO GIS

Model

Oil volume withol.lltfilt!er repllacement wirth filter l'1eplaceme'nt

2JJ I ~t!ers; (4r.23 p'~nts) 2'.2.5 'liters M.7'5, pints)

01.,1 ! tr, (0.2' pts.) 1'1 00 km

[Max. o,U consumpil(ion

Oil glrad:e

Br,and nlClme HI 0'0 i lforl nt,erna!~ (lombusti:o IiII e'ng i nes, see !(3 r'O!lI.!IP 00 f,oli" viscosiiry /tempera· tura diagram

OU iPu nilP:

10 i I pu mp desigrn

Eaton sv:stem (hypo-trocho'id teeth)

14001 In./hr.at 60100 rpm

57 ± a.os mm

~'0"46

,57 2T'IU· . ", . mm

,.,. 10 . I

I~O.01j5,

14 n 0····4· 5 mm

-ul.~·: .. _,

"Is,y bet,ween mat:inQiliunac:e I(pulmp housing!) aad se:aUII'IQI :surface '(fator)

0.02:5 to' OJl70 mm

[ 0 .: 12 to 0.201 mm

[Ma,x. scoring depth ln cover

~O.05'mm

Valhte: [Play,:

Adjustment for cold eng'ine' 2(tl'C (68,0,11=) ~ntake valvi8

E x[i'nal.llst v8:lve

01.,'10 mm 10.16 mm

[U[p.t.co .. 1 .. 00 .. 0." l:.m] 0.1:5 mm

0.20 mm

ntake opens

~ ntaikE) ch)ses E:xlhliEUllst opens Ex:h'alust closes

i~mh19lshaft setthn,g witlil 2' mm vai~ve platy 1308Q ,camshaft

16° befolfliJ TIDe 44'° after BlOC 156° Def'Dr,!! [I ee

40' amller T[lle

Vallves:

Tota I I enQlth of v,ab,e,s, 'Intake

[Exhaust

Va[l!ve Ihead dia.

Intake [Exhaust

)

98.8 -0.4 rnm

98.6 :± 0.:2: mm 'W hi lte code

42mm 38mm

_" .:::__::::_:__:~- - -. ". - i

(_. ---I

, '

-- ---

~--, ---

1___I1=; --j "~[ --, I ., II

'-------

1i1-,Q~4

Speeifiia't:iOlnIS

Va Iv,estem d ia .. ~Intalke

M~n. y,I;lJlive I~ead edgethi9k,rlles,s Iintake

E.xh:a:UiSlt

O.8mm (J.B mm

0.02 mm

Vallve Seat llnsert i Ou1l:si]de d la, Inta.ke

43.2~~'.02:!5 mm

Va Ive seatl rn~rt bore ~f111 loyl. Iilead Intake

Va lve seat angll e

Va'lw seat width Intalke

1.4 + 1(Ji,:Ji mm

O.2mm

\fabre Guhies.:, l~talll length

Ilnt.alke E;,xh!aJust

4~mm 44imm

Bore "nleyl lnder head

.,. "1+0. J01·a;

~ 0 mm

.,. AI '1 +0,{161

. "*. +(UJ5!O mm

V·a~ve Stem IPlay:

Ilnta!ke

0.050 to o.oeo mm

0..050 to 0.080 mm

Va~"e D~ive.:

Va IVle operation

)

i'

Hi.urd c.aist tappetsfmm lcamlshlaft PI:.!!sh f,ad androcke,r arm

Va~ve' Springs:

W~fle g:aiuge' tl11 lekness

31.:9 mm

IA: ee GIS

29 ± 11.16 kp at 37.6 rnm "] ... :2'.8 :ik.p at 28.5, mm

T ota I nu mbsr of wi nd i ngs

6

.Ax ia I p lay G~ rcekererm

1 ~11.39

Caniilsha.ft: .

F I,alnge' bearing bere in eraakease

" 0

40 -0 .. 016 mm

.-0.020 ,_ 25~.03,3mm

Camslha'ft b,e.ari ng .llou r'iiilii i dial.. .- a I'terllillart;o rend

",A+O.OZl

..:;:'t. 1]1 mm

-

(:;ams!haU b eari n9 bore d ~a. in

clI'anlik.ciil'S'El: -flywheel end

eranl!k;.shamrt bealri ng jOu m.ilIll cHaJ, -~Iywlnae~ emd

Axia ~play I:M3:~w!een camshaft thrust colilialra'rndl fllalrngle !:lea ri ng

:28mm

Cam HiTt

O.I(J75 mm

;I

r

11iQJ~1

S:peclifiicatiion:s

IEngline Model

R 80 GIS

CUln kshaft and Eh3ari !ilgs: era rikshaft

era nkshaft ,cod e

S'tall1ldiillrdl silze to

red/'red red Ib:llue blueh'ed blue/blue

IMia in IBearling .:JO'Ulrnall [0 ia. i rn nilm

A Iternljlltoll' IE ndl Flywhee:1 E fild

5'9.980 ... 691 .. 9:90 .59;980 •.• :5'9JiJ90

5:9.980 . " . 59.9,90 ,5'1'.'9'71 •.• 89.980

519.9711 ... 691 •• 9\80 59.'980 ..• 59.990

!5,'9.971 .•. 5fll.9',BO .591.'971 ••• 5,'9.980

1 st U nders:ize

0.25 red/Ired red~blue bll[ue/,red bi:ue/lo[1 ue

!!J19.730. , .. 5~l,140 5,9.730 ••• 091.740 519 .. 721[ •.• 59.730 5:9.72~ ••. BfL130

69.730 , . , 519.740 69.7'21 .•. ,5,9.7'30 59.7'310 ., .• 5,9.740 '69. "2'1 •.• 5,9.730

2nd underslzs

0.60 red/n!d red/lolu,e IOtl[ue/lred bl.ue/!bll ue

5,9,,480 .•. 591.490 59.480 .•. 59'..4,90 59.4111 .•• 691.,4:80 59.4111 .. ' . 591..4:80

59.4810 • , • 59.4,90 5'9.471 . . . ~9 .480 59,.48:0 •.• !J9.490 :69.471 ..• 59 .e 480

3rid u nders ile

O. 75redln~d red.~blu,e bl,u,e/rred blue/b!lue

5,9.2'30 .... 591.240 5,9.2~30 .•. 591.240 5:9.2'2'11 •.• 591.,230 5,9.2'211 . " . 59'.230

59.230 ... 59.2'40 59.:221 • , .59.230

59.230 5,9.2:40

59.221 , 5,9.230

era Iil kshah rna i n bea r i n9 bush i n9 d ]a. lin cralrll kcase

t:l~."'IJ .. 019

eo 0 mm

era n kshah ma i n bea ri ng bush i ng dia, mn bearing cap

65+O,019m '[I m

Ma i n hea ring ,~o urna I radia I p lay at :2!O°C '16SCi FI

red blue

0.01' 7 .. " . 0 .. 066 mm 0.01'9. , .. 0.057 mm

Grooved ball bearing! seillt dia. on front end of era nkshaft

le'),~O.!O09 m u"'-O.39 m

G moved ball bear i n.gl seat d la ,in 11: i ming case cover

MaI~n Bel8r ins [Bush i rng

Wa III 11:[~ iek nels'S, .

Sta ndard size 0 red

blue

:2.500 2.510 mm

:2.~04 2.514 rnrn

l' st Slep, Or.2!5 red

blue

:2.62,5 , , .. 2,635 mm :2.629 . " . 2.639 mm

2nd step (1.50 f'led

blue

2.7'50 .•. 2.n30 mm 2.754 .. " 2.7164 mm

2.87:5 .... 2"S8!5 mm 2,,879 " .• 2,,8891 mm

3:rd step 0.7'51 red

b~ue

A Dia. (Crksh. iBlearing BOlre)

B IDia. ([B'earing Cap Bo,ne)

c, +0.'02,6; .

1130'-0.(101 mm

129.99!3 .... , 30.02,6

Cranlb::ase

16,5 HIS mm 6,5.000 .••• 6\\),.«.1'191

6.5.000 ... ' .. 65.r1:n 9

130.003 .•. 130.02:8

Crankshaft !bearing dla, with press fit bealring

red = 610.007 .•. '60.046, mill bl ue' =69.:9919 . " .. '60.038 m m

Sprocket ta ke-up bore dis,.

-c ... ' . -, +0.003: .

313,.003 -0.013, rnm

10.81

:A 80 GIS

Thrun washer I~ed th lckness "S"

fbi ue t.h it kness "S" g'lI"eenth lckness i'S" y,elilow thickness "S"

Max. pefmis5~blle weall" clearance

Q~OB to O.~5, mm

2'.4,83: to 2',,530 mm :2'.~,30 to 2'.5,78 mm 2.5<7'8 to 2.:625: mm 2'.6,261:0 2:.6.73: mrn -O.20mm

Max. permisslbla runout on :sh~dt jOUlrnal '(,allt,erna,to'f end) outside wiith support on ma'j'liII bear]ng:s,

0.02 mm

COIMlrods ,and Bearings:

S1ta ndard size (II

Jou Hilii~: D ~armeter! " .... -CUJ09

48 . .00 ~1.02'5 rnrn

2:nd I.iIIlI'ldier'size 0.50

-(31.009

4"7. 2:5 -O~1Ji25 mm

'Co,nmd big end bear'ilmlQ bore dia.

1::2c .. +O.'.iQ~i 5

OJ .. mm

I] '.

eonrod bearing rad~allpllay'

1.0 .. 023 to 0 .. 0691 rnm

Com,od big end width

. ,+0.14'9 .22'+(UJ65 mm

COlnr·odax ia I play

.0.13.0 to 0.2166 mm

0.32 mm

,D~SiI:~u1loe betweenl bore centers:

135 mm

2- 4+0.021 ' - '0 mrn

COnfod srna llend bore d ia,

24.1060' tol 24. mo rnrn

.. ,+0.020 .22+01.015 mm

Pisto,n :ph1 bore cilia. in conrad bush

22' ,. 0,.040 mm

Max." permiilss,ibll!e dev'huiilon ln parallel], f·or ,comodi bores w~t:h b earl ng she Us at

dis,t'a nee of 1]50 m m

O.04mm

Max,. deviaJtion ~n displaeementtor eonrod bOf,!3'S at distanee 0,f1150 Imm

Permi~ssiiblle diff,erence in weight ,of both connectingl rods

±2g

11 -018

R 81l GIS

Cylhild!ell"S;

Sta ndai~d bo re cilia. A, B C

,B;!t.1!9S; 'to 84.,805 mm 84.805 te 84.81' 5 rom 84 .. 815 to 84.825, mm

Su rfeeeftn i:s'h

M1easulredfmm upper edge' d!]Sil:3 nee 20 mm .,. 0,,0015 mm diistance:11!J mrn = 0 e- 01 mm

Pis,tons,:

[Pi sto iii shape

:Sipher lcalte ov,a I

+ Or' - $talm ped (,o,mlliV ~nstaililp lsto nso~ one

we'igiht Igmu p) .

Standalrd IPliston d~a. A ,B,

C

84.765 mm 84.715 mm 84,.7815 mm

Total pElrmissiiblle wealr ,on piSitO'l1l ,and cy Under

max .. 0.0\6 mm

.Arrow and word n~ro'li!it" fac'ing forward

o

)

t

- -- - - - - - --- -

_-~_' -

II, - __ __- -== I

----- -_--

l_<i~J -:1 ,_~[ ~I - II

-------

Mode!1

IIi,sO GIS

P~is,ton R ~ngs,;

TaJpe'r face ring 1 st 'groo:v,e ill

He'ight

-cmo

1, .75_0.022: mm

End clearance

0.310 to 0.50 mm

0.050 'to 0.082' rnrn

Stiepped scraper ring 2'nd gr,oove II Height

' .. -0.010 2.00~,.622 mm

[1.:30 to 0.50 mm

Sidle clearance

0..1040 to 0.072 mm

8'e'v,e~ led ring Jrd gmove,U

Hie ig nit

0.2'5 to 0.40 m m

Side cle.a:ra nee

Installed direction of piiSitOn ring!s

'11]1 Not 1.0 Dill N sta nda rds, spec ia I veniolllil.f:or BMW

Pistolfl IPmn:s,;

P lston pin offset from center of piston

1.0mm

_ .... 1(1

white code: 22.....!0.004 mm

Piston pin bore dia.

2"l+O.004

''&'01 mrn

Piston pin running clearance in conrod bush

0.015 to 0.025 mm

Cyl. head nuts in 3 steps: 115-.25,-35 Nm o 1-18-2l5 'ft. lbs .. )

eo nrod bo Its

rCranlkcase (f I ywhee I) to era ni,kshamt Nut 'on v;ij,lve adjus,t~ngoorew ,Adapter flOr ICi1U'bu ret,olr

OU dra i n ph.!!19

35 + 4 Nm (25 + ,3 ft .. lbs.] 130 ± 2 INm (,36, :1;1 'ft. Ibs.~

.~ 00 + 5. Nm (72 + 4 frt. lbs.) 20 ± 2 INm 1114 ± 1 ft. Ibs .. ) :5'0 Nm 11.36h. lbs.) 3{J + 5 Nm 1~:22 + 4fitt. lbs .. )

ilii gl~te:n ,~IIII eths r be 19 aJnd InlU ts t?' comma n t igiMen in'QI !mqu e va lues as Illsted In taJbl,es hom bo lilt SU pp hers or the new BMW Sta nda rd 60002.10,.

11- 0/10

10.811

1" sst R,elPolrt 'fol!' Crankshaft lMialin IBealriing Ch!IEnanCes

(:all~o Ireftol!' ,to S'er'ltl'j,ce hdorrlm'8tiIQ[nl. G,r. IErngli[1l181, No,. 1 '11 015 8:0 U46 R:)

Model __ ---- __ ~_CharSSlils No .. --- ~Mlile8ige'--------~

Order Nro. E[llIcllo:sure' for GIA IN 01. __ - __ ~ ~

IMe:a:su r i ngl

IMarin l13.earing Jlournalls:

H

Measure front: main bea:ring jO'lllrnalrs V and rear rna i 11 bel:i!'r i 11119 jou rnsls HI in dkectkms a and b (ealch ,3 'times at same polntl, tnmsfening tOI plane'S Vv" Vh. Hv, Hh, with anaxternal mricnl~ meter, This, provides 24 dliif1ererll1 v~llues. which must be' entered [in following table. Galc:ul,arte

m een v,~dues a s shown.

P'llarol,es

rCrrorss Mean Vallue

Additions: 6: "" Main l8earing Journals

AV _a_v-+ r- -; :~6~.'-~--------~5~9~,.-.,-.-.,-m-iIm_' --9

air : lEi - 59 ., .. mm

-~~_F-------~----~--_r-----~~---------~~~~~-------~,-

A' R~ lEIV : 16 "" 59" ••• mm I

.- . ";;;;' ~----+------I-----~,;,,- -----=~...;..;:;.:.;;.:.:.;;..--~-~'I.,

ar : 16 = 59, .. ,. rnm

Mea,s-uring

M,ilin Sea ri 11191 ShE! I ls:

.-

1M 88iSUlre mail'll be,aring she ~ 1:9 in dirrecticms a" b and c. !Make marks 0 n cir,anrkcase a nd bee ri n9 caps w itll a feU Up marker as show nln ill ustration. Othe1rwi's.e proceed a's described abO'Vle. Tin i s predecss 36, d i'fiereili1i1t va ~ ues wil'iri[clll m ust be elnrteredi in follow~n9 table .. Calo~!lla1te mean va I ues as shown.

Planes

AV ..;_a __ v-+I ----+-----IF-----I-~-------=-~ ~91_"'_' ~ _ _=,6:'i0~,()=-1 .::..;.;_;m~· 1.;.;;111,;..·· _~_-I

er : 91 - '60,0 •• rnrn

60,0 ..

ar I

AR ClV : 91 = 60,0 .. mm

: 9 = 60,0 .. mm

C;;tllculating Malil1ll B,earing Pllay':

!Nominal Valu,e':;: 0 . .0120 •.. 0.065

minus,

minus,

Bearrii,liIg Sh~111 o:ia. II Bearing Joums! ma.. I

mm

AV ,a'll
at
AIR a:v
ar minus;

mm

mm

mm

- -- - - - - - --- -

_-~_I -

[I, - __ __- ---== I

----- ---~

r___.1~J-:1 ,~~[ ~I 'I[

'-------

1i1 ·-.0/11

V'alve Drlive

1 'I 'Tappet

2J Rubber plug 3,) liP'ush rod

4) Adjustmngs:arew'

5) Hocker arm

EH A oeker alrm s!nait:

7) Nut

8) Valve'

~9) SpliiilillQI reta i ner I l!Qwer

10) Valve spring

11) Spri n9 reta i ner, upp1er 1 ~;H Valve collets

111·~O/t2

1

2 3 ,

-"...._ ~

I

I .:-.----' e-

. ~) Camsha:ft splrocket 2) Bolt

3.) lock wMher

4) Flalilge bEMillring

5) WOlodruU key e}1 Camshaft 7),Ti m i n9 cha~"

,8) Loek w,aisher

9) Ie: halm n tenslener 1110) Spring

1111' Pis,ticl'n

12'1' Guide' rail,

13) Bolt

14) lock washer

.,

- -- - - ---- - --- -

-,--.-1

r::__ I _.~ _ __ - I

---- ----- - I

II ,,-- I ,- -l - 'I - I

__ J ~ ~t==: _

-------

11-0/1.3

.~) eran'!l:;s:1ila:ft

2) O;woved ball be~ring

3) Spf,oc:lk;et

4) W,oodwff key

5) rMlalilli1l baa r 1'1!1i!91 shell

6) ,A:x:ia I bealrhil'Qi Un nerl '1) Ax, la I bealriiliil'Qi ('ept:ed

8;) Shaft sea ~ "1

9) Roundooal

110) Ra.ce

111) e IlJIltch hou sii;ngl '1121 Stgn wa sher ~13) Hexagiolrl bollit: ~14}' Connect~ng rod 115,) C,onrod bolt

'~16,) Conmd Ibu:!lhing ~ll'l' C~dindric,a'i p'~n

'~I B,~ C'omo d ibearhllQ: shell

10.81

1 } Gover 1 1 ~I Gasket
2~ 'Bo~lit 12)1 W;;is~er
3~ Was~,ell 13} Bal~
~) Covet 14i~1 Ver1lt hose
5~ Wire cialmp 1 5) Hose clernp
IO~ Oove,r 16} Branch
n Gasket 17) Hose ch)mp
:fU Washer 18) Ve'J1ri hose, ~eft:
'9) Bolt lS!} Ve'r:!:t hose, r~ght
10) Caver 111 00 039 Cheoklin,g Compwessi,otnl o,f A,I II Cyllilfl:dielrs, 1. Unscrew spark pll ugs.

2,. Chi eek compt1e,ss;non wit;~, a oa Ub.ratled comeresslon pressure tester ,fu i Iy c:halrgied barl:.tery" ,engi ne!1,9Ivi !i1.g opew,8lting tern per,allit! re, throttle tw in 'grip at i11u!ll throttle iflnd (H1!Qli nEl' rli:,1 nl~,~n9 Zi,l id lespeed,

Impoftan'tl

Make su re ig liIi~tkm is i rlitermp:ted {p lug on ~ign itlon box -see 12 11! 0(4). si noll! ()iI( mHl!r'W ]se ~g !i1ldhm con waUlI~.d be deS'l:If(:lyed.

fest sheet for 'compressk)l!i'il rscorder.

See Specificat~ons for ,compressi,orl! 'lJa~ues.,

E81n

10J~1

" ~ Ol[!l 050 ReMGVlin,gand II nsta mlllg IE 11191i file A,emoveanoilins"l:a U ]lli'It<1l ke ~ i FIe 13 72 OBO. R,emove and i nS1a II tre nsrn is'S~on 23 DO 020.

Lower eng i ne w~th il:1I:'IO Ui~y j ac:k,. De1!a'Ch Ir:fgbt carburetor 0 riI' cy Under hiEliad8Jndl plsee bomhoarbu retors on lbatillelry {arrow) - aliso, tnlE! speedometer clriv,e cable', Remove rig~,t ,ex~laus,t mi31ni'iolld. pull (l,n spark plug !CiOn nsctoss iillnd p~,ace! river fr.alme' {11}.

Pu~11 on mlUllt~:pl,e·p~n phlJi.g on 'COr:litro'~, Unlit, dlsconnect tnr,ee·pi n p bg I~arrow) and pu I1II off mil;.! n~p,1 e·p~in p I ~Ig on govll!rno.r (1~'. Remove starter cover. .

D i scon nset two -p i n plliugi (3 now ~o n erliQl~iliil:E!'S wire ~amess;.

Uti engilrIl,El 'Dill'!: of 'frame. tilting !d'igl1rl:ly to ~eft or r~9ht. IPla:ce engine on aS5emlbl~y sta C1Id, iiFJMW No. 001 490, ln holder, BMW 11'1,10'. 11 01600, andsecure with 'twOi belts.

- -- - - - - - --- -

_-~_' -

II, - __ __- -== I

----- -_--

I_;I~J -:1 ,_~[ ~I - II

--------

11 ,~OlJf3

111 111 060 IR,emovlin,gand IlnstaJlllling CY'II~ndell" :Aemove and ill'll'!i,tt!111 cy'linde'r 'head 111 12080. Loosen cvlinder with several knocks, 'from a plastic ina mmer ,and ta ke o'lf o'f era nkcase.

INote:

Be ca reful not to kln,oclk p is.1iolrii 8,gai nst crankcase when ta k~lIli11g ,off iCy I i nder ~

Repla,ee Q·'rillillg on cyHnder base '~1) as well II as O-Irhilgs en up per staybo Its '12) each ti rn e un it is di s~ssemb lied.

2

Use! 'piston ring compressor, IBMW N'o. 11 2' 905" te gUlide plston into cylinder.

'Hun

11 ~ 11/1

11 12 0801 Rellilo,vi.l1Ig arndllf!,s1l:alllinQI (::ylll nde<r Bead Remow'alnd ill'l:s:caJU intake nrne 13 72 080.

ElrIigine rem.oved {~1 00 050 ~ orl nsta ned.

Re!mooe 'ex: &l!alusta,s>semb~y when eng i ne is, i flSli~:d lad - !See l' B 00 1020.

Unscrew ,cap nut and both nuts (arrowsl, remove av· Under head ,covel" a nd g;gsklet.

Remove both rocker a rms after u nscriE!w~:ngl 4 00 liar mns ,ons-taJvbo Its andl p ulleut pus,i11 rods,

Ufl:!iCJew !two he,xagon flU.Jlts (arIl'Qw\S.) • Leesen ,cylinder h,oo:dfrom ,cylinder wflth kneeksfrom a p~asHc hammer and puU oU ois,t~yiboI1l;s.,

II n'sta~llatl~Oir1l notef'or eyl i'rnd:sr liIea,(:i1

f'~:r;lhlten ,cy i i nder iIi1e.aid mOI.MlIi:i ngl 1l1li lilts: 'OIIi1 ecld 'El'ng i Fie ~nHu~e'Siteps in the order shown in thesketch. Refer mo, SiP,ec mcatiio'liil S for f~g hten i ng 1lorQlliJe va lues,

10.a,1

11-,t2H

111 12 5,113 Di$asSl8iliil1bli~n:~alild rusemb:Hrngl CY~li.!1lder

Hle,a;d and G rli fIIdi nglVa~l!Ies

A emove a rndi nsta UcyHnder head 11112 080.

App~y valve splrhllgcompressor,. BMW iNo. 1'~ 1 750, '~x)mp,~eSl5 valvE! springs,remove valve' ooHe:ts and pull out valve a,

Check. Icylli nder h:ead fe,r

®I) eraeks a nd da mage on mat i1fil'91 surfO'ii.c:es •.

b) t.ightness.of vallve gtil,ide:s (f~glLJrel and vii'llllv~:~'i.lit ~lnI'S€rts,

c) wear on valve guides.

d} damage on su rfaee om bear~.lr1gISi~:rlaces and ba II sockets,

e) rad la I p lay o~ eoekererms,

f ~ lill ~'9Ith of; va 1\I1E!spr~ ngs ar:ld iforc1eof ssme (see: $pecifiicat:]o FlS), and

g) t~)ghil:n,essojf adspters fo:r ca ribu,retor conn eetlon, lilf necessary, ili'il,srtalU eleaned threaded inserts with Leetlte No. '241.

,Miaelil i I1Ilini~ Va:IVie SeaJts

Mach i ne va Ive se,aft: i nsertsi n cy UII'lOIer head wilth a

H l!I!'~g,er va Iv,e~e,al1l mach wn i ng tool. Seat a ng:~e; 45° +20 ~ , i ntalke va 1v.E~ ssat wi~d1l:h : •. 1:.:!; m m; 10r ex hsust va Iv,e: 45° a nd2.0 m m width. Chamf'E!r 'of 151) faeeseo mlbusti 0 n c!:J!9Imber; 7Si;,inc!llin'artiO!m! faces ~ntak,e or e:x:hauSit port. :Se,arl~ seartshou lid close to I al'gieS1l: va Ive searl d ia me1l:er •

Grind seat on valve to ~!3·Q2'(]:' ]Irlal 9r~'li'ildelr. UiillJ.ax a, permlsslble 9rrinciing; up to '11 mm valw.3' head ed,g:e thickne~5,.

G rO!llIl nd va lve 00 nes and val~vese'ilt i nsert g.ml!.ill Iil,d wl~th a llf-h..! nQler t:oo I de not requl re grind i 1:19 of the va lves, but a 11~,ak 'test. (gaso nne po !lu',ed into vahte ,ohambe rs} hils to be made aftJE!r i nsta I lati on o,-ff va ~ vas,

248 l8 11 &21 I

~----------------------~---

111 - 1213

1 ~ 112 51611 R,ep,laciing Va~\le (iI,l!lides

'Remove' and insta,11 cyllrindru head ~ 1 120811.

[)'i saSSie:mbl e a~d a~mbl e cyMlnder h,ead a nrc! glri nd valve-5111 112 513.

Heet cylinder h,e,9,d 1110240 ..• 2.,60'~C (465 •.. 5000 F}, and knock out VaIVlE! ,guide, frem the' oombuS1llh:m chamber s~de' with a mandrel, BMW NQ .. 1111 780.

Knock in In'ew va Ive Qluidles (see Sp,eci,'fi,carticrns for everslzes and standard bores I n tv I i nder head] fitted with circlips in a warmcy'Ullldelr head '1240 .. ,.260°(;/ 465 ... 5000'F) with a malrlidr!el. IBMW Nlo. 11 il 7~90. ilRe'am Ollirtco,ldI \la lve glu ide w~'th a f ix;ed ,8 H ., re'(i mer"

10.81

- -- - - ---- - --- -

- '-~-==== I _

r:: __ 1 ~I

---- ----- - I

II ,,-- I ,- -l - 'I - I

__ J ~ ~t==: _

--------

111 114060 IA'emoying ,Sind IlliiIstaHing Timin,g Case Cover Eng i ne 'rern(tlled (11 00 050) olr i nrS1a II ed,

R,em().vealnd hiistai~1 altenlB'tO>f' 12 3,1' 020.

R,emo,v,eandi instllil sparilk trig,g:er ~2 11, 060.

U'nscrJew nine SOCklM head screws and three socket

nuts ..

MCrlilnit puller, IBMW No. 11 '~I 800. at taPP'EK:I hal,es:~or altemato r housl ng wit hi three 1M S, s;oclke'1t head screws.. Apply 'pr,@'ssure pad for puner ,iilnd pulloff cover.

AHalCihilngllhning Case Co,ver

Heat co¥er at seat of lOa U beari ngto ap'pr,o:K. 810°C ~ 1750 F) Bind mount ,on engine'.

Tighten socket head screws and nuts, S1!arbng fromthe 'center. Settle glroovedi balill bealring wirth sevl!;r,al, knocks ,ii]\g;a lnst bear~"g saat wit h ·ai p~ astle - ha mmer,

- -- - - ---- - --- -

_.--.-,

r::__ ' _.~ _ __ - I

---- ----- - I

II rr: I ,- -l - 'I ' I

__ J ~ ~t==: _

--------

111 -1412

~1114 U)ll Ae:pmaeirng R,adiall ,Qlill! Seal 'f:clIl' Crafillkshaft ,puIU~I9I OMit Seall:

Remove' ami. hlll5:ta II f~ ywhe;el 11 :22 (lOO.

0:.1 t nIP of sea lat bouomlleh ov'er g I elrQgi~ h o,i ,aplpr,ox.

5 em C2"L -

'M OU tnt member ,of p'!iJlner~,BMW No. 11 ~ 890, on era nk· case {'Jjop flight and bottom l~efU. Apply puner~pirucHe, Insert eeeentrie thirou.gh, ,OUi!: i n sea I ,alga i nns1l:op on thrust ri,lf'IIgi, wher,eby tall:). shou ~dface down lu~rn nl!ll ckJickw ise wh i I,e ho'IIOl~ng:Orl!l wrench su rface w iiliiha wrealil,ch and p!lJi U QU'I;seaL

Pressing in Sea I ; _

MOll nt m em ber olf pu Uell'", B MIW NO..,ll 1 .seo., '0 r:l cren k,eaIS€: (top rig htalli1d baUD m 1,81t)., FU mandre I j' BMW

1fi\iJ!o,. 1 " 11 8:801; with a sea laillild app,1 y pressu r~! pad •

. Ap p,ly m:allndlr'e~ on crankc:ase" ~re:w liP lndl eforwa rei Bind p re-:ssilr1! Siealil.

'.-

111 14 ,61511 Relpl1ae,ill1!g Radiail OU Si~ail'fo'f Coralnl!cshaft .Remove and~llilIls.talll 'timIng ,ca:S!@!oover .~ 1 14 060. IIr1stallll radwa I 0 i I seal Iii for f;n:.mt 'era nllksi1a1h jou rna i \IV ith mandre'll, BMW ru,Q, 11 1 8~O.

10.81

11 15, 101 Fb:.liP~achlg:E !:i!g,i ne V,ent :Hose FlemQvefue I 'l:ar~ k U 16 111 030.

Remove a i ~ clea ner ho!us~l!fi!gl uppe,r sect! Q nand IOU ll O'l4!lt fi I'ueif caHu idg,e.,

Unscl'l€W sQ(:;k:e~ head sCr'ews i n st:a rter ,cov,er a nd remove cover, D~iSCOlnl naetc la.mpo~1 breather dome '(ar" row) Vll'i1th a screwdri'VIer.

"

111211 OO~ Rernorving sind I nS'~arll hlgl Cranlblh:an RemOVei!MlId install ti[m ~ ng case rCiove,r 111 14 060. Remove an,d inS1allspr,oclkJ!l!;!:$ 1131 06,1,.

A E!m()v~ a nd ~nsta U p ~st:ons 11 25, 000,

R emov:e a nd i nsta II conll1lec'~ i ng wad 111 24 000. Remove a ~d i nsta II c luteh housi ng l' 1 22 000, Unscrew besri rtgcap m au rtti ng nuts,

Position e.ngilr1ire upright .. Screw two bol IS mmm p~lllrer~, BMW No. 00 "1 r500,ilntappred holes of rna in Ibear~rngl cap providred ma r th is pu rp,ose. II nstai!II!~ pu lli Fig bar Ipara~ie!1 to mai,lrl bear~n9 cap. Do n'11: forget p reS~!iJn!i pad for pu II Iller .' IPnJj II off ilia i n be-airing cap.

Knock o~f both 11:1:1 rust washers from tocatl ng p~It1Si wi~th ,~ screwdrh"er.

1i1 -,2:1/2

Measu ring Cn:.!llksha1lt a ncl IEh~alri ng 161l11sh i ngs:

Mea~su re rna in bsari 1191 jeu nril~adls cn:l'j!Swise in 1!,W>Q pia nes with i: mii::iro.mBtel".

F rent pll:al~iHi~

Mleasureflront crank;shaft bearin:g only wvth installed bealr~ngllcap.

Note:

H ealteng,ine bl,oCI~tO 1100 , .• 12(t" C (21' 5, .,.,. 25ft f) be~orre i nsta IIII i rli9the! beari nQ cap.

IE ngirn,e Ib! oek must be C(Ji~ d :a:gailrillf'O"r rneasu ri n;g .e

,important:!

The mal n bealring must O!r1I~ y be eheeksd witih help of ilJH9 "Test IR>eportfo r Cran kshatt IMa ~nIi B,earilr1lgl PlalY" - :see! Spec~f~cat~ons ~

To press Oliffi' be9ir~:li1Ig csp (without cn:uilkshamt), pi'Qlee ma nd re'l f[lr mali nl: bee ri ng" lEI MW No.1 '1! 2' 12iO (~Li n rear beariilrllQI. IPr18HilS ,)~f bsarhng Icap witihscr'ew nipp,lle, BMW No. 111 1 7 ul '0 (2) r a,li1!td pflessi I\g-o,l\f bridge w iil:llhi s,p i rn.d.lefrCHl! Ku klik:o ~17 K 1(:3,).

· .• and ronlrod be,8lri n;gs in sa me mal~neras de'SclrUJsd for 'the Clrank,shl2)lflt iii riI d Ibe~ri ng bus11il ings.

S:eie Spediic.a1lL ions f,olr 'be~ri n9 pi,ay va'! UE!S:.

10.81

'111 ,~2U3

111 21 531 Rep!Jaici 1iI!)1 Mali!iil Elear!r1!g B usb i!l1gs R.eiph:u:e! ora nk;s;~an 1:1 21 '001 ..

P'~essing Ma i n Beari ng IBushhil.9 Out 011' (;Ir.alin kcase: ~Iea~. cnl'nillkca:sf.l to 100 .•• 12100 C 1~215 ... 250Q F} and therrl! plaee iii: over cyUn:det o~f;ixture.8MW No.

1'~ 2' 71 O,in such ill manner tbart ~oca1ing pins 'VOl' hlllne'r th rust washer en,g;agI8 in he I,~~ of cyn n;der prevldedfer th ls purpose. 'P!'iE!S'5 OUI: be~drrg bushi n:9i n a m~ln~itd 'press, w~th ma ndre I r BMW No,. 11 :2' JOO. Wln!en pn~:ss~lI'1glilln'f use aluminum pan. BIMW 1~lo. '12710,

a nild a pilE!ce orff pipe 11:0 eeu nterhold,

H'e!.8It era nkcai~lio 10D .... 120f C (215 , •. 2500 F). IPlllace ahllmilli1lum p!ad Tlro.m 1fixtil.illlre, IBMIW No .e 11 :2 710, en remo,v~;ng 'Cv Under. I~ nsta ~ i era nk!Ca!S'e' 'over jfix~tWlre in sueh a rna Fli!i1I er iI;,~alt both locat ilr1lg plii ns engage ~n holes p rOI- videdi n a ilUm~il~liJm plad.

I nsta II new bealf'i ng bUS:~lmn9 t.llar b e,ari rig bush ]I!I1!ggap

is: II:oc~1:ed at :ljQIP r~gl~lt.a s ~seen ail: f~ywln~eill end ,and aU be res ofI:U1!ai~un,g bush ing a re pOis:i'~.iolt1!El:d 'tOI rneteh be 1i'E! ~n era nkc.2H~e! at bottom ~eh.

I nstall maJndll"ie~: w[th p,iI1asti,e slleeve! 'f,rom fixtliJllre, IBMW iN1o, 1] .2 7110, in bealring busi~lhllg •. Malk;le S!JJIllr'E! that lecat~ngl pins prOctmdi fl.QI from cran'kcasE! e%tlEl'nd iilliil!o o:pem,· ]ng!s s:t per~iphery 'of mSlindlre! atter press! n9 i n ths bssrin91 bushing. The be.ar[ng bushilrJI91 is s~zed that it wm

be posi"l:'iml1ed iba;clk h'1l1 :the bei31I!'~;ngl !JOI'lEl om craliilkcClse' O!!I1!1 beth swd\es.

Ifh;:\P!~aci rig Ma i n Bea rl n:g BUS~'~II~gl ~,trn Ma~nB·ealrg ng C:ap; II::. nock out locat~illI1lg. pin 'fo~ lbeari~ng blush i rug from i rilsidlll to ou1ts~:d,e, Heam lbeal!f~I!l1lg1 cap to 1100 .... 1.200 C (;215 .....

:2 Bl:t' ;F~' ill rid posi1liIQ'!I1I, 0.0 cyilli.nde:~ 0'" 1'i xtu,re s : BMW N,o. 11 :2"]' 1 [I'. PlrE!SSO!iU!lt bea ri 09 blush ing in ma nua I press with mi31nd!'ie~, BMW No. '111 2700.

10.61

Press 'rl'ew bea r i fig bush irilQI hil'!.o boo ri ng c;alp~eaJt)ed to 100 •.. 1 :2\OQC· 1~2~1 5, •... 2500 F ~Ij that beiar;~f1:g bushing g16l:P is k:l!::at!~d top leh asseen on inst:a Ued bea ri ng cap i3lnd ,Q i I bores an! pos~iti'o!lil,ed vlert ]Qa I, Onset be,alring bus!~ ~ ng gap from vert lea I byap'plf'QX. ;216Q (see arrrows) •.

C~lam p beelri ng capi ~18i vise fined wUh sQ~t]aws. Dlrmlll MO add illL ions I IQ i I bone's, !pos;.1 ill nd :2, i n bealr]l~g: bushi'~i9I·through both 3 .. 2. mm (0.1216") dlhlJ. hOlles8!keacly

p n.)vided ~!IFI bear~lng 'CZlp. Deb!.!!1fr ho'l es ln bear i ~gl tH.l!lsh·· iril!Q1 carleTrull.l~y.

tock hea ri tli.gl bu shilli1li91! Dri IIII a. center [ili1ll besri ng bush~ irtg th!r<ougl!1 the '(4IH8.) locat~lIfbg pin hole ~:n bealr~\li1Ig capl witlha 3 .. 9 mm (0 .. 1153'"') dia .. drilill b~t .. Then drWlI thirrcuJ'Qlh Ibealri ng bush i ng w~:th 3.8: mm 1~I~lHiO "} dia, drill bit (tlii1lls:k: ream size OGre) •.

00 not rea m til fO i!,lIgh beslri:ng! bu.sh i r1l.gl wi11!ih hand rea me~ ~411a L to prevent. leekpi n from m ov i n9 ln,

IDebu rr hole calr·efil!J Uy..

GI.81mp rna nd re ~, BMW N,Q .~11 .2 71 O. in a v~'!le •. II: nsta U bealrl~ng leap. Knock in IOClkpili1l1 on'll¥, sofar, that ilt stalnds bac:1k:. bam belllring bushing bOH! by 0.5 to 1,0 mm (O.JO~\O to O.040~j). Loek pwn with :tt:~ r'EHl' n()iI!ches •.

11- 2'11/5

11-2116,

Adj'll.!lst.ing Axialill piliay o,f Ci'snkslha.ft;

See Speolifi:catiom for table o,f tbrust washers"

To Ibe ab~e to, aJdjust ,axiall play ef crank'shalft ,e.asi,lly, it lis r,ecommendedtlo pllace a red-rna rked thrust washer on inside ,alnd outside of locatingi pins, IBoth h:u::at'ing

pi ns must he,v,e !Kilm e i31mIO'~ 1r1I~ of pm1Jms:ioii'l 'from era nk· case on cl utchaad c:ralnksha:n e nds, IH eat crain keasa to stra ig hten ,or i nM:a II ]ocat~iilgi pins,

1&-1 eat era" k:case to '~CO .• '. 120Q C .(:2 '15, ... 260QF L mou nt (11m, ,ii1ssemblys1tilnild and position uprmg.liirl:" Guide clfank· 'sh:arft into bloclk car,efull'V. I ns~all be,a,rling eeas and tig!hten bolts. Turin Cfli!inlik:case 1 :aO~. Instaill 'clutch housing.

FI,emo,veandi install clutch hous:ing 11122 000.

Betu:rn crankca,se 1:0 hOfliizontal po:sitiQII1. Mount d~al gilaluge holder, BMW No, 002' 500. em transmissien 'flange 'of cran kcase, C heck ax i,all, p4ay. :Remove flvwhee I and meaSl.llllr'e i nsta II'ed" red-marked 1I:h I"IU S1: washe r with a m ~:cr,om:e1:ier.

Examph3; Mieasl:ll~edalx.i.alill p~!ay Wa,~ru!dI aXiia I play

0. UJ mrn '[0.!007") 0.112 mrn '~O.Ii)05'··l

I[Hfference -

Measured thickness of: removed thrust wi!,snelr ,p lu s d iff.efience

0.06 rom (0.!i)02")

2.48 mm (0.09:8") + [1.06, rnrn (OJJ02"')

2.54 mm (0,.100"')

Se,I,ect a thrust wasiher, whose thlekness ils as close as possilblie to the deterrn i ned v,alule .. and does 1''I>I)t devi.alte from iit by mere then +0.03 rom (0.0012''') or _.JO.04 mm (0.1)016'''). II nsta II: th rustwasher of deterrn lned

th i,ckness 0 n looati I1g p~ns.

,'ress :siha.h seal into c:r.8ilnl.kcase with spec la ltee I, BMW No. 11 1, 890.1 i:n ~olifijl!llnc:tj,olrl with mmpac.t maiflldlre~ .• BMW No .11 -1 ,B80. Press :ill'l iimpact mandrell] U nt U it is, aga i nst the thrust wa:sher.

NOUN

Phlce' seal in QIU abcut 2 hours, ibef:'olr,e In:staIUng.

'10.81

11, 2201001 R:e'llilo,v'inQ and Ilnsil:alllinQI Clutclilli-lo'UlSi,I'iIQI

(FI,ywheeU -

R emO"lleand install c Ilu"l:ch 21 21 000.

MClilllllFlt holder" BMW' No. 11 2,800, on clutch ihous,ing and lJllnrSICrew bolts in crank:shalft.

S;E!;e Speci'ficarttions fo r tigh1te ni,ng 't,orq]UEl'.

Tum race (arrowl by one' haifa hole as compared W the crankshaft and pull 'off of cf,arnkshaft stub with 2 h oOlks (a ng had scr'Ellofildrivers).

- -- - - ---- - --- -

-,--.-1

r::__ I _.~ _ __ - 1

---- ----- - I

II ,,-- I ,- -l - 'I - I

__ J ~ ~t==: _

--------

11 -22'/1

11 :2:4 0001 !AemoY.in;g an d h'!lSta~11 i ng, 'Connecting IFIt cuil Remove a ndiIIi'lHs.tall~ i eng i ne 11 00 O~(l. Remo,veamji,~st~U cy ~ i ncJis!r h,eac!11: 1:2 mm .. Remov,ea,nd ilrn,stailll pistons '111 25 om}.

Onl~V petform an tesii.i n:gl a~d IrepiS! king procedures d Elser ihed in the pre~imil!i1l6i ry wOfl~. whenalbsol Mlte11ly necessary .e

CQntij'taicting rod ]s r,emo,vecl and ~'!i1I'stallllledl wi,th c:ralli1lk~ :s*l:ElI"ffti'mi i DC. Uns.crew co nrod bo~ ts w:~th a mll!l~ti.p~ e socket wrenc:lrnl, BMW N Q •. 11: :2 ;860. Remove oornnlscli ng !WOlS8nd conred bead mJ9] caps tOQlethelr wit~, Ibeari ng shel hi.

lnstallatlon: Iinstall both connec:twng: rods tha:;tt locaming pins o:fca~lnecti~.gl rods! are arwalng,oo on alternator side'.

I IIIQspl8iOitt i n,QI sl!i1Ia R'!!pa iwifilrQI;

MleasllIre connoc!iFUgJ trod thleknessat thrust bearing w~ith a micro meter. IRef·er to Speeif k';8rt.!.cII!i1l·s ~CH' dimensions,

Both conl!i1l'8iCt.ing rods in one lengine must ihliaJve the same weigJht etass ,ar c:o'~a,r code'.

Checlk "I:.iglhtness a ndslze a<11' IPiston Pc i 111 blUish i ng.

If ~,nside d ia,me·ter of piS1l!an phlll bu silinglis worn beyond limits, press out :piston pin bushing., Refier to S:pecifica· tic ns for dl merasions,.

10.81

The! pis:tJo:~1 pin 's:lhi:ou,lld sUde easily into a fIIl~ buslh~n9' u m:h~'r 1I:Inll.llimb presSiI!J re,

Me!2l'5U ri ng COlilfilleet~In,!!lfrl:lod

I nsta II the bear i rug shells Jj,roliiciedfor 1es:fin,g in 'the

OOIIFll necf~IIFIl'g rod. Ta ke up co I!1Inec'11i ngrod on a halrdeFIled :!imell gnl'lI.lIlliild master ma nd f!3lalli1ld t ig hten bo,~ ts, Master malndl'le~ must net ilhi,fllVE! rad ~Jiil ~ play i n '~h,ethrust hea r~ rtg bore .. Push a 91FOU ndand balrde:ned master millndre~ .• ;Qlpprox. 1 !:sO mm (lei "~I lo 1'119" into pi stQln ph"lll bush~Wilgi 00 that rna nd rei ex.te'f1Jjg, from both ends by same amount,

Se,t up il:w'O v-b locks of ssrn e si,ze on a ea llbrated moostIIlr~lnJS pl,a:te. p,~ alee master mane! rei wit h con neot~lrngl rod in v-blccks, PrOsmtmcHl ron necti:n'9l rod to be v,entica.l. with iixtUlre .. Ulse ,ii'I stand-type dlal g'alug,e an end~ of master ma ncl re'I .• to check whethe.r pist~lnl pin ax is is para ~ lie! with thr.liJIst Journal.axis. Re1ferto :Speclifircaticm for inllh::mmatkm on ,check~n91 palraUel ef connect~ngl rod,

Check d lsto rdon of 00 nOiecti og ro d. Th is req u i res that OOIri!tnec.t~ n:gl red be .agai n taken Iii.! P ~n v-bleeks am:! a support beplaoed !U1!iloerneailiih the piSliO'~1 pin ~¥e'j that 1I:11il,ere! ~sappr,ox~imaltiely ,equ,91111 dmst:a nos fromt ~.e meas.lIiJ ri ng plate· iliO' the' center Q·iIl the thrust be,a!ri ng bore and piston p~n here, Chelck oonnectiril,Q1 rod fOlr distort~on by ,Q!plPlly~ng .. a dla ~ gi8ugeo n e'Uilds at master rnsndrel.Refer tOI Speciific:a:tioIU1ls fOlr max, perm~ssib~e dev~ation.

~,nstall beadng shells in a elsan round connecting rod be<ad~lg bore,

~_~ ~_---="::__' 18 11 OiB

Prio,r 'to inst~UatkH' of; c~alrlkshaftr ,ap;~:dy a light COI!!t o,f M 0 ly!kOlte' Pas-te' G on mal lnsnd conrad boo ri ng shells,

10.81

--- - - - -- -

_-~'

11---, --,

--_ ---

---- ----

II__I [_ J J ~ I :=_'I II

-------

111 - 24/3,

11: 2:!~, 0001 Fl:e:rnovi 1119 and hils:taUi filg IPliswliI RemovlElaJnd h'1lI~1Ct'lU cy~ind!ew head 11 12 ~)80.

Pu 110ft ICy ll nder Trom 4 a:ru::!itolr b Q lts, Be COl refu I not ~o dama;gE! p iS1l:oFl w~,en pis.ton i eaves cyll~nder. III nstal II a, p ieee of we od be:~,~indi the 1P·~S1on, between the' anchor bol~s, '1:0 plliiOtect the p~ston.

IR:emove if} lston p ~ti!1 c~r,cll;ipwitha, spseial c i rei ip IP~ lers, If'ress out p~S1l:0n pi~ln bY' halrnd or with 0'31 manJlrlEl'l, BIMW NOI.. 11 2920.

In'srallatio(1.: ~In&tall piston that "vern" (,'" iflr,olnlllt) em p istoln ,crown 'faces: forwalrd. This gu.arantees eerrset instaUat~o n ot p~st(m with !81r1!1 ,otf\se1I: ax~is.

The piiisum lfil e~d nat bE! heatedto i nsta II the' p1lston pin .. On'~y use p,isto ns 'of s~me we i9 hit Iclllassi·fi,c.arti!OIlll~l!il

On1ie eng me .•

Instal/arion'.' Prierto lnseallatlcn Q~ cy~ilfil.der, clesn cyl iind!er baseallild cyUt~delr se.al~ illillQI fiU rfaess on leng i ne bloc,k wi1l:h nltro th inner. IBe ci3lremu I notto pi~fllch reu nd (lord seals, on upper stlillybo 111:&.

Illf cy I i nder Ibals:e' sea ling probl,ems ere e'xperienced, use "oversi.z1e" rOlliJ nd cOlrdsea Is '(SElelSpalre jpaJrl micm~ iI ml .

11,- 2511

111 ~.251.2

1.!fiI,~pect~lli1Iglalnd Repai ri "9:

Measure ,oyHnder bore with aJlijli.li1I.t:emallll c::al~iper:s, w~ich is applli ied in p[Mon il i n cUr,eoUon and 90° :llail:eraJIII from ~his poililll,'~. 10 mm (0.3914") ~IrOlm top, at ,oenter a'!1d bottem, The a mb~!ilnlt "I::emper.nIU Fe sholJJllld he :20Q e (6SoF).

lMeaSll,llllre p~S10n diameter at skirt oi piston with a m~cr(lmeter.. liR,efr:e!rto, S!Pecif~cation:s,

-

sidedeai~ali10e ·of !P]StOI!i1l rings. with a glaluge! blade .. IR:e1ferrto Spedfiaationsf,or standard size and 'ove'rs~ze! cyl ~:lli1deil' bOlre diameters a.nd piStlOlij' d ialme-:l:ers. as; weU as Bind a liids:ide cllean noes of p lsten rM1Qis.

11 3:1 01611 R,epllilc~n9 ,s:proclicets IEngine instailled or remQ,\I',ed. !Drain oill of installed ,engine!

R,emovli!i ,am]1 i nstsll ,eng i ne '111 01)1 500.

R,emove and install ~piilrk tri'gger 12 11 0.60., RemO'voEl c'lFna~i n g ~Iide ra ll (1) and cha i I'll t\ens:~(m i n9

II ~V'er (2'~'. -

Open cha i n lock Bind remove dna in, I'nst8Ua.tion;·

Chain I,o'ck must be' locked in running direction and chain guide, rail must be parallel to chain.

If'u II ~5p'ro eket together wit.h be,alri ng of'~ of era nlk:shafl. E:xchiange puller, BMW N,o. 11 :2 1600. and p'~lll~ing S!I·H~n. BIM'W' No. 11 :2 60S, against ill pldling shelill wiiith gr •. nove, In thi;s marmer the' beari,ng cenbe reused,

.Ins:ta#atiol"1 ;'

Bea/t sp,rocke'lllo a PP i'OIX • .s00 C (1 751) F) and i:ns,ta~ I the hestsd be,alring afterwards.

Press 'off' camshaft ~pll'ioc:ket wiith two scn~wdri\ff!'fs. !Don't darnag,e 'Sieal~ng :surlacE!'.

InstaJ:latlon,:

When instaI led the marks on both 'Sipro,ck,ets must be opposi~tle 'each other.

10.81

11-,3111

111 34 504 ,Adj usting Vall'we cmear.ance

U rn:scnlW' carp 1f1I:Ji.! tand both nuts (arrows). R emQve, cyUnder headcover and gasket.

A.d~ust va live' lei earance between the va Iv,e s:tte m ill nd mc~kler a.rm em a 100 ~d, stepped ,eng i ria' with ill giiiluge blade'. For this purpose' UIIfl'screw ths spark plugs end tum lengine unUll1 the ,cylinder being adlju'S~ed is at com:pn~ssiicm TDC. IBot:h valv'lil are elosed, Ilf necessary, eorrect adjusting screw after 11J1~'5Crewing the leek nut. Tiglhten l,oeil< nut. fI:ecilrneck valve clearance, See' Spe,cm· ficarti,ons for valve Icltearam::e.

- -- - - - - - --- -

_-~_I -

11,-_- __ - -== 1

----- ----

'-'I~J -:1 ,_~[ ~I - II

---------------

11 41 01001 Re'movi !'119: a nd II n:s,tailli ngl Oi'l Plum p F!,emove and i nsta Il,cllutch 211 21 000.

A,~,mO'Ii,e (!llIiId i nsta llf ywhee 111 22 (]Oo.

Remove fmd cover 0 n 0 i I p,ump ho!us~ng,aJne r tI nscrewling the four hexao'on head bolts,

Talke in ner rotor out of housi ng wi'1lh wi re hooks.

Ctu:llc:k~lIlgl::

See Spec.ificat~ons for p lay between outer rotor and Ipumpl housing.

- -- - - ---- - --- -

- '-~-==== I _

r:: __ I __ -~I

---- ----- - I

II ,,-- I ,- -l - 'I - I

__ J ~ ~t==: _

--------

1 1 ~4111

1

B'eile S:pecif leatlens fnr piliay between mati n9 su rface (pump ~ Dusing) a ndses I iiing sllIIlIrla·ce I~ retor],

Check cl earance between inner a no outer rotors, see Sipecif lcat ions for va ~ ues,

Don'it fro,rg'e;,: key w!ltiien ;8$sembUng snd mak>8' SUr"E! O·ring i nend cover~si n perfrect cQndi,t~on.

II n assembl,ec:l st,llit!9' the O·r~in9 (] ~ must be pressed into gl!"oove '~2~ so' m~ch that the end COIl/'er rsstsfu Uy on the! he'L!J!lsi,mlg malting surfsee.

Gondfrti (I n C,a use

Cempression pressurel I'lslUf"ff ielent Va,lve leaks Q,r be nrl:

P]stion ri n9 tenslen 'tIOO wellk: ~ exeesslve end c:le,8,ra nee

IPIII$ton rl rigs broken

Gil" ilnLd or rep la,ee Cheek or pep lace

Aep!llace

I nrSJuUicilent power I'Qlnitk)n, timing wrong Float Ilevel too low Air filW clogged

Fuel valv,e dirty

IE r1Igl~ne t1haird tc start or won't Va lvss rna l,adJ ust:ed

lita rt Choke will not e lose Illgn ition rna ladjusted

E lectrede 'gap cf spa rlk plugs wrong Spark IpmuQ:s wet

Check" adjust Cheek, ad]ust Repillace

CI ea n, check fl·ow raille

Check vah"e play" adjust Check ci'IDoll\:; e satti ng Chec11k: setti ng

Adjust

,Dry

Eng i ne aceelerat ion notqood I nsuffic~eillt or no centri'fug1alli co nt roll:

E I eetro de g,alp of spaek p lu gs w ro,ng

Engine mmsffires- high fuel co nSi~ rnptl 0 rill

I 9 n it'uon wmri ng defectvve" p ltilJ,g CCl:PS deifrectii~,i"e

Sth [eilld.ed resistors defective

Engine knocks

I 9 niltl·o n Umingl 'WiI"O n9

Need les pcsltlened i noorrectillyi n carburetor

Adju st ij'gn it io'n

IPosition needles canectly

Oil ,pressullI'ei Il$lU fIlici·ent

Check cranksiharft and bearings

Ctr,ankshaft main beall'in,gl p,lay e'X:C!l!ssiv,e

Suet ion II:ul!~11 ,clloglQjed

lPressur;ie w,eUe;~ valv,e snuck. mini open POs11tkln

Chock or rep lace Remove and relpairr \,I'alve

---- - - ---- - -

_"-~_l ~

11-- --- , _-- I

, -_' ---

---- -----

IL'C_J I "~l -=-_'I II

-------

Engiln,e' Ellectrical Equilpm,e'nt

'1:2 Engine~ IElectlrical Equi1pment

Sjpecifl:cati;ons ..•. , ' ' •..• ' ' , ., •••. ' .. " , .. , , •.•.•.• , ' , .• , P<a.ge l2- 0/.3

12 11 m14 1'9nwUo,riI 'ti;m~ng- adj,ust Static .•.• ' •. ' •. ' , •. ' .. ,.-. l2-11l1

. D1YIn'amic •••••• ' , ••• ' ' ••.•.•••• , • • .• .. '12-·1112

1 2 11 060 Spark trigger - Iremow and mn staill , .....•.•.. ' ' .. ' .. .. .. • .• 12-11/3:

119.n iticm iv,stem - treu b le!Sh,oolt, .. " ., • • • , •• ' , .•••••• , • • .. .. . .. . .. .. • • •• 12-'111 /!3

12'311 0201 A.lterrnato,r- r,emov.s and instialJIII , ., ., •••• ' •• ' , •• , • •• •• • . 12-31 n

AlilJ:,eril1latolr- trou b:leshoo,1I:. . • . • , • . .. . .. . .. ., .. • . • " • , • '. • . .. '. .. . • . • . " • , • . .. . '.. t2-31/~5

12 41 0'091 S'ta'l"ter ~n motorcyde - check , ' ..•. , .•.• , ' .. , , •. , , , 112-4,11/1

1 2 41 0.20 Starter - Il'emo,ve and ~1I1 sta II '. .' . .. .. .' '. ., . • . '. , • . • . • • • .' .. ., . ., . • • • . • .' • ., .. . . .,' .12 -4111'1

Starter - tw'olubllB'.silrl.'oO! , " , a- , •• , .• , .•••• ' •••• , , •••• , ••.•• ' , •• , •• '12-4'~ /7'

--- - - - -- -

II'=-- -'-~~I

--_ ._-

---- ----

II_I [_ J J "~ I :=_'I II

-------

t2 ~ 0111

A ;SO GIS

Starter:

Type

DF 12 'V

320 A

0 .. 7 K.W

Torque

0.150 mkp

Starter' re lay

Bosch

0.10 ..... O.U3, mm (0..004 •.. O.006~'·}

Alitemiall,or: iiyp,e

IBosch G114V 20 A 21/2:80 W

280 Wl14 V

20.A

R,es:istarm.:e' !betw. phase o,utllets

0.6;2 ohm

980 rpm

1 0 000 rpm

Max. speed

Min. sl~p ring dla,

26 .. 8 mm (1.055"1'

3 .. 4 + 0.34 'oih f1II'l

Wehrle E .~ ~Jt51 'BnI4· V

V'D~tage Reg,l!Ima~or:

Type·

Regul.8lting vQ,llitag:e on eill'gi,lliIEi! having opemtillilQ tlemperatu re, a mbie!l1t temperatulre 20° C 'loSo·F,). 5000 rpm

13..6 •... 14 .. 2 V

ID !,ode: Caniell"::

Type ,j:B'Qsoh)

~ gll'l itli'oll1l ICo~ll:

Type (Borscllll},

lDua I spark 'lgllil ~t:i 0 n coii 112 V

M 14 x 1.:215

Spiuik Plugs:

Threads

W7D

14-1 D

Champion

N lOY

Electrode galP

l[)ist1fliibutor:

Type ('BOSiCh)

Brrea ke rless ig ~Iiuti.o n pu ISG' il;lransmitt!er (IH,aJilil sensor) wlithintlegrrated centrifug!a,I]: advance contrel

115010 rpm

3000 rpm

t,

--- - - - -- -

--~'

11---· --

, . I

---- ----

II_I [_ J J ~ I :=_'I II

-------

For engin,e asse'.mbly Static ign ltlon 1I:i m ilrll,QI

Modell

R 80 GiS

Armatu re mort!J Ir1It~ll1!g bo It Spark plu.,gs

25 ± 2 Nlm 1~19 ± 1 ft~ ~bs,.) . 20 + 5 Nm U4 + 4 'ft.lbs,.)

Tighten a II, ot1tI'tu~r bel ts a nd nuts to oommOI~ltorque~a Iluies as listed i Ii1l tables :su pp~ ied by ibo,ltsUlp'p I lers orin new iBMW StaII1l dard 16CW02.0.

- -- - - - - - --- -

_-~_I -

11- _ --I

-_ ---

---- -----

'-'1~J - j _~l ~I - II

-------

Starter'

11) Cap :~UScrew

3) Wa:s!her

4) Beari ng bush

5) CommLiltafl:or be-air i m9 16) S<:rew

7') Washer

8,) Brush ho Idell' '9) Arimaltl.llnil

'10) Solenoid

'11 ) ~x,c~1ier coil '12'J NlJIt

'3}, (::irclip

14) Screw

15) Cts!c:,. S-Cf,ew

16) Drive bea ri n9 rn E.h:lalr'ilrrkQ bush ,I.e.) Opeir,atwng' Ileve'r il'9') Sw:rter 'gear 20) Il8ea.ring bush 21' J' SlIOP r"ng

:22}, Ctsk. screw

:23)1 :Sprmng

24}, Carlcen bfiliJlsh set 2:5 ~ Wa,sners

, 2111 OO~ A.dmu:!ltiIIi1QI II QWI iitilQ:n Iii mii flg (Statile) .I mpo.rtant!

Ttl is, mo,;ta,rc;y'c!!eis e,~!.11 i pp,ed 'wi,th a hliglh vo,l:taJ!Je tra 111' s~st:or ilgJliiliitiiolil systieliill,.l',Quchifllg IPower ,calrlfyilflQ parts, of sy:s,teliil'lwh i le ,ell1,9lilfiUil is ri!J.I rnnillilgi ls da:nger,ou;s!!

Remoi\leeng i ne DiM 8Ir"d,after U nSClrew i n:g both so eket t1,ead screws (arrows).

D i:5C() nneet 3·p i n pll ug, and co nnec~ i,gnillliontester, B,MW No. ul23 650"

.Alate.:

IF! etmove wiil'le c~amp of p lug con nectiiO n!

UnSCf'ew spark IP,~ug~: a nd era nkeng i ne' clm::kw isa '~o p. pos:ite forward dI~reotio,n,l' wUh socket head sc,rew 'For rotor • er cr.an1keng i nil! wi,'1 hi kj ek :s.1tarte'f.

:Ce nl1LelF w,rntte str~ipe orUywheel mark "S" must be a I iglnecl wirth i.nspecfkm hole rna rkon en91ilfl'e block (second pi,tt!ure O'~. page' '112-1 '1/2} when d~iode: on ig nitio rillte:ster 'comes en,

Tu r11i1l r.gn iii: ion box as shown Ii necessa.ry.

10..81

l2'-1U1

Check Ing llgn,iit~cl't~ Tl III I 1119 I( D'Ynilliil1'ilc~

Con nett .S!JrJ'bO!500pe I~amp on b~t.1;e!ryalndl igll1 ltlen wmre. Stalrt engi ne' a ncl bo,ostspeed to .3:900 rp rrr. W'he1ril aim ~ngS1l:mbOiSCQlpe ~lamp ait flywheel, wh iil:e poi:nil: "P" :s,~'OU II~dalp:pear i ntha 1~lnlSipectmcm ha,l,e (flui I adv.am::e igliiiliitkllliill~.

Te chec:lk the' iiign ltlon corrtrel ICluve" turnseitwhee.i ef :stroboscope lamp 1~"riIm:i I ',I[lC' , ma.rik appea rs, The o::ilctJua I igll1llitio n an:glile cain now be read from fieallle: (I IiilI :S1I!fobosco,pe I,amp.

See' SiPec'i1iTica1t ions mer [gn itlon ,al~glile clara.

When eni9l1lni,eis rmnm1l,iingalt ~(Ue spe.Eld (9160 ± 150 rpmL cerwter wh lil::es1ltr~p e o~ '~lyw~1U~e~~ ms rlk "":s" shou 101 be

a ligned with I niSp~i,olrili hOI~e rna rk. lif the' Istrwpe below center oa,n be :seen, ignh:.I'Olnil trum~ll"1Iglis too late, and whe:nlli\lib ove center, 191n hI: IOI~1 timmng'~s '!jOO ealr ~y •

Ad~II!I:slting·~ see pg,ge 12~1 '11/1.