BenutzerhandbuchInhaltsverzeichnisRepair Manual1Introduction3U sage4Key to symbols4Contents4Maintenance Schedule K 75 RT/K1100RS/LT5Pre-delivery Check K 75 RT/K1100RS/LT6Contents700 Maintenance and general instructions9Tightening torque11Table of operating fluids18Key to maintenance intervals19Changing engine oil19Inspections I, II, III, IV19Changing oil in transmission (gearbox)19Inspections I, III, IV19Changing oil in rear wheel drive20Inspections I, III, IV20Changing oil in telescopic fork20Inspection I, III, IV20Renewing intake air cleaner20Inspection III20Renewing fuel filter21Inspection III21Cleaning inductive pulse generator at rear wheel d...21Inspections I, III, IV21Checking brake pads, brake discs for wear and rene...22Inspection II, III22Front wheel brake22Rear wheel brake22Checking brake fluid level and correcting if neces...23Inspections I, II, III23Checking brake fluid level23Adding brake fluid23Checking brake system23Inspection III23Checking ABSsensor spacing and adjusting if neces...23Inspections I, II, III23Front sensor23Rear sensor23Renewing brake fluid24Renewing front brake fluid24Renewing rear brake fluid24Checking function of electric switch on side stand...25Inspections I, II, III25Checking clutch clearance and adjusting if necessa...26Inspections I, III26Reading out Motronic defect code memory26Inspections II, III26Checking increased starting speed (choke) and adju...27Inspections I, III27Checking increased starting speed27Checking valve clearance and adjusting if necessar...28Inspections I, III28Adjusting valve clearance28Removing sprockets28Removing camshafts28Installing camshafts29Installing sprockets29Installing cylinder head cover30Checking steering bearing play and adjusting if ne...31Inspection III31Lubricating guide pins, adjustable screen32Inspections III, IV32Checking idle speed, synchronising and CO value an...33Inspections I, II, III, IV33Adjusting idle speed33Adjusting CO value without catalytic converter3411 Motor35Removing engine45Dismantling engine46Removing intermediate flange47Removing driver47Removing clutch housing48Stripping down and re-assembling intermediate flan...49Removing the driver bearing49Installing driver bearing49Removing and installing shaft sealing ring for dri...50Removing countershaft and layshaft with freewheel50Dismantling and assembling freewheel51Stripping down freewheel51Assembling freewheel51Removing and installing layshaft needle roller bea...52Removing bearing52Installing bearing52Removing timing chain cover53Removing the Hall-effect signal transmitter53Remove the crankshaft cover53Removing cylinder head cover53Removing and installing sealing ring in timing cas...53Removing the timing chain54Removing chain tensioner54Removing chain tensioner rail54Renewing chain tensioner rail facing54Removing camshaft chain sprockets55Removing chain guide55Removing, stripping down and assembling cylinder h...56Removing camshafts56Removing cylinder head56Removing bucket-type tappets56Removing valves57Remachining valve seat57Installing valve and valve stem seal58Removing crankshaft59Removing big end bearings59Removing main bearings59Removing pistons with conrods, stripping down and ...60Removing piston with conrod60Dismantling piston60Checking piston dimensions60Assembling pistons61Checking cylinder dimensions61Removing and installing small-end bushing61Assembling pistons and conrods62Removing and installing crankshaft pinion and roto...62Removing, dismantling and assembling combined oil-...63Removing pump63Dismantling pump63Removing slipring seal and shaft sealing ring64Removing pressure relief valve64Installing pressure relief valve64Install the shaft sealing ring and slipring seal64Installing pump shaft and impeller64Removing output shaft65Removing oil sump65Removing oil filter65Removing lower section of crankcase65Removing and installing oil level sight glass65Stripping and assembling output shaft66Stripping down output shaft66Stripping down tensioning gear66Assembling tensioning gear67Installing damper67Assembling engine68Installing output shaft68Assembling the crankcase69Installing oil mesh strainer69Installing oil filter69Installing oil sump69Measuring crankshaft bearing play70Measuring radial play70Measuring endplay71Checking dimensions of crankshaft71Installing crankshaft72Installing piston with conrod73Measuring big end bearing play74Installing big end bearing74Installing combined oil-water pump75Installing cylinder head76Installing camshafts77Installing timing chain78Checking valve clearances79Installing intermediate flange80Installing freewheel80Installing countershaft80Installing intermediate flange80Installing driver80Installing alternator80Installing timing case cover81Installing hall-effect transmitter81Installing cover for Hall-effect transmitter82Installing cylinder head cover83Installing engine84Checking/adjusting valve clearances86Adjusting valve clearances8612 Engine electrics87Removing and installing Hall generator91Adjusting ignition timing92Removing and installing ignition coils94Removing and installing ignition output stage95Removing and installing alternator96Disassembling and assembling alternator97Alternator [only LT up to 1992 model year]97Checking exciter winding98Checking armature for short to earth99Checking resistance between phase outputs99Checking stator winding for short to earth99Alternator [LT from 1992 model year on, RS]100Checking alternator101Checking armature for short to earth101Removing and installing starter102Disassembling and assembling starter103Removing and installing brush holder104Renewing carbon brushes105Checking starter106Checking starter relay107Checking starter relay with ohmmeter107Troubleshooting108Troubleshooting on alternator108Troubleshooting on starter112Troubleshooting on battery11513 Fuel preparation and control119Adjusting idle speed123Checking start speed increase (choke), adjusting i...124Checking start speed increase124Adjusting start speed increase124Adjusting CO value125Removing/installing and checking/ adjusting thrott...126Removing and installing throttle position sensor126Checking trottle position sensor126Adjusting throttle position sensor126Removing and installing air cleaner insert127Removing and installing air cleaner housing128Removing and installing throttle rail130Removing and installing injectors131Removing and installing intake stub pipe131Removing and installing Motronic control unit13216 Fuel tank and lines133Removing and installing fuel tank137Removing and installing fuel filter138Removing and installing fuel level sensor139Removing and installing fuel pump140Checking fuel pump pressure14117 Radiator143Changing coolant147Draining coolant147Filling with coolant147Removing and installing thermostat148Checking thermostat148Removing and installing radiator149Removing and installing fan150Removing and installing coolant hoses151Checking cooling system152Checking cap for filler neck152Checking coolant system for leaks152Troubleshooting15318 Exhaust system155Removing and installing exhaust system157Removing and installing oxygen sensor15821 Clutch159Removing clutch163Removing clutch housing165Installing clutch housing166Installing clutch167Adjusting clutch clearance169Removing and installing clutch thrust bearing170Removing and installing clutch control rod171Removing and installing clutch release lever172Troubleshooting17323 Gearbox175Removing transmission (gearbox)179Preparatory work179Removing starter180Removing bearing mount with main stand181Removing transmission (gearbox)182Disassembling transmission (gearbox)183Removing transmission cover.183Disassembling/assembling transmission cover184Removing and installing bearing shell184Removing and installing shaft sealing ring on inpu...184Removing and installing locking lever184Removing gear selector drum185Removing gearshift forks185Removing transmission shafts186Removing pawl186Removing selector shaft187Removing segment187Removing and installing shaft sealing ring on inpu...187Removing and installing shaft sealing ring for gea...188Removing and installing bearing shell for taper ro...188Removing and installing ball bearing on intermedia...188Disassembling and assembling input shaft189Disassembling input shaft189Assembling input shaft189Disassembling and assembling output shaft191Removing ball bearing191Removing spur gears192Installing spur gears193Installing transmission shafts194Installing gearshift forks194Measuring distances between transmission shafts195Measuring bearing distance of shafts195Measuring transmission cover196Installing transmission cover198Installing transmission (gearbox)199Installing bearing mount with main stand200Installing starter201Re-assembling motorcycle20231 Front fork203Removing telescopic fork207Removing fork stabilisor207Removing telescopic fork without fork bridge207Removing telescopic fork with fork bridge207Removing upper fork bridge207Removing and installing lower taper roller bearing...208Removing taper roller bearing208Installing taper roller bearing208Removing and installing upper taper roller bearing...208Removing taper roller bearing208Installing taper roller bearing208Removing and installing bearing outer race in stee...209Removing bearing outer race209Installing bearing outer race209Measuring telescopic fork210Checking lower fork bridge210Checking parallel alignment of fixed tubes211Checking runout of fixed tube212Disassembling telescopic fork213Removing fixed tube213Disassembling slider tube213Disassembling fixed tube214Assembling telescopic fork216Assembling fixed tube216Assembling slider tube218Installing telescopic fork219Adjusting steering bearing play220Installing fork stabilisor22132 Steering223Removing and installing left and right handlebar f...227Removing and installing left handlebar fitting227Removing and installing handlebar weight227Removing and installing right handlebar fitting229Removing and installing handlebar230Removing and installing handlebar clamping blocks231Removing and installing accelerator cable232Removing and installing clutch cable233Removing and installing operating cable for increa...234Adjusting steering bearing play23533 Rear wheel drive237Removing, disassembling, assembling and installing...241Removing rear wheel drive241Removing, disassembling and assembling drive bevel...241Removing retaining ring241Disassembling drive bevel gear243Removing needle bearing for drive bevel gear244Installing needle bearing for drive bevel gear244Assembling drive bevel gear245Installing drive bevel gear246Removing and installing taper needle bearing in re...247Removing crown wheel248Installing crown wheel249Checking/adjusting tooth backlash250Checking contact pattern251Shimming housing cover252Installing housing cover252Installing slider252Installing rear wheel drive253Removing, disassembling and assembling rear swingi...255Removing and installing taper roller bearing255Removing and installing gaiter256Removing drive shaft256Checking universal joint for wear256Removing retaining ring256Installing drive shaft256Installing swinging arm257Installing footrest plates25734 Brakes259Removing and installing front brake caliper263Dismantling and assembling front brake caliper264Dismantling front brake caliper264Assembling front brake caliper265Removing and installing brake pads266Removing and installing front brake disc267Removing and installing ABS pulse wheel267Removing and installing front ABS sensor268Adjusting front ABS sensor gap269Removing and installing front brake line270Removing upper brake line270Removing lower brake line270Removing and installing ABS brake line from front ...271Removing and installing handbrake cylinder272Bleeding brake273Bleeding front brake273Bleeding brake caliper273[ABS II] Bleeding pressure modulator274Bleeding the handlebar fitting274Bleeding rear brake274Bleeding brake caliper274[ABS II] Bleeding pressure modulator274Removing and installing pressure modulator275[ABS I] Removing and installing front or rear pres...275[ABS II] Removing ABS unit276[ABS II] Installing ABS unit277[ABS II] Removing and installing relay and relay b...278[ABS II] Removing relay278[ABS II] Installing relay278[ABS II] Removing relay base279[ABS II] Installing relay base279Removing and installing rear brake caliper280Removing and installing rear brake pads280Dismantling and assembling rear brake caliper281Dismantling rear brake caliper281Assembling rear brake caliper281Removing and installing rear brake disc282Removing and installing rear ABS sensor283Measuring vertical runout at rear pulse wheel284Removing and installing rear master brake cylinder...285Disassembling rear master brake cylinder286Removing and installing brake pedal287Adjusting foot brake pedal288Troubleshooting: Front wheel/rear wheel brake28936 Wheels and tyres293Removing and installing front wheel297Removing and instaling wheel bearings298Removing left bearing298Removing right bearing298Installing left and right bearings298Removing and installing rear wheel299Removing rear wheel299Installing rear wheel299Static balancing of front and rear wheels300Static balancing of front wheel300Static balancing of rear wheel300Checking wheel for runout301Checking front wheel for runout301Checking rear wheel for runout30146 Frame303Removing and installing front mudguard307Removing and installing rear section308Removing and installing rear mudguard309Removing and installing fairing [LT]310Removing side sections of fairing310Removing radiator cowling310Removing and installing windshield311Removing and installing windshield complete with m...311Disassembling and assembling adjustable windshield...312Removing and installing actuator motor312Removing plate312Removing lever313Removing guide bush in lever313Removing sliding piece313Removing and installing upper section of fairing314Removing and installing fairing [RS]315Removing and installing lower section of fairing315Removing and installing side section of fairing315Removing and installing radiator cowling315Removing and installing upper section of fairing316Removing and installing windshield, spoiler and he...316Removing and installing fairing support bracket317Arrangement of cable clips [LT]317Arrangement of cable clips [RS]317Checking running gear318Measuring track offset318Checking frame with gauge320Removing and installing frame322Removing frame322Disassembling and assembling frame322Removing outer bearing race in steering head322Installing outer bearing race in steering head322Removing and installing seat lock323Removing and installing handle323Installing frame324Removing and installing main centre stand325Line arrangement for side stand325Disassembling and assembling side stand326Disassembling side stand326Assembling side stand327Disassembling and assembling main centre stand328Checking switching function of side stand32951 Equipment331Removing and installing ignition switch/steering l...333Removing and installing lock cylinder for fuel tan...334Removing lock cylinder334Installing locking cylinder334Removing lock cylinder with broken key334Removing and installing dualseat lock33561 General electrical equipment337Removing and installing Motronic control unit341[ABS I] Removing and installing control unit342[ABS II] Removing and installing control unit342Removing and installing battery343Relay locations (central electrical unit)344Locations and connections, ABS wiring loom345Locations, frame wiring loom346View from left346Wiring arrangement, fairing bracket, [LT]346View from right347Wiring arrangement fairing bracket, [RS]34762 Instruments349Removing and installing instrument cluster353[LT]353[RS]354Disassembling and assembling instrument cluster355Removing and installing indicator lamp355Removing and installing p.c. board356Removing and installing quartz clock356Removing and installing frame for indicator lamps356Removing and installing p.c. board for fuel gauge356Removing and installing revolution counter357Removing and installing speedometer357Removing and installing p.c. board for gear indica...35863 Lights359Disassembling and assembling headlights363Adjusting headlights364Größe: 8,19 MBSeiten: 364Language: EnglishHandbuch öffnen
