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BMW Poly-V Belt – R 1100 Models

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Filed Under (BMW) by admin on 16-11-2010

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Information: In an effort to reduce service volume, a maintenance-free ribbed Poly-V belt was adopted on all R1100 models from engine number 38946130 onwards (09/94 production onwards). This belt does not need to be retentioned (even at the 600 mile service). The old belt required replacement every 24,000 miles. The new style belt is to be replaced every 36,000 miles. Use the same torque procedure as the old belt. Replacement of an old style belt with the new maintenance free belt requires the use of the new parts below: Parts Kit: 12 31 1 342 086 (kit consists of the following) In addition to the Poly-V belt, the following parts were also changed: 1. Top pulley new: steel old: Aluminum 2. Bottom pulley new no spot welds: old: steel w/three spot welds on front 3. Belt new: Ribbed, printing on belt (1342059 Fa. Dayco) or (1341779 Fa. Conti) Slight squeaking may be heard for a short time after a cold start when temperature is below 50°F. The belt should reach it’s correct operating tension soon after the start up. The belt only needs retentioned if the slight squeaking does not stop after warm up.

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Lilac LS-18 Motorcycle Maintenance Standards

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Filed Under (Lilac) by admin on 25-11-2010

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CYLINDER AND CYLINDER HEAD MAINTENANCE ITEM STANDARD REPAIR LIMIT METHOD REMARKS Cylinder Bore 54 -0.01 54.1 Boring After boring honing should be performed Ovality 0.01 0.05 Boring After boring honing should be performed Taper 0.01 0.05 Boring After boring honing should be performed Oversize 0.25 steps 55 max. Do R and L cylinders at same time / 4 steps Valve Seat Width 0.8 – 1.0 1.3 Adjust Use a cutter Angle 45∞ Combustion Chamber Volume 18.2cc -0.5cc Remove carbon if heavy accumulation Compression Ratio 7.8:1 Head Gasket Thickness 1.0 Cylinder Head Nut Torque 3.0 kg/m (22 ft.-lb.) Out standard Adjust 8mm nut Intake and Exhaust Ports Port Wall SurfaceMust be smooth Remove carbon Intake and Exh. Valve GuidesOD 12 +0.09 +0.1 ID 7 +0.01 -0.0 7.06 Exchange Intake Valve Stem Diameter 7 -0.02 -0.03 6.9 Exchange Head Thickness 1 0.7 Exchange Exhaust Valve Stem Diameter 7 -0.02 -0.03 6.9 Exchange Head Thickness 1 0.7 Exchange Intake and Exhaust Valve Seat Face Width Range 0.8~1.0 1.3 Use valve seat cutter Intake Valve Guide Clearance 0.02~0.04 0.08 Replace valve or guide Exhaust Valve Guide Clearance 0.06~0.08 0.12 Replace valve or guide Valve Spring (Large) Installed Load 10.2 kg 8.7 kg Replace Fitted length 31.5 Free Length 36.5 34.7 Replace Tilt 1.5/100 3/100 Replace Valve Spring (Small) Installed Load 5.48 kg 4.65 kg Replace Fitted length 29.5 Page 4 of 10 Free Length 33.5 31.8 Replace Tilt 1.5/100 3/100 Replace Rocker Arm ID 12 +0.00 +0.02112.07 Replace Rocker Shaft OD 12 -0.06 -0.024 11.92 Replace Arm and Shaft Clearance 0.045~0.006 0.10 Replace arm or shaft Tappet Clearance 0.05 Out standard Adjust Measure cold at TDC Rocker Arm Ball Surface 1.8îR -0.006 -0.024 Replace if severe wear Pushrod Bend 0.1 0.5 Straighten Over 100mm (2) CRANKSHAFT, PISTON AND CONROD MAINTENANCE ITEM STANDARD REPAIR LIMIT METHOD REMARKS Piston OD @ Top 53.65 -0.02 Max Diameter 53.95 -0.015 53.85 Replace Ovality 0.1 Piston and Cylinder Clearance 0.04~0.05 0.15 Replace Piston Ring Groove Clearance 0.03~0.07 0.10 Replace Piston Oversize Step 0.25 4 steps Top Ring and 2nd Ring Thickness 2 -0.01 -0.03 1.92 Replace Width 2.5 -0.01 0.55kg Tension 0.85 – 1.15kg 1 Replace End Gap 0.15 – 0.35 Replace Oil Ring Thickness 3.2 -0.01 -0.03 3.12 Replace Width 2.5 -0.1 Tension 1.0~1.3kg 0.65kg Replace End Gap 0.15~0.35 1 Replace Ring Gap Position 120∞ 3 equal spacesOut standard Adjust Avoid Piston Pin Axis Ring Oversizes 0.25 steps 4 steps Piston Pin OD 15 -0.0 +0.006 14.95 Replace Pin Hole in Piston ID 15 +0.012 -0.015.05 Replace Pin and Piston Clearance -0.006 ~ +0.012 0.06 Replace Hand push fit piston at 100∞C Conrod Small End Bush ID 15+0.027+0.016 15.07 Replace bush Conrod and Piston Pin Clearance 0.01~0.027 0.07 Replace Crankpin OD 24.94 +0.0+0.0124.90 Replace Crankpin Roller OD 5 (+0.001+0.003) Refer to conrod ID Replace 3Sizes; 52 per assembly for selective fit 5 (+0.0 -0.002) 5 (-0.003 -0.005) Conrod ID 34.95+0.03+0.02435.02 Axial Play 0.2~0.4 0.5 Adjust Radial Play 0.026~0.036 0.06 Replace

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BMW R850, R1100, R1150, R1200 Oilhead Maintenance Manual

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Filed Under (BMW) by admin on 16-11-2010

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cold Engine and Drivetrain Procedures Check Alternator Belt Tools Parts T-handle hex – 4mm none Note: In most cases the alternator belt does not need to be checked any more. Early models should have the pulley and belt upgrade that came out a few years ago. Current recommendations are that the belt is installed and adjusted, then not disturbed until 36K when replacement is specified. 1. Remove the four bolts holding the black plastic alternator belt cover at the front of the engine, 4mm T-handle hex. 2. Remove the cover by sliding it straight down. 3. Check the belt for cracks or shredding. 4. Check the belt tension, quite tight, ~1/4″ deflection when you press on the center. Note: Paul Glaves suggests that proper belt tension is when you can twist the belt ~90 degrees, midway between the pulleys. If you can twist it more than 90 degrees, it is too loose. If you cannot twist it 90 degrees, then it is too tight. 5. Leave the cover off for the valve adjustment procedure on the next page. Change Alternator Belt Tools Parts T-handle hex – 4mm alternator belt socket – 13mm ratchet wrench – 13mm torque wrench 1. Remove the four bolts holding the black plastic alternator belt cover at the front of the engine, 4mm T-handle hex. 2. Remove the cover by sliding it straight down. 3. Loosen the 2 nuts and 1 bolt, 13mm, that hold the alternator – one is on top and one is on each side, thus allowing the alternator to pivot down. 4. Remove the old belt. (Some bikes have a pipe that traps the belt – loosen it enough to get the old belt out and the new belt in) 5. Install the new belt being sure it is properly seated. 6. BMW calls for a tensioning torque of 5.9 ft.lb. (8 Nm) on the adjuster bolt on the left side of the bike. You have to get at this bolt from the alternator side and you may have to lift the tank. Alternatively, you can pry the alternator up with a large screwdriver to tension the belt. 7. Once the belt is under proper tension, tighten the 2 nuts and 1 bolt, 13mm, to 15 ft.lb. (20 Nm). 8. Check the belt for proper tension (see above) and proper seating alignment

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BMW R1100 – R850R Maintenance Guide

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Filed Under (BMW) by admin on 27-11-2010

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R1100 Checklist – Carl Kulow • Check alternator belt (replace 36K miles) • Adjust valves • Spark plugs (replace 12K) • Air filter (replace 12K) • Lube and adjust clutch cable • Lube front shock lower mount • Lube side and center stand • Check brake fluid (replace yearly) • Check brake pads • Check battery acid level • Fuel filter (replace 24K) • Throttle body sync • Oil and filter (replace 6K) • Check transmission fluid level (replace 12K) • Check rear wheel drive fluid level (replace 12K) • Check tires and pressure • Check all nuts and bolts • Check all air and oil hose clamps • Check all lights PARTS – TOOLS Tools Parts Misc. sockets spark plugs compressed air wrenches oil filter anti seize torque wrench air filter carb cleaner hex sockets brake pads rag hex wrenches oil – 4 qt. BMW #10 grease feeler gauges gear oil – 1 1/4 qt. flexible tubing oil filter tool alternator belt (tygon) flashlight fuel filter, o-ring, clamps measuring cylinder crush washers Mityvac -3 small = trans.drain, rear drive fill and drain digital volt meter -1 medium = oil drain heat gun -1 large = trans.fill tire change tools 5 R1100 Maintenance Steps – Carl Kulow Note: This overview section serves only as a step by step reminder for experienced workers. If you are unfamiliar with any procedure you should read the parenthetical reference article or Paul Glaves’ Routine R1100 Service Article! Note to R1100RT and R1100RS Riders: remove the side panels as described in your owners manual “Service and Technical Booklet” except RT: instead of pulling the mirror off as the manual says, you need to hold the back of the mirror (front of bike) with one hand while you hit the front outside corner of the mirror with the palm of your hand thus knocking the mirror off. Check Alternator Belt remove four bolts holding black plastic cover(4mm hex), remove cover, check belt for cracks etc., check belt tension, replace belt every 36K miles, leave cover off for valve adjustment (see Jon Diaz “Alternator Belt Adjustment”)

Harley-Davidson EMERGENCY DRIVE BELT REPLACEMENT KIT Installation Manual

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Filed Under (Harley Davidson) by admin on 24-10-2010

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1. Shift transmission to neutral. Before installation of the emergency belt, to avoid personal injury and/or vehicle damage, secure the motorcycle. Both stand and motorcycle must be on solid, level ground. Failure to follow instructions could result in death or serious injury. 2. See Figure 1. Remove spring clip (4) (if present) and loosen rear axle nut (1). 3. Loosen rear axle adjuster (3) (or adjuster nut, if so equipped) on each side of motorcycle, and move rear wheel to full forward position. 4. Remove the damaged/broken belt. 5. Inspect sprockets and belt guard (2) for damage and/or debris. Remove any debris. If sprockets and belt guard are not damaged, proceed with the installation. 6. Remove belt guard. 40171-97,40146-00 1 WARNING i06186 Figure 1. Axle 1. Axle nut 2. Belt guard 3. Adjuster 4. Spring clip 2 4 1 3 7. See Figure 2. Install feeder strip on emergency belt. 8. Feed strip around transmission sprocket in a counterclockwise direction over frame cross support. 9. See Figure 3. Interlock the “v” ends of the emergency belt. a. Insert a hex socket key in the fourth (4) and ninth (6) tooth holes. b. Place the splice block (2) over the seventh (5) tooth hole. c. Install a socket head set screw (3) in the seventh tooth. Tighten using another hex socket key. d. Move the block to the next tooth, and repeat installation steps (b) and (c) in each tooth until all 12 screws are installed. NOTE There are 16 screws included in this kit. However, only 12 screws will actually be installed in the belt. The remaining four screws are spares. 10. See Figure 4. Grasp the emergency belt at the mid point of the lower run between your thumb and forefinger and lift the belt up to take up any slack in the belt. Measure the distance that the belt deflects (2) under tension (1). When two pounds of tension is applied to the lower run of the emergency belt, the belt deflection should be within the following measurements

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BMW F 650 CS Rear belt wheel cracks Removal And Installation Manual

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Filed Under (BMW) by admin on 12-11-2010

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Relieve the tension of the toothed belt and lift the belt off the belt wheel (refer to F 650CS Repair Manual, 00.57). 2) Remove 6 screws (see arrow in photo at right). 3) Remove the rear belt wheel. 4) Clean and degrease the tapered bores and the threads of the mounting screws 5) Carefully place the new belt wheel in position on the damper, coat the screw threads with Loctite 243 and hand tighten the securing screws. 6) Tighten the securing screws to the specified torque maintaining a diagonally opposite tightening sequence throughout (Torque to 28 NM, curing time 12 hours). 7) Measure the vertical runout of the belt wheel (refer to F 650 CS Repair Manual, 33.15). 8) Install and adjust the rear drive belt (refer to F 650 CS Repair Manual 00.57 – 00.58) 2.1 Removal of the front belt wheel Remove the front belt wheel in accordance with the instructions detailed in the F 650 CS Repair Manual. Remove the securing screw of the activated charcoal filter and let the filter canister hang by one side by the hoses, or remove it and lay it aside. Clean the splines and threads of the main shaft in order to remove all traces of Loctite. If necessary, remove corrosion from the main shaft spline (use only a brass bristle brush). 2.2 Visual inspection Check the splines of the main shaft for damage. Replace the main shaft if the splines are damaged (broken, chipped, bent or damaged teeth). Refer to the F 650 CS Repair Manual for this procedure.

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BMW F 650 GS Repair Manual And Maintenance schedule

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Filed Under (BMW) by admin on 19-11-2010

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Replace oil in telescopic forks Check the coolant and restore to correct level if necessary *) Replace the coolant (every 2 years) every 2years Check valve clearances, adjust if necessary Replace the spark plug Drain the outlet hose from the air filter box Replace intake air filter If motorcycle is operated in very dirty or dusty conditions, clean or replace the intake air filter every 10,000 km (6,000 miles); check every 3,000 km (1,800 miles) Replace fuel filter (every 20,000 km/12,000 miles) 20,000 km Check clutch play, adjust if necessary Check wheel spoke tension and tighten if necessary more frequently if motorcycle is ridden in severe off-road conditions Examine brake pads and discs for wear, replace if necessary *) more frequently if motorcycle is ridden in severe off-road conditions Check brake fluid level at front and rear and top up if necessary *) Check for operation of brake system and freedom from leaks; repair/replace if necessary *) Replace the brake fluid at least once a year Replace the primary front/rear brake master cylinder cup (every 40,000 km/24,000 miles on a motorcycle with ABS ) 40,000 km Check wheel bearings and replace if necessary *) Check or, if necessary, replace chain, sprocket, chain guide rollers and pinion *) more frequently if motorcycle is ridden in severe off-road conditions Check chain tension and adjust if necessary *) Check battery acid level, add distilled water if necessary more frequently if motorcycle is ridden in severe off-road conditions Clean and grease the battery terminals, if necessary Check steering head bearings and adjust *) or replace if necessary *) Grease the side and main stands Grease the brake pedal Check bolts and nuts on engine mountings, frame connections, exhaust system mountings, swinging fork pivot, suspension levers, brake pedal, main and side stands and quick-release axles for tightness Final inspection with road safety and functional check

1994 – 2004 BMW Motorcycle History

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Filed Under (BMW) by admin on 17-11-2010

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1994 brought many changes to BMW, most obviously by the introduction of the “R259″ series twins and the elimination of the old standby “Airhead” twins that had been BMW’s trademark for seven decades. While it is interesting to look at all the technologies introduced during the 1994 to 2004 time block, it is also exciting to look into what was going on as far as changes in BMW more esoteric than measurable. In this author’s opinion there were unspoken changes in BMW’s mindset and philosophy. BMW had forged it’s reputation for long lasting, simple machines built to the highest standards and quality; aimed at a dwindling, older (OK, Jeff, more mature) market of enthusiastic but eccentric riders. They built motorcycles that were easy for the owners to maintain and modify to fit their specific wants. BMW had always built their bikes their way; often it seemed like they did so in spite of what the younger and upwardly mobile riders were looking for. By 1994, the airhead was simply not a sellable motorcycle; the buying market was younger and wanted performance in line with what the Japanese products offered at much lower prices. The K 75/100 series that were so far ahead of their time in 1984 when they were introduced were also showing their age. No doubt, BMW knew this was coming many years before the new “Oil Head” was introduced. They knew that the riding community had reduced its mean age substantially. The younger riders had money to spend on a bike that had to be BMW, yet had to be totally more modern both in performance and in perception than what BMW had been selling. Thus, the R259 was born. The Birth of the R259 Twins The new BMW corporate mindset, if you will, was no longer concerned with selling motorcycles that would be handed down from one generation to the next, nor was BMW concerned about ease of maintenance with standard hand tools. Although the new bikes were still able to outlast the riders, the concern for building units to last a quarter-million miles was not so much in the forefront of the design. The new models would have to be powerful, fast, handle better than anything on the road; they would need to offer a standard of technology that the Japanese would never build. They should be complex pieces of rolling art. Most obvious, though, was that they would build a product aimed at an entirely new market of riders who would likely not be interested in maintaining the bikes themselves or really understanding the nuances of design. The new customers BMW was looking for were serious riders who were more interested in the fun and excitement of riding than they were in savoring the history of the older designs

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BMW R1100RT, BMW R1150RT Signal Mirror Installation Instructions

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Filed Under (BMW) by admin on 26-10-2010

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1. These instructions start with the right side mirror. Grab the mirror housing as shown and slowly push down to disengage housing from motorcycle. 2. Once you have the mirror housing removed partially, twist and remove the light bulb from mirror housing. Remove mirror housing and set it on a cloth covered surface. 3. Remove the factory mirror by inserting a slotted screwdriver against each mirror mount snaps. Slowly twist and pry each snap until it releases from motor actuator. Repeat process until factory mirror disengages. NOTE: Insert the slotted screwdriver as close to each of the snaps as possible before prying out the OE mirror. Not doing so may cause the crossbar on the motor actuator to break. Connect the two mating connectors from the adapter Signal® mirror wire harness and the new Signal® mirror wire harness. Cut a slot in the foam disc to accommodate the anti-vibration prongs on the motor adapter. Place the foam disc onto the center of the Signal® mirror motor interface. Connect the Signal® mirror mating connector to the Signal® mirror wire harness. 5. Remove Cap Sheet from two-sided adhesive disc on back of Signal ® mirror. Align the anti-rotation prongs found on the top and bottom or left and right with the corresponding slots on the motor mount. Use the palm of your hand, push down on the Signal® mirror and the mirror housing until the Signal® mirror motor mount is fully engaged. Note: Push firmly on all sides of the Signal® mirror to ensure proper engagement and travel. Not doing so could result in mirror falling off. 6. Locate the light bulb and carefully disconnect the original light blue with black stripe wire [hot wire]. Connect the red wire from the Signal® mirror wire harness to the spade terminal on the light bulb. Connect the original light blue with black stripe wire to the other spade terminal located on the red wire of the Signal® mirror wire harness. Repeat the process for the original brown wire and the black wire from the Signal® mirror wire harness [ground wires]. Insert the light bulb back into the mirror housing. 7. Align the 3-pins with their corresponding snap holes and snap the mirror housing into place. 8. Insert key into the ignition and turn to the “ON” position. Activate the right hand turn indicator to verify that the new Signal® mirror is working correctly. Replace any other accessories necess

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HARLEY DAVIDSON SOFTAIL CHROME LOWER BELT GUARD INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-04-2011

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REMOVING STOCK PLASTIC LOWER BELT GUARD 1. See Figure 1. Remove the hex head bolt (2), washer (3), acorn nut (5), hex head screw (4) and acorn bolt (8) attaching plastic belt guard to rear fork. 2. Remove the plastic belt guard. Save fasteners (2), and (4), washer (3), acorn nut (5) and acorn bolt (8) for installing new chrome belt guard. INSTALLING CHROME LOWER BELT GUARD 1. See Figure 2. Position the new chrome belt guard from kit over belt. Align the holes in guard with mounting lugs on rear fork. Install acorn bolt (9) through mounting lug and fasten to belt guard. Finger tighten only. 2. Install screw (4) with washer (5, from kit) through belt guard and fasten to threaded mounting lug. Position the guard for adequate clearance and finger tighten screw. 3. At the upper belt guard, install the original forward hex bolt (2) and original washer (3) through the upper guard (1), then through the upper hole in chrome belt guard and through mounting lug on rear fork. Secure with original acorn nut. 4. Tighten all hardware to 110 in-lbs (12.4 Nm)

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