Document Outline

• Repair Manual
• Introduction
  • U sage
  • Key to symbols
    • Contents
• Maintenance Schedule K 75 RT/K1100RS/LT
• Pre-delivery Check K 75 RT/K1100RS/LT
• Contents
• 00 Maintenance and general instructions
  • Tightening torque
  • Table of operating fluids
  • Key to maintenance intervals
  • Changing engine oil
    • Inspections I, II, III, IV
  • Changing oil in transmission (gearbox)
    • Inspections I, III, IV
  • Changing oil in rear wheel drive
    • Inspections I, III, IV
  • Changing oil in telescopic fork
    • Inspection I, III, IV
  • Renewing intake air cleaner
    • Inspection III
  • Renewing fuel filter
    • Inspection III
  • Cleaning inductive pulse generator at rear wheel d...
    • Inspections I, III, IV
  • Checking brake pads, brake discs for wear and rene...
    • Inspection II, III
    • Front wheel brake
    • Rear wheel brake
  • Checking brake fluid level and correcting if neces...
    • Inspections I, II, III
    • Checking brake fluid level
    • Adding brake fluid
  • Checking brake system
    • Inspection III
  • Checking ABSsensor spacing and adjusting if neces...
    • Inspections I, II, III
    • Front sensor
    • Rear sensor
  • Renewing brake fluid
    • Renewing front brake fluid
    • Renewing rear brake fluid
  • Checking function of electric switch on side stand...
    • Inspections I, II, III
  • Checking clutch clearance and adjusting if necessa...
    • Inspections I, III
  • Reading out Motronic defect code memory
    • Inspections II, III
  • Checking increased starting speed (choke) and adju...
    • Inspections I, III
    • Checking increased starting speed
  • Checking valve clearance and adjusting if necessar...
    • Inspections I, III
  • Adjusting valve clearance
    • Removing sprockets
    • Removing camshafts
    • Installing camshafts
    • Installing sprockets
    • Installing cylinder head cover
  • Checking steering bearing play and adjusting if ne...
    • Inspection III
  • Lubricating guide pins, adjustable screen
    • Inspections III, IV
  • Checking idle speed, synchronising and CO value an...
    • Inspections I, II, III, IV
    • Adjusting idle speed
    • Adjusting CO value without catalytic converter
• 11 Motor
  • Removing engine
  • Dismantling engine
    • Removing intermediate flange
      • Removing driver
      • Removing clutch housing
    • Stripping down and re-assembling intermediate flan...
      • Removing the driver bearing
      • Installing driver bearing
      • Removing and installing shaft sealing ring for dri...
    • Removing countershaft and layshaft with freewheel
    • Dismantling and assembling freewheel
      • Stripping down freewheel
      • Assembling freewheel
    • Removing and installing layshaft needle roller bea...
      • Removing bearing
      • Installing bearing
    • Removing timing chain cover
      • Removing the Hall-effect signal transmitter
      • Remove the crankshaft cover
      • Removing cylinder head cover
      • Removing and installing sealing ring in timing cas...
    • Removing the timing chain
      • Removing chain tensioner
      • Removing chain tensioner rail
      • Renewing chain tensioner rail facing
      • Removing camshaft chain sprockets
      • Removing chain guide
    • Removing, stripping down and assembling cylinder h...
      • Removing camshafts
      • Removing cylinder head
      • Removing bucket-type tappets
      • Removing valves
      • Remachining valve seat
      • Installing valve and valve stem seal
    • Removing crankshaft
      • Removing big end bearings
      • Removing main bearings
    • Removing pistons with conrods, stripping down and ...
      • Removing piston with conrod
      • Dismantling piston
      • Checking piston dimensions
      • Assembling pistons
      • Checking cylinder dimensions
      • Removing and installing small-end bushing
      • Assembling pistons and conrods
    • Removing and installing crankshaft pinion and roto...
    • Removing, dismantling and assembling combined oil-...
      • Removing pump
      • Dismantling pump
      • Removing slipring seal and shaft sealing ring
      • Removing pressure relief valve
      • Installing pressure relief valve
      • Install the shaft sealing ring and slipring seal
      • Installing pump shaft and impeller
    • Removing output shaft
      • Removing oil sump
      • Removing oil filter
      • Removing lower section of crankcase
      • Removing and installing oil level sight glass
    • Stripping and assembling output shaft
      • Stripping down output shaft
      • Stripping down tensioning gear
      • Assembling tensioning gear
      • Installing damper
  • Assembling engine
    • Installing output shaft
      • Assembling the crankcase
      • Installing oil mesh strainer
      • Installing oil filter
      • Installing oil sump
    • Measuring crankshaft bearing play
      • Measuring radial play
      • Measuring endplay
    • Checking dimensions of crankshaft
    • Installing crankshaft
    • Installing piston with conrod
    • Measuring big end bearing play
    • Installing big end bearing
    • Installing combined oil-water pump
    • Installing cylinder head
    • Installing camshafts
    • Installing timing chain
    • Checking valve clearances
    • Installing intermediate flange
      • Installing freewheel
      • Installing countershaft
      • Installing intermediate flange
    • Installing driver
    • Installing alternator
    • Installing timing case cover
    • Installing hall-effect transmitter
    • Installing cover for Hall-effect transmitter
    • Installing cylinder head cover
  • Installing engine
  • Checking/adjusting valve clearances
    • Adjusting valve clearances
• 12 Engine electrics
  • Removing and installing Hall generator
  • Adjusting ignition timing
  • Removing and installing ignition coils
  • Removing and installing ignition output stage
  • Removing and installing alternator
  • Disassembling and assembling alternator
    • Alternator [only LT up to 1992 model year]
      • Checking exciter winding
      • Checking armature for short to earth
      • Checking resistance between phase outputs
      • Checking stator winding for short to earth
    • Alternator [LT from 1992 model year on, RS]
      • Checking alternator
      • Checking armature for short to earth
  • Removing and installing starter
    • Disassembling and assembling starter
      • Removing and installing brush holder
      • Renewing carbon brushes
  • Checking starter
    • Checking starter relay
      • Checking starter relay with ohmmeter
  • Troubleshooting
    • Troubleshooting on alternator
    • Troubleshooting on starter
    • Troubleshooting on battery
• 13 Fuel preparation and control
  • Adjusting idle speed
  • Checking start speed increase (choke), adjusting i...
    • Checking start speed increase
    • Adjusting start speed increase
  • Adjusting CO value
  • Removing/installing and checking/ adjusting thrott...
    • Removing and installing throttle position sensor
    • Checking trottle position sensor
    • Adjusting throttle position sensor
  • Removing and installing air cleaner insert
  • Removing and installing air cleaner housing
  • Removing and installing throttle rail
    • Removing and installing injectors
    • Removing and installing intake stub pipe
  • Removing and installing Motronic control unit
• 16 Fuel tank and lines
  • Removing and installing fuel tank
  • Removing and installing fuel filter
  • Removing and installing fuel level sensor
  • Removing and installing fuel pump
  • Checking fuel pump pressure
• 17 Radiator
  • Changing coolant
    • Draining coolant
    • Filling with coolant
  • Removing and installing thermostat
    • Checking thermostat
  • Removing and installing radiator
  • Removing and installing fan
  • Removing and installing coolant hoses
  • Checking cooling system
    • Checking cap for filler neck
    • Checking coolant system for leaks
  • Troubleshooting
• 18 Exhaust system
  • Removing and installing exhaust system
  • Removing and installing oxygen sensor
• 21 Clutch
  • Removing clutch
  • Removing clutch housing
  • Installing clutch housing
  • Installing clutch
  • Adjusting clutch clearance
  • Removing and installing clutch thrust bearing
  • Removing and installing clutch control rod
  • Removing and installing clutch release lever
  • Troubleshooting
• 23 Gearbox
  • Removing transmission (gearbox)
    • Preparatory work
    • Removing starter
    • Removing bearing mount with main stand
    • Removing transmission (gearbox)
  • Disassembling transmission (gearbox)
    • Removing transmission cover.
    • Disassembling/assembling transmission cover
      • Removing and installing bearing shell
      • Removing and installing shaft sealing ring on inpu...
      • Removing and installing locking lever
    • Removing gear selector drum
    • Removing gearshift forks
    • Removing transmission shafts
    • Removing pawl
    • Removing selector shaft
    • Removing segment
    • Removing and installing shaft sealing ring on inpu...
    • Removing and installing shaft sealing ring for gea...
    • Removing and installing bearing shell for taper ro...
    • Removing and installing ball bearing on intermedia...
    • Disassembling and assembling input shaft
      • Disassembling input shaft
      • Assembling input shaft
    • Disassembling and assembling output shaft
      • Removing ball bearing
      • Removing spur gears
      • Installing spur gears
    • Installing transmission shafts
    • Installing gearshift forks
    • Measuring distances between transmission shafts
      • Measuring bearing distance of shafts
      • Measuring transmission cover
    • Installing transmission cover
  • Installing transmission (gearbox)
    • Installing bearing mount with main stand
    • Installing starter
      • Re-assembling motorcycle
• 31 Front fork
  • Removing telescopic fork
    • Removing fork stabilisor
    • Removing telescopic fork without fork bridge
    • Removing telescopic fork with fork bridge
      • Removing upper fork bridge
    • Removing and installing lower taper roller bearing...
      • Removing taper roller bearing
      • Installing taper roller bearing
    • Removing and installing upper taper roller bearing...
      • Removing taper roller bearing
      • Installing taper roller bearing
    • Removing and installing bearing outer race in stee...
      • Removing bearing outer race
      • Installing bearing outer race
    • Measuring telescopic fork
      • Checking lower fork bridge
      • Checking parallel alignment of fixed tubes
      • Checking runout of fixed tube
  • Disassembling telescopic fork
    • Removing fixed tube
    • Disassembling slider tube
    • Disassembling fixed tube
  • Assembling telescopic fork
    • Assembling fixed tube
    • Assembling slider tube
  • Installing telescopic fork
    • Adjusting steering bearing play
    • Installing fork stabilisor
• 32 Steering
  • Removing and installing left and right handlebar f...
    • Removing and installing left handlebar fitting
      • Removing and installing handlebar weight
    • Removing and installing right handlebar fitting
  • Removing and installing handlebar
    • Removing and installing handlebar clamping blocks
  • Removing and installing accelerator cable
  • Removing and installing clutch cable
  • Removing and installing operating cable for increa...
  • Adjusting steering bearing play
• 33 Rear wheel drive
  • Removing, disassembling, assembling and installing...
    • Removing rear wheel drive
    • Removing, disassembling and assembling drive bevel...
      • Removing retaining ring
      • Disassembling drive bevel gear
      • Removing needle bearing for drive bevel gear
      • Installing needle bearing for drive bevel gear
      • Assembling drive bevel gear
    • Installing drive bevel gear
    • Removing and installing taper needle bearing in re...
    • Removing crown wheel
    • Installing crown wheel
    • Checking/adjusting tooth backlash
    • Checking contact pattern
    • Shimming housing cover
    • Installing housing cover
    • Installing slider
    • Installing rear wheel drive
  • Removing, disassembling and assembling rear swingi...
    • Removing and installing taper roller bearing
    • Removing and installing gaiter
    • Removing drive shaft
      • Checking universal joint for wear
      • Removing retaining ring
    • Installing drive shaft
    • Installing swinging arm
      • Installing footrest plates
• 34 Brakes
  • Removing and installing front brake caliper
  • Dismantling and assembling front brake caliper
    • Dismantling front brake caliper
    • Assembling front brake caliper
    • Removing and installing brake pads
  • Removing and installing front brake disc
    • Removing and installing ABS pulse wheel
  • Removing and installing front ABS sensor
  • Adjusting front ABS sensor gap
  • Removing and installing front brake line
    • Removing upper brake line
    • Removing lower brake line
  • Removing and installing ABS brake line from front ...
  • Removing and installing handbrake cylinder
  • Bleeding brake
    • Bleeding front brake
      • Bleeding brake caliper
      • [ABS II] Bleeding pressure modulator
      • Bleeding the handlebar fitting
    • Bleeding rear brake
      • Bleeding brake caliper
      • [ABS II] Bleeding pressure modulator
  • Removing and installing pressure modulator
    • [ABS I] Removing and installing front or rear pres...
    • [ABS II] Removing ABS unit
    • [ABS II] Installing ABS unit
  • [ABS II] Removing and installing relay and relay b...
    • [ABS II] Removing relay
    • [ABS II] Installing relay
    • [ABS II] Removing relay base
    • [ABS II] Installing relay base
  • Removing and installing rear brake caliper
  • Removing and installing rear brake pads
  • Dismantling and assembling rear brake caliper
    • Dismantling rear brake caliper
    • Assembling rear brake caliper
  • Removing and installing rear brake disc
  • Removing and installing rear ABS sensor
  • Measuring vertical runout at rear pulse wheel
  • Removing and installing rear master brake cylinder...
    • Disassembling rear master brake cylinder
  • Removing and installing brake pedal
  • Adjusting foot brake pedal
  • Troubleshooting: Front wheel/rear wheel brake
• 36 Wheels and tyres
  • Removing and installing front wheel
    • Removing and instaling wheel bearings
      • Removing left bearing
      • Removing right bearing
      • Installing left and right bearings
  • Removing and installing rear wheel
    • Removing rear wheel
    • Installing rear wheel
  • Static balancing of front and rear wheels
    • Static balancing of front wheel
    • Static balancing of rear wheel
  • Checking wheel for runout
    • Checking front wheel for runout
    • Checking rear wheel for runout
• 46 Frame
  • Removing and installing front mudguard
  • Removing and installing rear section
  • Removing and installing rear mudguard
  • Removing and installing fairing [LT]
    • Removing side sections of fairing
    • Removing radiator cowling
    • Removing and installing windshield
    • Removing and installing windshield complete with m...
    • Disassembling and assembling adjustable windshield...
      • Removing and installing actuator motor
      • Removing plate
      • Removing lever
      • Removing guide bush in lever
      • Removing sliding piece
    • Removing and installing upper section of fairing
  • Removing and installing fairing [RS]
    • Removing and installing lower section of fairing
    • Removing and installing side section of fairing
    • Removing and installing radiator cowling
    • Removing and installing upper section of fairing
    • Removing and installing windshield, spoiler and he...
    • Removing and installing fairing support bracket
      • Arrangement of cable clips [LT]
      • Arrangement of cable clips [RS]
  • Checking running gear
    • Measuring track offset
    • Checking frame with gauge
  • Removing and installing frame
    • Removing frame
    • Disassembling and assembling frame
      • Removing outer bearing race in steering head
      • Installing outer bearing race in steering head
      • Removing and installing seat lock
      • Removing and installing handle
    • Installing frame
  • Removing and installing main centre stand
    • Line arrangement for side stand
    • Disassembling and assembling side stand
      • Disassembling side stand
      • Assembling side stand
    • Disassembling and assembling main centre stand
  • Checking switching function of side stand
• 51 Equipment
  • Removing and installing ignition switch/steering l...
  • Removing and installing lock cylinder for fuel tan...
    • Removing lock cylinder
    • Installing locking cylinder
    • Removing lock cylinder with broken key
  • Removing and installing dualseat lock
• 61 General electrical equipment
  • Removing and installing Motronic control unit
  • [ABS I] Removing and installing control unit
  • [ABS II] Removing and installing control unit
  • Removing and installing battery
  • Relay locations (central electrical unit)
  • Locations and connections, ABS wiring loom
  • Locations, frame wiring loom
    • View from left
    • Wiring arrangement, fairing bracket, [LT]
    • View from right
    • Wiring arrangement fairing bracket, [RS]
• 62 Instruments
  • Removing and installing instrument cluster
    • [LT]
    • [RS]
    • Disassembling and assembling instrument cluster
      • Removing and installing indicator lamp
      • Removing and installing p.c. board
      • Removing and installing quartz clock
      • Removing and installing frame for indicator lamps
      • Removing and installing p.c. board for fuel gauge
      • Removing and installing revolution counter
      • Removing and installing speedometer
      • Removing and installing p.c. board for gear indica...
• 63 Lights
  • Disassembling and assembling headlights
  • Adjusting headlights