BMW AG Motorcycle (K1100LT, K1100RS). Manual - part 4

11.1

Contents

Page

................................................................................................................................5

Removing engine

........................................................................................................................11

Dismantling engine

....................................................................................................................12

Removing intermediate flange

.................................................................................................13

Removing driver ................................................................................................................................13
Removing clutch housing ..................................................................................................................14

Stripping down and re-assembling intermediate flange

..............................................15

Removing the driver bearing ..............................................................................................................15
Installing driver bearing .....................................................................................................................15
Removing and installing shaft sealing ring for driver ..........................................................................16

Removing countershaft and layshaft with freewheel

.....................................................16

Dismantling and assembling freewheel

...............................................................................17

Stripping down freewheel ..................................................................................................................17
Assembling freewheel .......................................................................................................................17

Removing and installing layshaft needle roller bearing

................................................18

Removing bearing .............................................................................................................................18
Installing bearing ...............................................................................................................................18

Removing timing chain cover

..................................................................................................19

Removing the Hall-effect signal transmitter  .......................................................................................19
Remove the crankshaft cover  ............................................................................................................19
Removing cylinder head cover  ..........................................................................................................19
Removing and installing sealing ring in timing case cover  .................................................................19

Removing the timing chain

.......................................................................................................20

Removing chain tensioner  .................................................................................................................20
Removing chain tensioner rail  ...........................................................................................................20
Renewing chain tensioner rail facing  .................................................................................................20
Removing camshaft chain sprockets  .................................................................................................21
Removing chain guide .......................................................................................................................21

Removing, stripping down and assembling cylinder head

.........................................22

Removing camshafts  .........................................................................................................................22
Removing cylinder head  ....................................................................................................................22
Removing bucket-type tappets  .........................................................................................................22
Removing valves  ...............................................................................................................................23
Remachining valve seat .....................................................................................................................23
Installing valve and valve stem seal  ...................................................................................................24

Removing crankshaft

...................................................................................................................25

Removing big end bearings ...............................................................................................................25
Removing main bearings ...................................................................................................................25

11 Motor

11.2

Contents

Page

Removing pistons with conrods, stripping down and re-assembling

...................26

Removing piston with conrod  ............................................................................................................26
Dismantling piston .............................................................................................................................26
Checking piston dimensions  .............................................................................................................26
Assembling pistons  ...........................................................................................................................27
Checking cylinder dimensions ...........................................................................................................27
Removing and installing small-end bushing .......................................................................................27
Assembling pistons and conrods  ......................................................................................................28

Removing and installing crankshaft pinion and rotor flange

......................................28

Removing, dismantling and assembling combined oil-water pump

......................29

Removing pump  ................................................................................................................................29
Dismantling pump  .............................................................................................................................29
Removing slipring seal and shaft sealing ring  ....................................................................................30
Removing pressure relief valve  ..........................................................................................................30
Installing pressure relief valve ............................................................................................................30
Install the shaft sealing ring and slipring seal .....................................................................................30
Installing pump shaft and impeller  .....................................................................................................30

Removing output shaft

...............................................................................................................31

Removing oil sump ............................................................................................................................31
Removing oil filter ..............................................................................................................................31
Removing lower section of crankcase ...............................................................................................31
Removing and installing oil level sight glass ......................................................................................31

Stripping and assembling output shaft

...............................................................................32

Stripping down output shaft  ..............................................................................................................32
Stripping down tensioning gear  .........................................................................................................32
Assembling tensioning gear  ..............................................................................................................33
Installing damper  ...............................................................................................................................33

Assembling engine

....................................................................................................................34

Installing output shaft

..................................................................................................................34

Assembling the crankcase ................................................................................................................35
Installing oil mesh strainer .................................................................................................................35
Installing oil filter ................................................................................................................................35
Installing oil sump ..............................................................................................................................35

Measuring crankshaft bearing play

.......................................................................................36

Measuring radial play ........................................................................................................................36
Measuring endplay ............................................................................................................................37

Checking dimensions of crankshaft

.....................................................................................37

Installing crankshaft

.....................................................................................................................38

Installing piston with conrod

....................................................................................................39

Measuring big end bearing play

.............................................................................................40

Installing big end bearing

..........................................................................................................40

Installing combined oil-water pump

......................................................................................41

Installing cylinder head

...............................................................................................................42

Installing camshafts

.....................................................................................................................43

11.3

Contents

Page

Installing timing chain

..................................................................................................................44

Checking valve clearances

.......................................................................................................45

Installing intermediate flange

...................................................................................................46

Installing freewheel  ............................................................................................................................46
Installing countershaft  .......................................................................................................................46
Installing intermediate flange  .............................................................................................................46

Installing driver

...............................................................................................................................46

Installing alternator

.......................................................................................................................46

Installing timing case cover

......................................................................................................47

Installing hall-effect transmitter

...............................................................................................47

Installing cover for Hall-effect transmitter

..........................................................................48

Installing cylinder head cover

..................................................................................................49

Installing engine

..........................................................................................................................50

Checking/adjusting valve clearances

.............................................................................52

Adjusting valve clearances

.......................................................................................................52

11.4

11.5

Technical data

K 1100 LT

K 1100 RS

Engine, general

Engine design

Inline four-stroke engine installed longitudinally,
with double overhead camshafts, liquid cooling
and electronic fuel injection.

Location of engine number

At lower rear right of engine block

Cylinder bore

mm (in) 70.5 (2.77)

Stroke

mm (in) 70 (2.75)

Number of cylinders

Effective displacement

cc 1093

Compression ratio

11.0 : 1

Power output

kW (hp) 74 (100) at 7500 min

-1

Max. torque

Nm 107 at 5500 min

-1

Permissible maximum engine speed

min

-1

8900

Permissible continuous engine speed

min

-1

8500

Idle speed

min

-1

950

+50

Direction of rotation

Anti-clockwise. looking at ignition system

Compression test pressure

bar (psi)

good

above 10.0 (142.3)

normal

8.5…10.0 (120.9...142.3)

poor

below 8.5 (120.9)

Engine lubrication

Pressurised oil circuit

Oil filter

Full-flow type

Difference for opening bypass valve

bar (psi) 1.5 (21.3)

Oil pressure warning light comes on below

bar (psi) 0.2…0.5 (2.8...7.1)

Pressure relief valve opens at

bar (psi) 5.4 (76.8)

Oil content

without filter change

l 3.50 (6.2 Imp. pints)

with filter change

l 3.75 (6.6 Imp. pints)

Permissible oil consumption

l/100km

(mile/gal) 0.15 (1,875)

Oil pump

Gear-type

11.6

Valves

Valve clearances with engine cold
(max. 35 °C)

Inlet valve

mm (in) 0.15…0.20 (0.0059…0.0079)

Exhaust valve

mm (in) 0.25…0.30 (0.0098…0.0118)

Valve timing

at 5/100 mm (0.002 in) preload and
3 mm (0.118 in) lift

Inlet opens

14° after TDC

Inlet closes

18° after BDC

Exhaust opens

18° before BDC

Exhaust closes

14° before TDC

Valve length

Inlet

mm (in) 115.1 (4.531)

Exhaust

mm (in) 113.7 (4.476)

Valve head dia.

Inlet

mm (in) 26.45 (1.041)

Exhaust

mm (in) 22.95 (0.886)

Stem dia.

Inlet

mm (in) 5.96…5.975 (0.2346…0.2352)

Wear limit

mm (in) 5.94 (0.2339)

Exhaust

mm (in) 5.945…5.96 (0.2341…0.2346)

Wear limit

mm (in) 5.925 (0.2333)

Valve head edge thickness

Inlet

mm (in) 1.04 (0.041)

Exhaust

mm (in) 1.09 (0.043)

Max. valve head runout

Inlet, exhaust

mm (in) 0.02 (0.0008)

Valve seat angle

Inlet, exhaust

44° 30’…20’

Valve seat width

Inlet

mm (in) 1.1 (0.043)

± 0.15 (0.006)

Wear limit

mm (in) 2.5 (0.098)

Exhaust

mm (in) 1.3 (0.051)

± 0.15 (0.006)

Wear limit

mm (in) 3.0 (0.118)

Length of valve guide

Inlet

mm (in) 45 (1.772)

Exhaust

mm (in) 57.5 (2.264)

Technical data

K 1100 LT

K 1100 RS

11.7

Valves

Valve guide dia.

Extl. dia.

mm (in) 11.533…11.544 (0.4541…0.4545)

Intl. dia.

mm (in) 6.0…6.012 (0.2362…0.2367)

Wear limit

mm (in) 6.1 (0.2402)

Bore in cylinder head

mm (in) 11.5…11.518 (0.4528…0.4535)

Repair stage

mm (in) 11.7…11.718 (0.4606…0.4613)

Valve stem clearance

Inlet

mm (in) 0.025…0.052 (0.001…0.002)

Exhaust

mm (in) 0.040…0.067 (0.0016…0.0026)

Valve spring

Extl. dia.

mm (in) 21.6 (0.8504)

±0.2 (0.0079)

Wire dia.

mm (in) 3.2 (0.126)

Spring length, off-load

mm (in) 41.1 (1.618)

Wear limit

mm (in) 39.6 (1.559)

Winding direction

clockwise

Number of effective windings

3.8…6

Total number of windings

7.8

Camshaft

Inlet camshaft

° 284

Exhaust camshaft

° 284

Guide bearing dia.

mm (in) 29.970…24.0 (1.180…0.945)

Wear limit

mm (in) 29.95 (1.179)

Guide bearing bore

mm (in) 30.02…30.041 (1.1819…1.1827)

Camshaft bearing bore

mm (in) 24.02…24.041 (0.945…0.9465)

Radial clearance

Guide bearing

mm (in) 0.020…0.071 (0.0008…0.0028)

Camshaft bearing

mm (in) 0.020…0.071 (0.0008…0.0028)

Cam base circle dia.

mm (in) 30 (1.181)

Cam height, inlet and exhaust

mm (in) 38.855 (1.5297)

±0.031 (0.0012)

Wear limit

mm (in) 38.550 (1.5177)

Tappets

Extl. dia.

mm (in) 26.853…26.840 (1.0572…1.0567)

Wear limit

mm (in) 25.970 (1.0224)

Bore in cylinder head

mm (in) 26.065…26.086 (1.0262…1.0270)

Wear limit

mm (in) 26.170 (1.0303)

Radial clearance

mm (in) 0.072…0.106 (0.0028…0.0042)

Wear limit

mm (in) 0.200 (0.0079)

Timing chain

Single roller chain, endless,
pre-stretched, with 126 links

Technical data

K 1100 LT

K 1100 RS

11.8

Crankshaft

Main bearing and crankpin markings

no colour spot

Grinding stage 0

with colour spot

Grinding stage 1

Width of guide bearing

mm (in) 23.020…23.053 (0.9063…0.9076)

Axial play

mm (in) 0.080…0.183 (0.0031…0.0072)

Wear limit

mm (in) 0.250 (0.010)

Main bearing dia.

Grinding stage 0

mm (in) 44.976…45.000 (1.7707…1.7716)

Grinding stage 1

mm (in) 44.726…44.750 (1.7609…1.7618)

Main bearing radial play

mm (in) 0.020…0.056 (0.0008…0.0022)

Wear limit

mm (in) 0.130 (0.0051)

Main bearing bore dia.

mm (in) 49.00…49.14 (1.929…1.935)

Crankpin dia.

Grinding stage 0

mm (in) 37.976…38.000 (1.4951…1.4961)

Grinding stage 1

mm (in) 37.726…37.750 (1.4853…1.4862)

Big end bearing width

mm (in) 21.810…22.065 (0.8587…0.8687)

Connecting rod

Small end bore dia.

mm (in) 41.000…41.016 (1.6142…1.6148)

Wide big end bearing

mm (in) 21.973…22.025 (0.8651…0.8671)

Big end bearing endplay

mm (in) 0.130…0.312 (0.0051…0.0123)

Wear limit

mm (in) 0.400 (0.0157)

Piston pin bore dia.

mm (in) 20.000…20.021 (0.7874…0.7882)

Piston pin bore dia. with
bushing

mm (in) 18.000…18.021 (0.7087…0.7095)

Distance between centers

up to 1992 model year

mm (in) 125.0 (4.9213)

±0.1 (0.0039)

from 1993 model year on

mm (in) 131.0 (5.1575)

±0.1 (0.0039)

Permissible weight difference

g ± 4

Cylinders

Bore

mm (in) 70.500 (2.7756)

±0.005 (0.0002)

mm (in) 70.510 (2.7760)

±0.005 (0.0002)

Wear limit

mm (in) + 0.05 (0.002)

Pistons

Weight group identification

stamped + or -

Piston dia.

Make: KS

mm (in) 70.473 (2.7745)

±0.007 (0.0003)

mm (in) 70.483 (2.7749)

±0.007 (0.0003)

Direction of installation

Arrow on piston crown points forward

Installed clearance

mm (in) 0.015…0.039 (0.0006…0.0015)

Wear limit

mm (in) 0.130 (0.0051)

Technical data

K 1100 LT

K 1100 RS

Content .. 2 3 4 5 ..