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BMW AG Motorcycle (K1100LT, K1100RS). Manual - part 6

11.17

Dismantling and assembling freewheel

Stripping down freewheel

•

Pull freewheel gear (1) off layshaft (5).

•

Clamp the layshaft into a vice with soft jaws
(smooth side down).

•

Remove cover plate (2).

•

Pull off freewheel cage (3).

•

Take out cup spring (4).

•

Pull needle roller bearing (6) out of the freewheel
gear with counter-holder, BMW No. 00 8 570,
and internal puller 21/3, BMW No. 00 8 574.

LT110160

LT110170

00 8 574

00 8 570

Assembling freewheel

•

Press the needle roller bearing into the freewheel
gear so that distance (x) is the same at both
sides.

Distance “X” .............. 0.4

± 0.2

mm (0.016

± 0.008

in)

LT110180

11.18

•

Place the cup spring in position.

•

Insert the freewheel (oiled with engine oil) into the
outer race.

•

Install the outer race (with clamp block facing
cover plate); the cup spring must snap into the
outer race.

•

Place the cover plate in position.

Tightening torque:

Retaining screws.......................................... 10 Nm

•

Push the freewheel gear on to the layshaft while
turning it clockwise.

•

Push the thrust washer and O-ring on to the lay-
shaft.

Removing and installing layshaft nee-
dle roller bearing

Removing bearing

•

Heat the bearing seat to 100 °C.

•

Pull out the bearing with counter-support,
BMW No. 00 8 570, and internal puller 21/3,
BMW No. 00 8 574.

•

If the bearing is defective and cannot be pulled
out, carefully cut through the needle roller sleeve
with a grinder.

Installing bearing

•

Heat the bearing seat to 120 °C.

•

Centre the bearing and drive it in with a
21 mm (0.82 in) drift with a pin of smaller
diameter (15.95 mm/0.628 in).

LT110190

11.19

Removing timing chain cover

Removing the Hall-effect signal transmitter

•

Remove cover (1).

•

Take off gasket (2).

•

Remove Hall-effect signal transmitter (3), noting
the semi-circular shim washers.

Note:

Mark the correct installed position of the adjusting
washer on the engine block, or remove it in the TDC
position.

•

Remove gate rotor (4) and take off adjusting
washer (5).

Remove the crankshaft cover

•

Detach the coolant hose at the water pump and
radiator.

•

Remove the cover.

Removing cylinder head cover

•

Remove the ignition leads.

•

Remove the cylinder head cover.

Removing and installing sealing ring in timing
case cover

•

Drive the sealing ring out with a suitable drift.

•

Drive the sealing ring in from the inside using
handle, BMW No. 00 0 500, and drift,
BMW No. 11 1 610.

LT110200

LT110210

11.20

Removing the timing chain

•

Set cylinder 1 (timing end) to TDC, noting direc-
tion of rotation (arrow). Pin (1) on the crankshaft
must be aligned with the marking on the housing.

Removing chain tensioner

•

Secure chain tensioner (1) with clamp,
BMW No. 11 5 500, (arrow) and remove it.

LT110230

11 5 500

LT110240

Removing chain tensioner rail

•

Remove clip (2) and washer (3).

•

Pull out tensioner rail (4).

Renewing chain tensioner rail facing

LT110790

11.21

Removing camshaft chain sprockets

•

When taking out the retaining screws, hold the
hexagon on the camshaft to prevent it from turn-
ing.

•

Remove chain guide (1).

LT110260

LT110250

Removing chain guide

•

Remove keepers (2) and washers (3) at the pivot
pins.

•

Raise chain guide (4) slightly at the cylinder head
and press it down again.

•

The toothed washer with eccentric (arrow) must
project slightly.

•

Pull out the toothed washer.

•

Take off the chain guide with the timing chain.

11.22

Removing, stripping down and assem-
bling cylinder head

Removing camshafts

•

Remove the bearing caps (1) for the thrust bear-
ings first, to prevent tilting.

•

Release tension uniformly at radial bearing
caps (2) and remove them.

•

Take out the camshafts.

Removing cylinder head

•

Unscrew the cylinder head bolts (3) with Torx in-
sert, BMW No. 00 2 610.

•

Strike the cylinder head lightly with a plastic-
faced hammer to dislodge it.

Removing bucket-type tappets

•

Using special suction tool, BMW No. 11 3 251,
pull bucket tappets (5) out of the cylinder head.

•

Make a note of which tappet belongs to which
valve.

LT110270

11.23

Removing valves

•

Screw support plate, BMW No. 11 1 749, for the
valve spring clamping tool on to the rear of the
cylinder head.

•

Attach valve spring clamping tool,
BMW No. 11 1 740.

•

Use pressure cage (1), BMW No. 11 1 748.

•

Place the cylinder head flat on a wooden board
and clamp the valve spring.

•

Pull valve collets (1) out with a magnetic screw-
driver.

•

Release valve spring (3) and remove the various
components.

•

Upper spring plate (2), lower spring plate (4).

•

Pull out the valve stem seal with pliers,
BMW No. 11 1 250.

Remachining valve seat

D = valve diameter
B = valve seat width

•

When remachining, the correct width of the valve
seat must always be maintained.

Note:

Machine the valve seat with turning tool,
BMW No. 11 0 500.

•

If the valve seat has been remachined, a new
valve must be installed.

LT110280

11 1 749

LT110290

11 1 740

LT110300

LT110310

11.24

Installing valve and valve stem seal

Note:

If a valve was removed, the valve stem seal must be
renewed.

•

Oil the stem when installing the valve.

•

Insert the lower spring plate.

•

Push assembly sleeve (arrow),
BMW No. 11 1 960, on to the valve stem.

•

Drive in sealing ring (1) with drift,
BMW No. 11 5 601, until the drift reaches the
cylinder head.

Caution:

Remember to remove the assembly sleeve from the
valve stem.

•

Insert the valve spring.

•

Install the upper spring plate.

•

Clamp the valve spring, lightly oil the valve collets
and insert them, then release the spring.

•

Clean and oil the bucket-type tappet before in-
serting.

LT110320

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