BMW AG Motorcycle (K1100LT, K1100RS). Manual - part 9

11.41

Installing combined oil-water pump

•

Apply a thin coat of 3-Bond 1209 to the sealing 
faces, which must be free of oil and grease.

•

Place O-ring on water passage.

•

Insert the input pinion into the output shaft with 
an oiled O-ring.

•

Attach the pump housing and insert the screws 
loosely at first.

L

 Note:

Turn the crankshaft several times in order to centre 
the gearwheels, at the same time gradually tighten-
ing the retaining screws.

•

Tighten the retaining screws fully.

X 

Tightening torque:

Pump housing to crankcase........................... 7 Nm

•

Insert the wire for the oil pressure telltale and 
temperature display through the housing and 
connect it.

•

Apply a thin coat of 3-Bond to the sealing faces 
on the cover and housing, which must be free 
from oil and grease.

•

Place the housing cover in position and tighten it.

X 

Tightening torque:

Cover to pump housing.................................. 7 Nm

11.42

Installing cylinder head

•

Move the piston in cylinder 1 to top dead centre 
(cylinder 1 = timing end).

•

Place the cylinder head gasket in position; no 
holes or passages must be obstructed.

L

 Note:

Use only cylinder head bolts with long thread 
[from 12/94].

•

Place the cylinder head in position and insert 
bolts (1) with washers (2) as far as possible.

•

Tighten the cylinder head bolts in the order 
shown.

X 

Tightening torque:

Cylinder head bolts  ..................................... 20 Nm

•

Attach tighten angle measuring device,
BMW No. 11 2 500, using two T 50 Torx inserts, 
BMW No. 00 2 630.

•

Tighten the cylinder head bolts, to the specified 
torque and angle, as specified.

Tightening angle................................................ 90°

1

2

LT110640

1

2

3

4

5

6

7

8

9

10

LT110660

11.43

Installing camshafts

L

 Note:

Note correct identification of camshafts.

Inlet side

: three grooves after thrust bearing

Exhaust side: two grooves after thrust bearing

•

The camshaft bearing caps are also marked.

Inlet side:

 odd numbers

Exhaust side: even numbers

•

The numbers increase from the front (timing end) 
to the rear.

•

Oil the camshafts at their bearing points.

•

Tighten the bearing caps uniformly, working from 
the inside outwards.

•

Install the thrust bearing (timing end) with chain 
guide last of all.

X 

Tightening torque:

Bearing cap.................................................... 9 Nm

11.44

Installing timing chain

•

Turn the camshaft so that the grooves on the 
ends are vertical in relation to the cylinder head 
at the rear.

•

The grooves at the front end must point towards 
the crankshaft.

•

Insert adjusting tool, BMW No. 11 3 700, and at-
tach it to the camshaft bearings.

•

Place the timing chain in guide rail (1) and press 
in spacing bushing (arrow).

•

Place the timing chain round the crankshaft 
chain sprocket and press the guide rail on to the 
pivot pin.

•

Secure the guide rail at the lower pivot pin (2) 
with the washer and clip.

•

Install chain sprocket (3) for the inlet camshaft so 
that the timing chain is pulled taut towards the 
guide rail.

•

Insert the retaining screw as far as possible.

•

Press tensioning rail (4) on to the pivot pin and 
secure with the large washer and clip (5).

•

Install chain sprocket (6) for the exhaust cam-
shaft so that the timing chain is as taut as possi-
ble between the chain sprockets.

•

Insert the retaining screw as far as possible.

•

Using tensioning tool, BMW No. 11 5 500, install 
chain tensioner (7) and secure.

X 

Tightening torque:

Chain tensioner .............................................. 9 Nm

1

2

3

4

5

6

7

8

LT110660

LT110670

11 3 700

11.45

•

Press serrated washer (8) with eccentric shoul-
der into the chain guide rail spacing bushing by 
a small amount.

•

Turn the serrated washer until the guide rail is 
touching the outer edge of the cylinder head.

•

Press the serrated washer in fully and allow it to 
engage at the two pins.

•

Secure the serrated washer with the small wash-
er and clip.

•

Remove the special tool.

•

Tighten the chain sprockets, holding the hexa-
gon on the camshaft to prevent it from turning.

X 

Tightening torque:

Chain sprocket............................................. 54 Nm

Checking valve clearances

•

Turn the engine over at the crankshaft (counter-
clockwise).

•

Measure valve clearance with feeler gauge.

Valve clearances:
Inlet ..................... 0.15…0.20 mm (0.006…0.008 in)
Exhaust ............... 0.25…0.30 mm (0.010…0.012 in)

•

If the valve clearance has to be corrected, re-
move the timing chain and camshaft again.

•

Renew the bucket tappets.

8

LT110680

11.46

Installing intermediate flange

Installing freewheel

•

Insert the freewheel into the crankcase with the 
helical-cut gearwheel leading.

•

Oil the needle roller bearing well.

Installing countershaft

•

Insert countershaft (1) into the crankcase with 
the small gearwheel facing downwards.

•

Insert spring (2) with the larger external
diameter (arrow) projecting upwards and located 
behind the freewheel gear.

Installing intermediate flange

•

Apply a thin coat of 3-Bond 1209 to the sealing 
faces, which must be free from oil and grease.

•

Attach the intermediate flange (with all collets in 
position).

•

Tighten screws with Torx insert, 
BMW No. 00 2 600.

X 

Tightening torque:

Intermediate flange......................................... 9 Nm

L

 Note:

Note rubber filler in the starter motor area.

Installing driver

•

Clean tapped hole and screw (must be free from 
grease).

•

Push driver on to layshaft.

•

Secure retaining screw with Loctite 273 FL.

X 

Tightening torque:

Driver ........................................................... 33 Nm

Installing alternator

•

Install the alternator with the damping rubber.

X 

Tightening torque:

Alternator ..................................................... 22 Nm

1

2

LT110690

11.47

Installing timing case cover

•

Apply a thin coat of 3-Bond 1209 to the sealing 
faces, which must be free from oil and grease.

•

Pass the wires for the telltale lights (oil pressure, 
coolant temperature) through the cable duct (ar-
row).

•

Place the timing case cover in position and tight-
en it.

X 

Tightening torque:

Timing case cover .......................................... 7 Nm

Installing hall-effect transmitter

•

Screw adjusting disc (1) and gate rotor (2) to the 
crankshaft.

X 

Tightening torque:

Gate rotor ................................................... 2.5 Nm

•

Insert baseplate (3) for Hall-effect transmitter.

•

The cutouts in the baseplate and timing case 
cover should coincide.

•

Insert the retaining screws with shim washer and 
semi-circular washer (4).

X 

Tightening torque:

Baseplate....................................................... 6 Nm

3

1

2

4

LT110701

11.48

Installing cover for Hall-effect transmit-
ter

•

Install the wire for the Hall-effect transmitter with 
rubber grommet (arrow) in the timing case cover.

•

Secure the wire for the oil pressure telltale and 
coolant temperature with clip (1).

•

Install cover with cork gasket.

X 

Tightening torque:

Cover ............................................................. 6 Nm

1

LT110710