Maintenance instructions for sporty off-roading HP2 Enduro
Motorcycle data/dealership details Motorcycle data
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Person to contact in Service department
Vehicle identification number
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Details described or illustrated in this booklet may differ from the motorcycle's actual specification as purchased, the accessories fitted or the national-market specification. No claims will be entertained as a result of such discrepancies. Dimensions, weights, fuel consumption and performance data are quoted to the customary tolerances. The right to modify designs, equipment and accessories is reserved. Errors and omissions excepted. Š 2005 BMW Motorrad Not to be reproduced either wholly or in part without written permission from BMW Motorrad, After Sales. Printed in Germany.
LastPage.fm Seite 0 Mittwoch, 10. August 2005 12:04 12
BMW recommends
9
BMW Motorrad
Order No: 01 41 7 698 321 08.2005 1st edition GB/RF
The Ultimate Riding Machine
Maintenance instructions for sporty off-roading These maintenance instructions were compiled for riders who want to leave metalled roads and use their motorcycles for sporty off-roading. Before you go off-roading, BMW Motorrad recommends installing the accessories supplied with the motorcycle. In this way you can effectively protect parts of the motorcycle that could otherwise be at risk. These maintenance instructions describe the procedures for installing the off-road accessories and the procedure for removing the numberplate carrier and the mirrors.
Use the headlight guard only when off-roading. Riding on public roads with the headlight guard fitted to the motorcycle is prohibited. Sporty off-roading inevitably increases wear and tear on the motorcycle, so extra checks and maintenance work over and above those described in the Rider's Manual are necessary. They too are described in this publication. All the work described in these Maintenance Instructions is supplementary to the standard maintenance work described in the "Service" section of the Rider's Manual. Please bear in mind that if the motorcycle is used for sporty off-roading, you must comply with these additional maintenance instructions in order to
keep the motorcycle in good running order. Some of the work calls for special tools and a thorough knowledge of motorcycles. If you are in doubt consult a specialist workshop, preferably your authorised BMW Motorrad dealer. Damage not attended to in good time or inadequately repaired can result in consequential damage to the motorcycle. Consult a specialist workshop, preferably an authorised BMW Motorrad dealer, as soon as possible if you discover that the motorcycle is damaged.
Table of Contents You can also consult the index at the end of this Rider's Manual if you want to find a particular topic or item of information. 1 General instructions . . . 3 Notes on these Maintenance Instructions . . . . . . . . . . . . . . 4 Abbreviations and symbols . . . . . . . . . . . . . . . . . . 4 2 Overview . . . . . . . . . . . . . . Conversion work preparatory to off-roading . . . . . . . . . . . . . . . Maintenance work . . . . . . . .
5
6 6
3 Installing and removing components . . . . . . . . . . . 9 Removing number-plate carrier . . . . . . . . . . . . . . . . . . 10 Installing number-plate carrier . . . . . . . . . . . . . . . . . . 11 Removing mirror . . . . . . . . . 12
Installing mirrors . . . . . . . . . Installing headlight guard . . . . . . . . . . . . . . . . . . . Installing guard for final drive . . . . . . . . . . . . . . . . . . . . Installing cylinder guard . . . . . . . . . . . . . . . . . . . Installing deflector for footbrake lever . . . . . . . . . . Installing left and right hand protectors . . . . . . . . . Replacing left and right hand frame-protector strips . . . . . . . . . . . . . . . . . . . 4 Maintenance . . . . . . . . . Work to be carried out always before off-roading . . . . . . . . . . . . . . Work to be carried out after five hours of riding in sand, dust or mud . . . . . . . Work to be carried out after ten hours off-roading . . . . . . . . . . . . . .
12
Work to be undertaken once a year. . . . . . . . . . . . . . 29
12
5 Threaded fasteners . . . Anchorage points, engine and swinging arm . . . . . . . . Anchorage points, frame and mounted components . . . . . . . . . . . . . Anchorage points, front . . . . . . . . . . . . . . . . . . . . Threaded fasteners, front wheel . . . . . . . . . . . . . . . . . . . Body-panel screws . . . . . .
13 14 14 15
18 19
20
20
25
31 33
34 36 38 38
6 Technical data . . . . . . . . 39 Tightening torques for internally mounted components . . . . . . . . . . . . . 40 Tightening torques for checking threading fasteners . . . . . . . . . . . . . . . . 42
General instructions
General instructions Notes on these Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . 4
1 3
General instructions
Abbreviations and symbols . . . . . . 4
z
1
General instructions
4
z
Notes on these Maintenance Instructions The work explained in these Maintenance Instructions should be carried out in accordance with the schedule outlined below. Use the operating-hours counter described in the "Operation" section of the Rider's Manual to check the operating hours. Work you must always undertake before leaving surfaced roads for sporty offroading. Work you must undertake after five hours of riding in mud, dust or sand. Work you must undertake after ten hours off-roading. Work you must undertake once a year.
You will find detailed information on maintenance and repair work in the Repair Manual on the CD-ROM that accompanies your motorcycle.
Abbreviations and symbols Indicates warnings that you must comply with for reasons of your safety and the safety of others, and to protect your motorcycle against damage. Specific instructions on how to operate, control, adjust or look after items of equipment on the motorcycle. Indicates the end of an item of information. Instruction. Result of an activity.
Reference to a page with more detailed information.
Overview
Overview Conversion work preparatory to off-roading . . . . . . . . . . . . . . . . . . . . . . 6
2 5
Overview
Maintenance work . . . . . . . . . . . . . . . 6
z
2
Overview
6
z
Conversion work preparatory to off-roading Removing number-plate carrier ( 10) Removing mirror ( 12) Installing headlight guard ( 12) Installing guard for final drive ( 13) Installing cylinder guard ( 14) Installing deflector for footbrake lever ( 14) Installing left and right hand protectors ( 15)
Maintenance work Work to be carried out always before off-roading Checking brake disc wear ( 20)
Checking brake pads for wear ( 20) Checking spokes ( 20)
Work to be carried out after five hours of riding in sand, dust or mud Checking alternator drive belt ( 20) Checking air filter for dirt ( 21) Checking ease of movement of footbrake lever ( 23) Checking ease of movement of shift lever ( 24) Cleaning slider tubes ( 25)
Work to be carried out after ten hours off-roading Checking air filter for dirt ( 21)
Checking ease of movement of footbrake lever ( 23) Checking ease of movement of shift lever ( 24) Cleaning slider tubes ( 25) Checking steering-head bearing ( 25) Checking wheel bearing for play ( 26) Checking telescopic-fork protector and slip-ring ( 26) Bleeding telescopic forks ( 27) Checking ease of movement of side stand ( 27) Check operation of sidestand switch ( 27) Checking spring-strut mount for play ( 28) Checking swinging-arm bearings for play ( 28) Checking flexible gaiter ( 29)
Checking Paralever bearing for play ( 29) Checking security of threaded fasteners ( 29)
2 7
Changing telescopic-fork oil ( 29)
Overview
Work to be undertaken once a year
z
z Overview
2 8
Installing and removing components
Installing and removing components
3 10
Installing number-plate carrier . . . . . . . . . . . . . . . . . . . . . . . .
11
Removing mirror. . . . . . . . . . . . . . .
12
Installing mirrors. . . . . . . . . . . . . . .
12
Installing headlight guard . . . . . .
12
Installing guard for final drive . . .
13
Installing cylinder guard . . . . . . . .
14
Installing deflector for footbrake lever . . . . . . . . . . . . . . . . . . . . . . . . . .
14
Installing left and right hand protectors . . . . . . . . . . . . . . . . . . . . .
15
Replacing left and right hand frame-protector strips . . . . . . . . .
18
Installing and removing components
9
Removing number-plate carrier . . . . . . . . . . . . . . . . . . . . . . . .
z
3
Installing and removing components
10
z
Removing numberplate carrier Make sure the ground is level and firm and place the motorcycle on its stand. Remove the seat.
Push wiring-harness end of plug 1 into the holder of protective plug 2.
Remove screws 3 on left and right.
Remove screws 4 and screw 5. Remove the number-plate carrier and thread out the cables.
Remove plug 1 from its holder and disconnect the plug. Remove protective plug 2 from its holder. Connect plug 1 to protective plug 2. Reinstall screws 4.
Installing numberplate carrier
3
Remove screws 4. Manoeuvre the cables into place and hold the numberplate carrier in position.
Install screws 4 and screw 5. Disconnect the numberplate plug and the protective plug.
Install screws 3 on left and right.
Remove wiring-harness end of plug 1 from the holder. Connect plug 1 and seat it in the holder.
Installing and removing components
11
z
3 12
Seat protective plug 2 in its holder. Install the seat.
Installing mirrors
Use the headlight guard only when off-roading. Riding on public roads with the headlight guard fitted to the motorcycle is prohibited.
Installing and removing components
Removing mirror
z
Push back rubber sleeve 1. Release threaded fastener 2 and remove the mirror. Remove clamping piece 3.
Installing headlight guard
Install clamping piece 3. Clamping piece to clamping block 30 Nm Install the mirror and adjust it to the correct position. Tighten threaded fastener 2. Mirror to clamping piece 25 Nm Slip rubber sleeve 1 down over the threaded fastener.
Position the headlight guard with bore 1 against the instrument carrier from below and secure it with cable tie 2.
Installing guard for final drive
3
Bend the headlight guard down at the front and use cable ties 3 to mudguard struts 4. In order to avoid injury, be sure to turn the cable tie so that the lock is at the back.
Insert attachment 1 long end toward the rear into housing for final drive 2.
Position guard for final drive 3 on the attachment and secure it with screw 4. Guard, final-drive housing 8 Nm
Installing and removing components
13
z
3
In order to avoid injury, be sure to turn the cable tie so that the lock is at the back.
Installing cylinder guard
14
Installing and removing components
Installing deflector for footbrake lever
z
Remove screw 1.
Remove screws 2 and 3.
Working from the inside, insert the front reinforcing plate into the cylinder guard. Use the screws and bushings provided to secure the cylinder guard, inserting the screws into the tapped holes left by the screws removed beforehand. Cylinder guard to engine Thread-locking compound: Mechanical thread lock 8 Nm Install cable tie 3.
Screw threaded pin 2 into the tapped hole in the footbrake lever until nut 1 can just be screwed on. Lock the pin with nut 1. Footbrake lever deflector to lever Hand-tight
Installing left and right hand protectors Removing mirror (
12)
3 15
Remove screws 1 and remove top part of mirror clamping block 2. Hold the clutch fitting or handbrake fitting, as applicable, when removing the clamping block.
Install screws 1 of the mirror clamping block for the hand protector, but do not tighten them at this point. Align the clamping block so that pin 2 of the grip unit projects into the gap in the mirror clamping block. Tighten screws 1 in such a way that the gap between the top and bottom halves of the clamping block is the same width at front and rear. Handlebar fitting to handlebar
Installing and removing components
Insert screw 3 through eye 4 and install it in the motorcycle's frame. Align the eye as shown in the illustration. Footbrake lever deflector to frame 5 Nm Remember to remove the deflector for the footbrake lever before you next use the motorcycle on public roads.
z
3
Installing and removing components
16
z
Position holders 3 in such a way that the cables pass through recess 4. Note the identifying marks RK for the right hand protector and LK for the left hand protector. Install screws 5, but do not tighten them at this point.
Use screws 6 and washers to secure the hand-protector holder to the hand protector. Use hand-protector holder 7 684 575 for the left side and 7 684 576 for the right side. Hand protector to holder for hand protector 3 Nm
Use screw 7 and washer to secure the hand-protector holder to the mirror clamping block. Holder for hand protector to mirror clamping block 3 Nm Use screw 8 and washer to secure the hand protector to holder 3. Hand protector to clamping block 3 Nm Tighten screws 5 of the holder in such a way that the gap between the top and bottom halves of the
3 17
Installing and removing components
holder is the same width at front and rear. Clamp to clamping block 4 Nm Installing mirrors ( 12)
z
3 18
Replacing left and right hand frameprotector strips
Installing and removing components
1
z
Positions of the left and right protector strips to be checked and, if necessary, replaced
Maintenance
Maintenance
4 20
Work to be carried out after five hours of riding in sand, dust or mud . . . . . . . . . . . . . . . . . . . . . . . . . .
20
Work to be carried out after ten hours off-roading . . . . . . . . . . . . . .
25
Work to be undertaken once a year. . . . . . . . . . . . . . . . . . . . . . . . . . .
29
19
Maintenance
Work to be carried out always before off-roading . . . . . . . . . . . . .
z
4 20
Work to be carried out always before off-roading
Maintenance
Checking brake disc wear
z
Consult the following source for a description of how to check the brake discs for wear: Repair manual on CD-ROM / Construction group 34 / Repair manual
Checking spokes Draw the handle of a screwdriver or a similar instrument across the spokes and listen to the notes of the individual spokes. If the notes vary: Have the spokes checked by a specialist workshop, preferably an authorised BMW Motorrad dealer.
Work to be carried out after five hours of Checking brake pads for riding in sand, dust or wear mud Consult the following source for a description of how to check the brake pads for wear: Repair Manual on CD-ROM / Construction group 34 / Repair manual Rider's Manual / chapter entitled "Maintenance"
Remove screws 1. Remove the cover of the alternator drive belt.
Checking alternator drive belt Make sure the ground is level and firm and place the motorcycle on its stand. Check for foreign matter on the belt cover and in the
vicinity of alternator drive belt 1. If foreign matter has built up: Remove the foreign-matter accretions.
4
Place the cover of the alternator drive belt in position. Install screws 1.
Checking air filter for dirt Check alternator drive belt 1 for cracks and wear. If the belt is cracked or badly worn: Have the alternator drive belt replaced by a specialist workshop, preferably an authorised BMW Motorrad dealer.
Make sure the ground is level and firm and place the motorcycle on its stand.
Remove screw 1 from the intake guard. Remove the intake guard. Remove screws 2 from the side panel. Remove the right side panel.
Maintenance
21
z
Check the air filter for dirt. If the air filter is dirty: Tap the air filter to remove foreign matter; replace if necessary
4
Maintenance
22
Remove retaining clips 1.
Pull air intake 2 to one side out of mount 3 and remove it from the air filter box.
z
Introduce air filter element 1 into the air filter box from below.
To do so, press the rear of the clip arrow and pull out the clip.
Pull the air filter element 1 down and out of the air filter box.
the throttle valve is seated against the stop.
4
Working from the side, slip air intake 2 into mount 3 and the guides on the air filter box. Make sure that the air filter is not squashed inside the air filter box.
Push in retaining clips 1. The retaining clips engage with an audible click.
Install right side panel with screws 2. Install intake guard with screw 1, making sure the guard is correctly seated.
Checking ease of movement of footbrake lever
Check that the throttle-valve cable is seated in the guide of the intake arrow and that
Make sure the ground is level and firm and place the motorcycle on its stand.
Maintenance
23
z
Checking ease of movement of shift lever
4
Make sure the ground is level and firm and place the motorcycle on its stand.
Maintenance
24
z
Check the ease of movement of pivot mount 1 and footrest adjuster 2. If the pivot mount is stiff: Have the pivot mount checked by a specialist workshop, preferably an authorised BMW Motorrad dealer.
Check the deflector for the footbrake lever for bent parts and check that the footbrake lever is in full working order. If parts of the deflector for the footbrake lever are bent: Replace the deflector for the footbrake lever.
If the footrest adjuster is stiff: Lubricate the footrest adjuster. Staburags NBU 30 PTM
If the footbrake lever is not in full working order: Restore the footbrake lever to full working order.
Check the ease of movement of lever pivot 1. Check the ease of movement at pivots 2 and 3. If pivots are stiff: Have the shift lever checked by a specialist workshop, preferably an authorised BMW Motorrad dealer.
Cleaning slider tubes
Work to be carried out after ten hours off-roading
Make sure the ground is level and firm and place the motorcycle on its stand.
Use plenty of water to wash out the space between the fork protector and the slider tube. Use a damp cloth to wipe clean the right and left slider tubes. In this process, be sure to pull the cloth through between the fork protector and the slider tube at the front.
4 25
Push left and right sealing boots 1 down. Use a dry cloth to wipe dirt off the sealing boots and slider tubes. Pack the groove of each sealing boot with grease. Molykote 111 Slide the sealing boots back up into position.
Checking air filter for dirt ( 21) Checking ease of movement of footbrake lever ( 23) Checking ease of movement of shift lever ( 24) Cleaning slider tubes ( 25)
Checking steering-head bearing Place the motorcycle on the auxiliary stand (see Rider's Manual).
Maintenance
Work already described
z
Have the bearing replaced by a specialist workshop, preferably an authorised BMW Motorrad dealer.
4 26
Maintenance
Checking wheel bearing for play
z
Take a grip at the bottom of the fixed fork tubes and pull the forks back and forth. If the bearing is not free of play: Have the steering head bearing adjusted by a specialist workshop, preferably an authorised BMW Motorrad dealer. Allow the handlebars to swing left and right from the straight-ahead position. If the handlebars feel stiff or there is a perceptible notching effect at the straight-ahead position:
Place the motorcycle on the auxiliary stand (see Rider's Manual).
try to turn the wheel in opposite directions and check whether play is perceptible in the bearing. If there is play in the wheel bearing: Have the wheel bearing checked by a specialist workshop, preferably an authorised BMW Motorrad dealer.
Checking telescopic-fork protector and slip-ring Make sure the ground is level and firm and place the motorcycle on its stand.
Lift the front wheel clear of the ground, let it turn and check whether play is perceptible. Take a firm grip of the front wheel at top and bottom,
Check for wear at the insides of left and right telescopic-fork protectors 1 and check left and right slip-rings 2 for wear. If evidence of wear is visible: Have the condition of the telescopic-fork protectors and the slip-rings checked by a specialist workshop, preferably an authorised BMW Motorrad dealer.
Bleeding telescopic forks Make sure the ground is level and firm and place the motorcycle on its stand.
Back off and then retighten screw 1 on the left in the fork bridge.
Place the motorcycle on the auxiliary stand (see Rider's Manual). Extend and retract the side stand to check the freedom of its movement. If the side stand is stiff: Have the side stand checked by a specialist workshop, preferably an authorised BMW Motorrad dealer.
Check operation of sidestand switch
Back off and then retighten screw 1 on the right in the fork bridge.
Switch off the engine and extend the side stand. With the clutch disengaged, switch on the ignition and start the engine. The engine starts. Engage first gear. The engine cuts out.
4 27
Maintenance
Checking ease of movement of side stand
z
4
Maintenance
28
z
If the engine does not cut out: Have the side-stand switch checked by a specialist workshop, preferably an authorised BMW Motorrad dealer.
Checking spring-strut mount for play Make sure the ground is level and firm and place the motorcycle on its side stand. Remove the seat.
motorcycle against the side stand. Repeat this check at bottom spring-strut mount 2. If the mounts are not free of play: Have the spring-strut mounts checked by a specialist workshop, preferably an authorised BMW Motorrad dealer.
Checking swinging-arm bearings for play Place the motorcycle on the auxiliary stand (see Rider's Manual).
Lay one hand on top springstrut mount 1 and push the
Place one hand on the swinging-arm bearing and the frame on the left. Move the rear wheel to left and right, while checking for play in swinging-arm bearing 1. Repeat the procedure for the right swinging-arm bearing. If the bearings are not free of play: Have the swinging-arm bearings checked by a specialist workshop, preferably an authorised BMW Motorrad dealer.
Make sure the ground is level and firm and place the motorcycle on its side stand.
Checking Paralever bearing for play Place the motorcycle on the auxiliary stand (see Rider's Manual).
authorised BMW Motorrad dealer.
Checking security of threaded fasteners Check the security of the threaded fasteners, as described in the section entitled "Threaded fasteners".
Work to be undertaken once a year Changing telescopic-fork oil Check that flexible gaiter 1 is correctly seated and free of cracks. If the flexible gaiter has worked loose or if cracks are visible: Have the flexible gaiter checked by a specialist workshop, preferably an authorised BMW Motorrad dealer.
Place one hand on the Paralever bearing. Move the rear wheel to left and right, while checking for play in Paralever bearing 1. If the bearings are not free of play: Have the Paralever bearings checked by a specialist workshop, preferably an
Have the oil in the telescopic forks changed by a specialist workshop, preferably an authorised BMW Motorrad dealer.
4 29
Maintenance
Checking flexible gaiter
z
z Maintenance
4
30
Threaded fasteners
Threaded fasteners
5 33
Anchorage points, frame and mounted components . . . . . . . . .
34
Anchorage points, front . . . . . . . .
36
Threaded fasteners, front wheel . . . . . . . . . . . . . . . . . . . . . . . . .
38
Body-panel screws . . . . . . . . . . . .
38
31
Threaded fasteners
Anchorage points, engine and swinging arm . . . . . . . . . . . . . . . . . .
z
z Threaded fasteners
5
32
5
1
33
2 3
4 5 6
Rear frame section to engine at top, left and right Frame front section to engine, left and right Rear frame section to engine at bottom, left and right Swinging arm to rear frame section, right Reaction link to frame Reaction link to finaldrive housing
If a locking compound is specified for a threaded fastener in the table of torques, be sure to comply with the instructions in the appropriate chapter of the Repair Manual on CD-ROM.
Threaded fasteners
Anchorage points, engine and swinging arm
z
5 34
Anchorage points, frame and mounted components
Threaded fasteners
1
z
Frame front section to rear frame section, left and right 2 Spring strut to rear frame 3 Spring strut to rear swinging arm 4 Rear carrier to rear frame section, left and right 5 Rear wheel to wheel carrier 6 Rear silencer to rear frame section 7 Side stand to pivot mount 8 Stop screw, front footrest, left, to side-stand pivot mount 9 Pivot mount, side stand to rear frame section 10 Swinging arm to rear frame section, left
5 35
Threaded fasteners
If a locking compound is specified for a threaded fastener in the table of torques, be sure to comply with the instructions in the appropriate chapter of the Repair Manual on CD-ROM.
z
5
Anchorage points, front
36
1
Threaded fasteners
2 3
4 5 6 7
z
8
Front mudguard to headlight, left and right Mudguard carrier to top fork bridge, left and right Handlebars to handlebar clamping blocks, left and right Handlebar clamping block to fork bridge Fork bridge to steering tube Top fork bridge to fixed fork tube, left and right Bottom fork bridge to fixed fork tube, left and right Mudguard carrier to fork bridge, bottom
If a locking compound is specified for a threaded fastener in the table of torques, be sure to comply with the instructions in the
5 37
Threaded fasteners
appropriate chapter of the Repair Manual on CD-ROM.
z
5
Threaded fasteners, front wheel
Threaded fasteners
38
z
1 2
Pinch bolt, axle holder, left and right Front wheel, axle screw in axle holder
If a locking compound is specified for a threaded fastener in the table of torques, be sure to comply with the instructions in the appropriate chapter of the Repair Manual on CD-ROM.
Body-panel screws The body-panels crews listed below are locked by means of nylon thread and are handtightened. Check the locking effect of the nylon threads and the security of the screws. Body-panel screws Five screws in each front body panel, left and right. Two screws in each rear body panel, left and right. Four screws in the protector for the rear light. Nine screws in the bottom front mudguard. Five screws in the numberplate carrier.
Technical data
Technical data
6 40
Tightening torques for checking threading fasteners . . . . . . . . . . . .
42
39
Technical data
Tightening torques for internally mounted components . . . . . . . . .
z
6
Tightening torques for internally mounted components Activity
Type of threaded connection
40
Tightening torques
Technical data
Mirrors
z
Clamping piece to clamping block M10
30 Nm
Mirror to clamping piece
25 Nm
M10
Guard for final drive Guard, final-drive housing
8 Nm
Cylinder guard Cylinder guard to engine
M6 x 20, Mechanical thread lock
8 Nm
Deflector, footbrake lever Footbrake lever deflector to lever Footbrake lever deflector to frame
Nut M5
Hand-tight 5 Nm
Type of threaded connection
Tightening torques
41
Hand protectors Handlebar fitting to handlebar
6
M5 x 20
5 Nm
Hand protector to holder for hand M5 x 14 protector
3 Nm
Holder for hand protector to mirror M5 x 14 clamping block
3 Nm
Hand protector to clamping block
M8 x 16
3 Nm
Clamp to clamping block
M5 x 12
4 Nm
Technical data
Activity
z
6
Tightening torques for checking threading fasteners Activity
Type of threaded connection
Tightening torques
Frame front section to rear frame section
M8 x 20
19 Nm
Frame front section to engine front / rear
M12, Micro-encapsulated
66 Nm
42
Technical data
Frame
z
Rear frame to engine, bottom
M12 x 50
55 Nm
Rear frame to engine, top
M10 x 40
38 Nm
Rear carrier to rear frame section
M6 x 25
8 Nm
Link Reaction link to final-drive housing M10 x 55 10.9, Mechanical thread lock
43 Nm
Reaction link to rear frame section M10 x 50 10.9
38 Nm
Type of threaded connection
Tightening torques
43
Rear wheel swinging arm Swinging arm to rear frame section, left, locknut
M24 x 1.25
145 Nm
Swinging arm to rear frame section, left, bearing stud
M24 x 1.25
7 Nm
Swinging arm to rear frame section, right
M6
9 Nm
M10 x 53 x 1.25
60 Nm
Spring strut to rear swinging arm
M12
66 Nm
Spring strut to rear frame
M12
66 Nm
Rear wheel Rear wheel to wheel carrier
6
Spring strut
Side stand Side stand to pivot mount
M10 x 1, Loctite 603
41 Nm
Pivot mount, side stand to rear frame section
M8 x 16, Micro-encapsulated
19 Nm
Front footrest stop screw to sidestand pivot mount
M8, Micro-encapsulated
19 Nm
Technical data
Activity
z
6 44
Activity
Type of threaded connection
Tightening torques
Rear silencer Rear silencer to rear frame section M8 x 45
19 Nm
Technical data
Handlebars
z
Handlebar clamping block to fork bridge
M10 x 100, grease thread, Optimoly TA
38 Nm
Handlebar to handlebar clamping block
M8 x 30, grease thread, Optimoly TA
19 Nm
Fork bridge, top, to steering tube
M8 x 30
24 Nm
Mudguard carrier to fork bridge, top
M6 x 16 A2-70 special steel, bright, Optimoly TA
10 Nm
Mudguard carrier to fork bridge, bottom
M6 x 16 A2-70 special steel, bright, Optimoly TA
10 Nm
Front mudguard to headlight carrier
M8 x 20
20 Nm
Fork bridge, top, to fork fixed tube M8 x 30
24 Nm
M8 x 30
10 Nm
Front mudguard
Clamps, slider tubes Fork bridge, bottom, to fork fixed tube
Type of threaded connection
Tightening torques
6 45
Front wheel Front wheel, axle screw in axle holder
M22 x 1.5 - Elox H, Optimoly TA
50 Nm
Pinch bolt, axle holder
M6 x 30
8 Nm
Technical data
Activity
z
7
Index
46
z
A Abbreviations and symbols, 4 Accessories Installation, 6, 9 Air filter Test, 21 Alternator drive belt Test, 20 B Brake discs Test, 20 Brake pads Test, 20 C Cylinder guard Installation, 14 D Deflector, footbrake lever Installation, 14 F Final-drive guard Installation, 13
Flexible gaiter Test, 29 Footbrake lever Test, 23 Frame-protector strips Overview, 18 H Hand protectors Installation, 15 Headlight guard Installation, 12 M Maintenance After five hours offroading, 6, 20 After ten hours offroading, 6, 25 Always before offroading, 6, 20 Annually, 7, 29 Mirrors Installation, 12 Removal, 12
N Number-plate carrier Installation, 11 Removal, 10 P Paralever Checking bearing, 29 S Shift lever Test, 24 Side stand Checking switch, 27 Test, 27 Slider tubes Cleaning, 25 Slip-ring Test, 26 Spokes Test, 20 Spring strut Test, 28 Steering-head bearing Test, 25
T Telescopic fork Bleeding, 27 Changing oil, 29 Checking protector, 26 Threaded fasteners Body panels, 38 Engine and swinging arm, 33 Frame and mounted components, 34 General view, front, 36 General view, front wheel, 38 Test, 29 Torques, 40 W Wheel bearing Test, 26
7 47
Index
Swinging arm Checking bearing, 28
z