bmw k1200 gt clutch removal

15
MW-Motorrad emoving right side panel i KU .SI RAGOOSb Open stowage-compartment lid (1). Remove the following components, noting the retainers (arrows): - Screws (2) - Screws (3) - Screws (4) - Side panel (5) ^/20^0

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Page 1: Bmw k1200 gt clutch removal

MW-Motorrad

emoving right side panel

i

KU .SI RAGOOSb

• Open stowage-compartment lid (1).

• Remove the following components, noting the retainers (arrows):

- Screws (2)

- Screws (3)

- Screws (4)

- Side panel (5)

^/20^0

Page 2: Bmw k1200 gt clutch removal

MW-Motorrad

emoving right side panei

• Open stowage-compartment lid (1).

• Remove the following components, noting the retainers (arrows):

- Screws (2)

- Screws (3)

- Screws (4)

- Side panel (5)

?/2010

Page 3: Bmw k1200 gt clutch removal

MW-Motorrad

emoving clutch slave cylinder

KU R21C«a>

A Attention

If the clutch lever is pulled v^/ith the slave cylinder or the clutch cover removed, theis a possibility of the piston dropping out of the slave cylinder or suffering damage.

Do not operate the clutch lever with the slave cylinder or the clutch cover removed

Remove screws (1).

Pull clutch slave cylinder (2) out of the clutch cover and lay it aside in such a waythat there is no strain on the line.

E/2010

Page 4: Bmw k1200 gt clutch removal

MW-Motorrad

emoving clutch cover

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^ Removing heat shield from crankcase cover, right

• Remove the following components:

- Screws (1)

- Heat shield (2)

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• Remove the following components:

- Screws (1) and (2)

- Clutch cover (3)

- Thrust piece (4)

- Thrust bearing (5)

- Seal (6)

>/2010

Page 5: Bmw k1200 gt clutch removal

MW-Motorrad

] 21 21 000 Removing and Installing or replacing clutch

•- 21 21 606

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Preparatory work

Removing right side panel

Removing complete engine spoiler

Removing clutch slave cylinder

Removing clutch cover

Core activity

(-) Removing clutch cage

^ Removing crankshaft sensor

• Remove screw (1).

Attention

Oil is hazardous to the environment; oil can attack plastic and rubber parts; oilspillages make the ground slippery and dangerous.

Catch escaping oil.

• Pull out crankshaft sensor (2) and allow it to dangle from the cable, taking care nto lose or damage sealing ring (3).

» Note that oil can escape from the bore in the crankcase.

^ Locking engine with locating pin

• Introduce locating pin {No, 11 1 842) into the sensor bore.

• Install screw (1) to secure the locating pin.

» Engine locked.

Remove nut (1) from the clutch while holding the clutch cage with driver lock (No21 4 651).

^/20^0

Page 6: Bmw k1200 gt clutch removal

MW-Motorrad

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^ Removing plate cluster

• Remove plate cluster (1) and thrust washer (2).

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^ Removing locating pin

• Remove screw (1).

• Remove locating pin (No. 11 1 842) from the sensor bore.

Preload tensioning gear (1) of the alternator freewheel with locating pin (No. 11 2671).

firNote

Do not remove or install the locating pin unless the clutch cage is installed.

- Insert the locating pin vertically as far as it will go.

- Turn the locating pin to the horizontal position.

5/2010

Page 7: Bmw k1200 gt clutch removal

MW-Motorrad

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• Remove clutch cage (2).

(+) Installing clutch

(+) Securing crankshaft sensor

Finishing work

Securing clutch cover

Securing clutch slave cylinder

Installing entire engine spoiler

Installing right side panel

Final check of work performed

2/2010

Page 8: Bmw k1200 gt clutch removal

MW-Motorrad

] 21 21 000 Removing and installing or replacing clutch

H 21 21 606

Preparatory work

Removing right side panel

Removing complete engine spoiler

Removing clutch slave cylinder

Removing clutch cover

Core activity(-) Removing clutch cage

^ Removing crankshaft sensor

• Remove screv*/ (1).

A Attention

Oil is hazardous to the environment; oil can attack plastic and rubber parts; oilspillages make the ground slippery and dangerous.

Catch escaping oil.

• Pull out crankshaft sensor (2) and allow it to dangle from the cable, taking care n'to lose or damage sealing ring (3).

» Note that oil can escape from the bore in the crankcase.

1 842

^ Locking engine with locating pin

• Introduce locating pin (No. 11 1 842) into the sensor bore.

• Install screw (1) to secure the locating pin.

» Engine locked.

Remove nut (1) from the clutch while holding the clutch cage with driver lock (No21 4 651).

?/2010

Page 9: Bmw k1200 gt clutch removal

MW-Motorrad

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^ Removing plate cluster

• Remove plate cluster (1) and thrust washer (2).

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^ Removing locating pin

• Remove screw (1).

• Remove locating pin (No. 11 1 842) from the sensor bore.

Preload tensioning gear (1) of the alternator freewheel with locating pin (No. 11 2671).

Note

Do not remove or install the locating pin unless the clutch cage is installed.

- Insert the locating pin vertically as far as it will go.

- Turn the locating pin to the horizontal position.

>/2010

Page 10: Bmw k1200 gt clutch removal

MW-Motorrad

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Remove clutch cage (2).

(-) Installing clutch

Adjusting chain tension of oil-pump drive

> Removing bearing for oil-pump drive

• Remove sleeve (1) and needle roller bearing (2),

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Slacken screw (1).

Insert eccentric gauge (No. 11 1 931) between the sprocket and the gearbox inpishaft.

Align the mark on the eccentric (arrow) at right angles to the oil-pump drive chainUse your hand to push the tensioning rail toward the chain and tighten screw (1).

NTightening torques

Chain guide, oil pump to crankcase

^/2010

Page 11: Bmw k1200 gt clutch removal

MW-Motorrad

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111 931

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• Without applying more pressure against the tensioning rail, turn the sprockets twifull turns counter-clockwise.

• Align the mark on the eccentric (arrow) at right angles to the oil pump drive chain

Test

• Check the tension of chain (1).

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Result: Chain too tight or too loose

Measure:

• Repeat the adjustment procedure.

• Remove eccentric gauge (No. 11 1 931).

> Installing bearing for oil-pump drive

• Lubricate needle roller bearing (2) with engine oil.

• Install sleeve (1) and needle roller bearing (2).

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Slide clutch cage (2) onto the gearbox shaft.

>/2010

Page 12: Bmw k1200 gt clutch removal

MW-Motorrad

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• Preload tensioning gear (1) with locating pin (No. 11 2 671

» The locating pin is horizontal.

• Push clutch cage (2) onto the gearbox shaft until tensioning gear (1) engagestensioning gear for alternator freewheel (4) and crankshaft pinion (5).

• Install assembly tool (No. 21 4 652) in clutch cage (2).

» The drilled hole in the assembly tool is above the mark (arrow) on clutch cage (2)

• Turn clutch cage (2) counter-clockwise with assembly tool (No. 21 4 652) untilgearwheel (3) engages.

• Push on clutch cage (2) until seated.

» The gearwheels of clutch cage (2) and crankshaft (5) are flush at the outside.

A Attention

If the oil-pump drive is unable to transmit sufficient driving force, an adequatesupply of lubricant to the engine is not ensured.

Make sure that the oil-pump drive is reliably able to transmit sufficient driving forceto the pump.

• Pull the oil-pump drive chain (arrow) to check that the oil-pump drive is correctlyengaged in the rear of the clutch cage.

» Hold the clutch cage and check that the oil-pump drive chain no longer movesfreely.

Remove locating pin (No. 11 2 671) from tensioning gear (1).

2/2010

Page 13: Bmw k1200 gt clutch removal

MW-Motorrad

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^ Installing plate cluster

> Lubricating new plate cluster

A Attention

Clutch plates can burn if Installed dry.

Immerse the new clutch-plate stack In clean engine oil before installing.

• Before slackening cluster (1), apply a mark (arrow).

- Do not change the positions of the lined plates relative to each other.

• Slacken screws (2) until the clutch plates can be turned.

• Immerse plate cluster (1) in engine oil.

» The friction faces of the lined plates are wetted by oil.

• Turn the lined plates to the positions Indicated by the mark (arrow).

Align the lettering (arrow) of the first plate projection with the bore (arrow) in tclutch cage.

Note

There is only one position in which the plate cluster can be fitted into the clutch cag

Install spacing washer (1) and plate cluster (2). noting the mark applied when theplate cluster was lubricated.

In order to insert plate cluster (2), engage a gear and turn the rear wheel by hanc

Tighten screws (1).

Tightening torques

Pressure bowl to pressure plate

M5x 16 tighten In diagonally

>/2010

Page 14: Bmw k1200 gt clutch removal

MW-Motorrad

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opposite sequence

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^ Locking engine with locating pin• Introduce locating pin (No. 11 1 842) into the sensor bore.

• Install screw (1) to secure the locating pin,

» Engine locked.

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Install nut (1), while holding the clutch cage with driver lock (No. 21 4 661).

Tightening torques

Clutch to gearbox input shaft

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^ Removing locating pin

• Remove screw (1).

• Remove locating pin (No. 11 1 842) from the sensor bore.

>/2010

Page 15: Bmw k1200 gt clutch removal

MW-Motorrad

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(+) Securing crankshaft sensor

Finishing work

Securing clutch cover

Securing clutch slave cylinder

Installing entire engine spoiler

Installing right side panel

Final check of work performed

?/2010