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Bmw k1200 gt clutch removal

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Procedure to removal clutch in a BMW K1300 S / R / GT

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Bmw k1200 gt clutch removal

  1. 1. MW-Motorrad emoving rightside 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
  2. 2. MW-Motorrad emoving rightside panei • Open stowage-compartment lid (1). • Remove the following components, noting the retainers(arrows): - Screws(2) - Screws(3) - Screws(4) - Side panel(5) ?/2010
  3. 3. MW-Motorrad emoving clutch slave cylinder KU R21C«a> A Attention Ifthe clutch lever is pulled v^/ith the slave cylinder or the clutch cover removed,the is a possibility ofthe piston dropping out ofthe 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)outofthe clutch cover and lay it aside in such a way that there is no strain on the line. E/2010
  4. 4. MW-Motorrad emoving clutch cover RaA_3J ftnai36 ^Removing heatshield from crankcase cover,right • Remove the following components: - Screws(1) - Heatshield(2) K44Jt.Rt10l4& • Remove the following components: - Screws(1)and(2) - Clutch cover(3) - Thrust piece(4) - Thrust bearing(5) - Seal(6) >/2010
  5. 5. MW-Motorrad ]21 21 000 Removing and Installing or replacing clutch •- 21 21 606 K44 (KSOtGfl Preparatory work Removing right side panel Removing complete engine spoiler Removing clutch slave cylinder Removing clutch cover Core activity (-) Removing clutch cage ^Removing crankshaftsensor • Remove screw(1). Attention Oil is hazardous to the environment; oil can attack plastic and rubber parts; oil spillages make the ground slippery and dangerous. Catch escaping oil. • Pull out crankshaft sensor(2)and allow it to danglefrom the cable,taking care n to 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(No 21 4651). ^/20^0
  6. 6. MW-Motorrad 21 4651_;^ K53HV_R2lOlCb MW_R210066 ^Removing plate cluster • Remove plate cluster(1)and thrust washer(2). 11 1 842 — MA mi021& ^Removing locating pin • Remove screw(1). • Remove locating pin(No. 11 1 842)from the sensor bore. Preload tensioning gear(1)ofthe alternatorfreewheel with locating pin (No. 11 2 671). fir Note Do not remove or install the locating pin unless the clutch cage is installed. - Insert the locating pin vertically asfar as it will go. - Turn the locating pin to the horizontal position. 5/2010
  7. 7. MW-Motorrad -7 M3HV^ft2100Sn • 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
  8. 8. 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 crankshaftsensor • Remove screv*/(1). A Attention Oil is hazardous to the environment; oil can attack plastic and rubber parts; oil spillages make the ground slippery and dangerous. Catch escaping oil. • Pull out crankshaft sensor(2)and allow it to danglefrom 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(No 21 4651). ?/2010
  9. 9. MW-Motorrad 214651 /r .' f K43HV RJtoioe tesiiCTii M3HVIQini»> ^Removing plate cluster • Remove plate cluster(1)and thrust washer(2). K44.R1102t6 ^Removing locating pin • Remove screw (1). • Remove locating pin(No. 11 1 842)from the sensor bore. Preload tensioning gear(1)ofthe alternatorfreewheel with locating pin(No. 11 2 671). Note Do not remove or install the locating pin unless the clutch cage is installed. - Insert the locating pin vertically asfar as it will go. - Turn the locating pin to the horizontal position. >/2010
  10. 10. MW-Motorrad y^KiSHvjnioo® 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), <] Slacken screw(1). Insert eccentric gauge(No. 11 1 931)between the sprocketand the gearbox inpi shaft. Align the mark on the eccentric(arrow)at right angles to the oil-pump drive chain Use your hand to push the tensioning rail toward the chain and tighten screw(1). NTightening torques Chain guide,oil pump to crankcase ^/2010
  11. 11. MW-Motorrad / M2HV_ftnoi0b 111 931 K40Jll1CSa3 M6x20 10 Nm !VI6x30 lONm • Without applying more pressure againstthe tensioning rail, turn the sprockets twi full turns counter-clockwise. • Align the mark on the eccentric(arrow)at right angles to the oil pump drive chain Test • Check the tension ofchain(1). m Result:Chain too tight or too loose Measure: • Repeatthe 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). < Slide clutch cage(2)onto the gearbox shaft. >/2010
  12. 12. MW-Motorrad K13HV.RJI0050 K43W R21000l> • Preload tensioning gear(1)with locating pin(No. 11 2671 » The locating pin is horizontal. • Push clutch cage(2)onto the gearbox shaft until tensioning gear(1)engages tensioning gear for alternatorfreewheel(4)and crankshaft pinion (5). • Install assembly tool(No. 21 4652)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 4652)until gearwheel(3)engages. • Push on clutch cage(2) until seated. » The gearwheels ofclutch cage(2)and crankshaft(5)are flush atthe outside. A Attention If the oil-pump drive is unable to transmit sufficient driving force, an adequate supply of lubricant to the engine is not ensured. Make sure thatthe oil-pump drive is reliably able to transmitsufficient driving force to the pump. • Pull the oil-pump drive chain(arrow)to check thatthe oil-pump drive is correctly engaged in the rear ofthe clutch cage. » Hold the clutch cage and check that the oil-pump drive chain no longer moves freely. Remove locating pin(No. 11 2671)from tensioning gear(1). 2/2010
  13. 13. MW-Motorrad K43MV_R21008c K43»<V.R2IOl«n K43HV R210)1 ^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 notchange the positions ofthe 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 ofthe lined plates are wetted by oil. • Turn the lined plates to the positions Indicated by the mark(arrow). Align the lettering(arrow)ofthe first plate projection with the bore(arrow)in t clutch 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 the plate 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
  14. 14. MW-Motorrad KAiHV ft2lOl7b opposite sequence 8^^ Nm M4.Rno?1b ^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. -i ^ J- s 214651 i£. , ^i ^ Install nut(1), while holding the clutch cage with driver lock(No.21 4661). Tightening torques Clutch to gearbox inputshaft M20X1.5 190 Nm ^Removing locating pin • Remove screw(1). • Remove locating pin(No. 11 1 842)from the sensor bore. /2010
  15. 15. MW-Motorrad M4_Rn02t (+)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

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