Back off adjusting nut (2) completely.
Detach and remove clutch cable (3) from lever (4).

19

Loosen clutch cable (1) from holder (2).

28
Releasing rear exhaust manifold

CAUTION
Hot exhaust system
Risk of burn injury
Do not touch a hot exhaust system.
Remove bolt (1) and washer (2) from exhaust manifold (3).

29
Relieving chain tension
Loosen nut (1).
Release lock nuts (2) on left and right.
Slacken drive chain with tensioning screws (3) on left and
right.

20

30
Removing pinion
Remove nut (1) and locking washer (2).
Work pinion (3) free from drive chain (4) and remove.

31
Draining coolant
Place a suitable container in position.
Remove bolt (1).
Release clamp (2) with pliers (17 5 571).
Pull off coolant hose (3), push down and catch emerging
coolant.

Removing radiator cap
Seal off overflow hose (1) with hose clip (13 3 010).
Remove radiator cap (2).

Drain the coolant from the radiator and the lines.

21

32
Releasing oil cooler
Remove screws (1).
Release oil cooler (2).

33
Releasing engine wiring harness
Remove cable strap (arrow).
Unlock and disconnect connector (1) for transmission potentiometer.

Remove cable strap (arrow) and disconnect the connector (1).

22

with tyre pressure control (RDC) OE (0530)

Remove cable strap (arrow).
Disconnect connector (1) for RDC control unit.

Remove cable strap (arrow).
Disconnect connector (1) for coolant temperature sensor.

Remove bolt (1).
Release crankshaft sensor (2) and hang to one side.
Release the cable (3) from the holder (arrow).

Remove the cable strap (arrows).
Disconnect connector (1) for camshaft sensor.
Remove bolt (2) and release ground connection (3).
Disconnect connectors for knock sensors (4).

23

Release wiring harness (1) from holders (arrows).

34
Releasing relay holder
Remove cable strap (arrow).
Remove screws (1).
Release relay holder (2) with relay and hang to the side
releasing wiring harness (3) for Gear Shift Assistant and
side-stand switch and cable (4) for alternator.

35
Disconnecting connector for sidestand switch
Disconnect connector (1) for side-stand switch.
Loosen cable (2) from holder (3).
Remove cable strap (arrow).

24

36
Releasing cable for voltage regulator

ATTENTION
Use of hard or sharp-edged objects in proximity to
component
Component damage
Take care not to scratch components; cover or mask as
necessary.
Remove cable strap (arrow).
Disconnect connector (1) from voltage regulator (2).
Work connector (1) with cable (3) for alternator through to
the front.

Thread cable (1) for alternator to the front and release
from holders (arrows) and from frame.

25

37
Disconnecting oxygen sensors
Information on disconnecting vibration-resistant plug

ATTENTION
Disconnection of the connector not in compliance
with correct procedure
Damage to locking tab
Push the connector away from the locking tab, do not lift
or bend the locking tab.
Unlock locking tab (1) in direction of arrow (arrow 1).
Press down locking tab (1) in direction of arrow (arrow 2)
and disconnect connector (2).

Remove cable strap (arrow).
Disconnect plug connection (1) for monitoring oxygen
sensor.

Release the cable (1) for the monitoring oxygen sensor
from the holder (arrow).

26

Release plug connection (1) for front oxygen sensor from
holder (2).
Remove cable strap (arrow).
Disconnect plug connection (1) for right front oxygen
sensor.
Release and guide out cable (3) from holder (4).

Release plug connection (1) for left front oxygen sensor
from holder (2).
Remove cable strap (arrow).
Disconnect plug connection (1) for left front oxygen
sensor.
Release and guide out cable (3) from holder (4).

Release cable (1) for left monitoring oxygen sensor and
side-stand switch from holders (arrows).
Release plug connection (2) for left monitoring oxygen
sensor and work clear from relay holder (3) outward.
Disconnect plug connection (2) for left monitoring oxygen
sensor.

27

38
Removing bracket for engine spoiler on right
and left
Remove bolt (1) and remove bracket (2).

Remove bolt (1) and remove bracket (2).

39
Installing engine lifter

ATTENTION
Vehicle toppling to side
Risk of damage to parts if vehicle topples
Make sure that the vehicle is secured so that it cannot
topple sideways.
Secure extensions (00 1 575) to scissor-type lifter (00 1
571).
Secure engine fixture (00 1 673) with included bolts (1)
with washers (2) and bolt (3) with washer (4) on the engine.
Raise scissor-type lifter (00 1 571) and install in engine fixture (00 1 673), making sure that engine fixture (00 1 673)
is positioned centrally on scissor-type lifter (00 1 571).
Raise the engine lifter until the motorcycle is standing
firmly.

28

40
Remove the engine

ATTENTION
Use of hard or sharp-edged objects in proximity to
component
Component damage
Take care not to scratch components; cover or mask as
necessary.
Release the cable (1) for the servomotor for exhaust flap
from the holder (arrow).
Release cable clip (2) and (3) with wiring harness from
crankcase.

Thread coolant venting hose (1) through frame to the inside and place onto engine.

Use straps (1) to secure the motorcycle to assembly crane
(46 5 670).
Secure the straps to the rear frame and the main frame,
not to the handlebars.

29

Loosen screws (1).

Loosen screws (1).

Remove screws (1) with expander elements (2) and taper
elements (3).

Remove screws (1).

30

Lower engine with engine lifter and slide it to the front.
Feed out Bowden cables (1) for exhaust flap on holder (2).

Position engine with engine lifter so that the drive chain (1)
of the transmission output shaft can be threaded out.
Thread out the drive chain (1) from the transmission output shaft (2).

Lift motorcycle (1) with assembly crane (46 5 670) and roll
it away, noting engine (2).

41
Releasing exhaust manifold

CAUTION
Hot exhaust system
Risk of burn injury
Do not touch a hot exhaust system.

31

NOTICE
Support the exhaust system to make it easier to remove and
install the assembly.
Remove nuts (1).
Lower exhaust manifold (2).
Exhaust manifold released from cylinder head.

Remove exhaust manifold seals (1).

42
Removing the left and right switching cam
adjusters
Remove screws (1).
Remove switching cam adjuster on left (2) and right (3)
with O-rings (arrows).

32

43
Remove the direct ignition coils
Clean the cylinder-head cover with compressed air.
Remove direct ignition coils (1) using puller (12 3 621).

44
Removing spark plugs
Clean the spark plug shaft with compressed air.
Remove spark plugs (1) with spark plug wrench (12 1
220).

45
Removing cylinder head cover
Remove bolts (1) with seals .
Remove cylinder head cover (2) with seals (3) and (4).

33

46
Removing right crankshaft cover
Remove crankshaft cover (1) with O-ring (2).

47
Adjust engine to firing TDC
Turn crankshaft on screw connection of the timing chain
pinion in clockwise direction until marks on camshaft
sprockets (1) and (2) are flush with marks on camshaft
bearing bridge (arrows).

Intake cam (1) and exhaust cam (2) for cylinder 1 are in
position as shown and recesses (arrows) are flush with
edge of housing.
Firing TDC of cylinder 1 is set.

34

48
Removing the camshaft bearing support
Slacken the bolts evenly in sequence from (20) to (1).

Remove screws (1).
Remove camshaft bearing brackets (2) and (3), thereby
observing fitting sleeves (4) and dowel pins (arrows).

Remove O-rings (1) and (2).

35

49
Remove the camshafts
Remove exhaust camshaft (1) and intake camshaft (2).

50
Removing valve shims
Swing rocker arm (1) up.
Remove adjustment plate (2) from the valve and place it in
the correct position in rack (11 1 844).

51
Removing timing-chain tensioner
Remove timing chain tensioner (1) with sealing ring (2).

36

52
Removing chain sprocket reduction gear for
camshafts
Remove bolt (1).
Remove axle (2) with needle bearing (3).
Feed out chain sprocket (4) from timing chain (5) and remove.

53
Removing air intake stub
Remove screws (1).
Remove air intake stub (2).

54
Remove bypass distributor
Remove bypass distributor (1) with O-rings (2).

37

55
Removing cylinder head
Slacken the screws in reverse sequence from (10) to (1).

Remove screws (1) with washers (2).

Remove (1) cylinder head.

38

Removing cylinder head gasket (1).

56
Removing coolant venting hose
Release clamp (1) with pliers (17 5 571).
Pull off coolant venting hose (2).

57
Installing coolant vent hose on new cylinder
head
Slide on coolant venting hose (2).
Secure clamp (1) with pliers (17 5 571) while aligning it
with mark.

39

58
Installing cylinder head
Clean the sealing surfaces.
Install cylinder head gasket (1) and align fitting sleeves (arrows).

NOTICE
If the power train, engine housing, piston, crankshaft or connecting rod will be replaced, measure the piston protrusion
to determine the correct cylinder head gasket.

NOTICE
The new cylinder-head gasket must be the same thickness as the cylinder-head gasket it replaces.
Install cylinder head (1), noting the passing sleeves (arrows).

Degrease bolts (1) with washers (2).
Insert screws (1) with washers (2), but do not tighten
them.

40

Tighten bolts in specified sequence (1) to (10).
Tightening torques
Cylinder head to crankcase
M8

1st tightening
torque, 20 Nm
1st additional
angle of rotation, 90°
2nd additional
angle of rotation, 90°
3. Additional
angle of rotation, 45°

59
Installing bypass distributor
Check O-rings (2) and renew, if required.
Lubricate O-rings (2).
Installation tool
Silicone spray

83 19 2 208 609

Install bypass distributor (1) with O-rings (2).

60
Install intake manifold
Clean the threads.
Position intake manifold (2).
Install screws (1).
Tightening torques
Air intake to cylinder head
M6 x 16, Renew screw
Thread-locking compound (micro-encapsulated)

41

8 Nm

61
Installing chain sprocket reduction gear for
camshafts
Insert chain sprocket (4) into timing chain (5).
Insert needle bearing (3) in axle (2).
Install bolt (1) and counter-hold axle (2) with suitable tool.
Tightening torques
Axle for timing chain drive reduction gear to cylinder head
M10 x 40

60 Nm

62
Installing timing chain tensioner
Renew sealing ring (2).
Install timing chain tensioner (1) with sealing ring (2).
Tightening torques
Timing-chain tensioner to cylinder head
M20 x 1.5

42 Nm

63
Installing valve shim
Place lightly oiled adjustment plate (2) on the valve.
Swing rocker arm (1) down.

42

64
Installing camshafts
Lubricate camshafts at bearing positions with engine oil.
Install exhaust camshaft (1) and align to firing TDC of cylinder 1.
Recess on camshaft (arrows) edge of housing of cylinder
head flush, cams (2) point up.
Install intake camshaft (3) and align to firing TDC of cylinder 1.
Recess on camshaft (arrows) edge of housing of cylinder
head flush, cams (4) point up.

65
Installing camshaft bearing bridges
Make sure that fitting sleeves (1) are installed in the cylinder head.
Install new O-rings (2) and (3).

Make sure that dowel pins (arrows) are installed in cylinder head.

ATTENTION
Incorrectly positioned camshaft axial guide
Component damage
Before tightening down the fasteners of the bearing cap,
make sure that the camshaft axial guide is correctly positioned.
Position and align camshaft bearing bridges (3) and (2),
while observing fitting sleeves (4) and dowel pins (arrows).
Fit bolts (1), do not tighten.

43

Check if marks on camshaft sprockets and camshaft bearing bridge (arrows) are flush; remove camshaft bearing
bridges and correct the position of the camshafts where
required.

Tighten bolts in sequence (1) to (20).
Tightening torques
Camshaft bearing cap to cylinder head
M6 x 35

Tightening
sequence:
See repair
manual
1st tightening
torque, 5 Nm
2nd tightening
torque, 13 Nm

Check if marks on camshaft sprockets and camshaft bearing bridge (arrows) are flush; remove camshaft bearing
bridges and correct the position of the camshafts where
required.

44

66
Checking valve clearance