Check
Determine valve clearance with feeler gauge (1) by measuring between cams and rocker arms.
Technical data
Inlet valve clearance

Engine
cold

0.14...0.2 mm

Exhaust valve
clearance

Engine
cold

0.2...0.26 mm

Check cylinder 1.
Check all other cylinders by turning the engine clockwise
by half a crankshaft turn each time:
cylinder 3
cylinder 4
cylinder 2

Noting measured results
Note down the measured results on a record sheet.

Result
Valve clearance is outside specified range.
Measure
Adjust valve clearance before installing the camshafts.

45

67
Adjusting valve clearance
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).

46

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

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).

Check the thickness of the adjustment plates with a caliper
gauge.
Determine the thickness of the new adjustment plate in
accordance with the valve clearance measurement.

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

Installing camshafts
Lubricate camshafts at bearing positions with engine oil.

47

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.

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.
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.

48

Tighten bolts in sequence (1) to (20).
Tightening torques
Camshaft bearing cap to cylinder head
Tightening
sequence:
See repair
manual

M6 x 35

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.

68
Recheck the valve clearance
After assembly, recheck valve clearances for all cylinders.
Technical data

49

Inlet valve clearance

Engine
cold

0.14...0.2 mm

Exhaust valve
clearance

Engine
cold

0.2...0.26 mm

69
Checking timing
Adjust engine to firing TDC
Turn crankshaft on screw connection of alternator in
counter-clockwise direction until intake cam (1) and
exhaust cam (2) for cylinder 1 are in the position shown
and recesses (arrows) are flush with edges of housing.

Check if marks on camshaft sprockets (1) and (2) are flush
with marks on camshaft bearing bridge (arrows).
Firing TDC of cylinder 1 is set.

Lock the crankshaft in TDC position
Check if TDC mark (arrow) is visible through opening in
left engine cover (1).

50

Insert alignment pin (11 0 993) until it noticeably engages to limit position and, if necessary, turn crankshaft on bolt (1) in counterclockwise direction.

NOTICE
Crankshaft must always be turned in direction of rotation.
If the alignment pin does not engage, turn crankshaft two
rotations in counterclockwise direction until the firing TDC for
Cylinder 1 is reached.
Install bolt (2).

Slide sliding piece (1) to the inside.
Check
Attach holding fixture (11 0 991) with side A CHECK on
camshafts (2) and (3).
Chain guard (11 0 991) must rest flat on edge of housing
and test springs must slide to limit position in grooves (arrows) without great force.
Result
Chain guard cannot be pushed on.
Measure
Adjust timing (cylinder head cover removed) (description in
labour operation: 11 30 501, to be billed as a separate line
item)
Result
Chain guard can be pushed on.
Measure
Remove holding fixture (11 0 991) from camshafts (2)
and (3).
Slide sliding piece (1) to the outside.

Removing locating pin
Remove bolt (1).
Remove locating pin (11 0 993).

51

70
Installing right crankshaft cover
Check O-ring (2) and replace if required.
Install crankshaft cover (1) with O-ring (2).
Tightening torques
Screw plug for crankshaft
M40

12 Nm

71
Installing cylinder head cover
Check seals (1) for SLS system and replace as needed.
Make sure that seals (1) are installed.

Make sure that seals (1) and (2) are installed in cylinder
head cover (3).

52

Install cylinder head cover (2) with seals (3) and (4).
Before installing the bolts (1), check if seals (3) and (4)
are resting correctly on the sealing surfaces.
Install screws (1) with seals.
Tightening torques
Cylinder head cover to cylinder head
M6 x 20

10 Nm

72
Installing spark plugs
Install spark plugs (1) with spark-plug wrench (12 1 220).
Tightening torques
Spark plug in cylinder head
M10 x 1

12 Nm

73
Installing direct ignition coils
Install direct ignition coils (1).
Direct ignition coils must engage.
All connectors point exactly in direction of travel.

53

74
Installing left and right switching cam adjuster
Check O-rings (arrows) and replace, if required.
Lubricate the O-rings (arrows) with engine oil.
Install switching cam adjusters left (2) and right (3).
Install screws (1).
Tightening torques
Switching cam adjuster to camshaft bearing cap
M6 x 30 - 10.9

13 Nm

75
Securing exhaust header

NOTICE
Support the exhaust system to make it easier to remove and
install the assembly.
Insert exhaust manifold seals (1).

Position exhaust manifold (2).
Install nuts (1).
Tightening torques
Exhaust manifold to cylinder head
M7

54

14 Nm

76
Installing 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.
Place motorcycle (1) on the frame with the assembly crane
(46 5 670) over the engine and lower.
Guide engine (2) into motorcycle (1) and position.

Remove belts (1).
Remove assembly crane (46 5 670).

Position engine with engine lifter so that the drive chain (1)
can be guided onto the transmission output shaft.
Guide drive chain (1) onto transmission output shaft (2).

55

Thread in Bowden cables (1) for exhaust flap on
holder (2).
Lift engine with engine lifter and slide it to the rear.

Cable (1) for right monitoring oxygen sensor must be
routed behind engine screw connection (arrow).

Pull engine (1) to the left in frame (2) and position.
Install screws (3) and tighten until hand-tight.

Insert taper elements (3) with the taper to the outside.
Insert expander elements (2) with tapered side facing
taper element (3).
Install screws (1) and tighten until hand-tight.

56

Tighten screws (1).
Tightening torques
Engine to frame
Engine, left, to frame,
M10 x 50

60 Nm

Tighten screws (1).
Tightening torques
Engine to frame
Engine, right, to frame,
M10 x 50, with taper
elements (expander element outside)

90 Nm

Renew screw

Work out coolant venting hose (1) through the frame.
Lay wiring harness (2) for front oxygen sensor and knock
sensor to the front right.

Wiring harness (1) for front oxygen sensor and left knock
sensor must be routed over the engine screw connection (arrow).
If necessary, secure wiring harness (1) in holder (2).

57

Secure cable clip (2) and (3) with wiring harness on bridge
of crankcase.
Secure cable (1) for servomotor for exhaust flap in
holder (arrow).

77
Removing engine lifter
Lower engine lifter until it is free of load. Make sure that
the vehicle is standing securely on the rear-wheel stand
and cannot topple.
Remove scissor-type lifter (00 1 571) from engine adapter
(00 1 673).
Remove bolts (1) with washers (2) and bolt (3) with
washer (4) and loosen engine fixture (00 1 673) from
engine.
Lower scissor-type lifter (00 1 571).
Disengage extensions (00 1 575) from scissor-type lifter
(00 1 571) and remove.

78
Installing the holder for the left and right engine spoiler
Position holder (2) and install bolt (1).
Tightening torques
Bracket for rear left engine spoiler to engine
M10 x 12 - 10.9

58

19 Nm

Position holder (2) and install bolt (1).
Tightening torques
Bracket for engine spoiler right rear to engine
M8 x 16

19 Nm

79
Connecting oxygen sensors
Information for connecting vibration-resistant connectors
Check if the contact carrier (1) protrudes significantly from
the connector housing (2).
If necessary, hold down the connector housing (2) and
slide contact carrier from the rear at the cable inlet (3) toward the front until the contact carrier (1) is visible

Ensure that the release tab (1) is unlocked.
Slide connector (2) in direction of arrow (arrow 1).
The connector (2) engages audibly.
Slide connector (2) in direction of arrow (arrow 2) further.
The connector (2) engages audibly.
Slide locking tab (1) in direction of arrow (arrow 3).
The locking tab (1) engages audibly.

59

Connect plug connection (2) for left monitoring oxygen
sensor.
Insert plug connection (2) behind relay holder (3) and secure.
Secure cable (1) for monitoring oxygen sensor and sidestand switch in holder (arrows).

Route cable (3) and secure in holder (4).
Connect plug connection (1) for left front oxygen sensor.
Route excess cable lengths (3) in loops and secure with
cable strap (arrow).
Secure plug connection (1) for left front oxygen sensor in
holder (2).

Lay cable (3) and secure in holders (4).
Connect plug connection (1) for right front oxygen sensor.
Secure plug connection (1) for right front oxygen sensor in
holder (2).
Form excess cable lengths (3) into loops and secure cable
strap (arrow).

Secure the cable (1) in the holder (arrow).

60

Connect plug connection (1).
Secure the cable strap (arrow).

80
Securing cable for voltage regulator
Work cable (1) for alternator in through frame, route to the
rear and secure in holders (arrows).

Work connector (1) with cable (3) through to the rear.
Connect connector (1) with voltage regulator (2).
Secure the cable strap (arrow).

61

81
Connecting connector for side-stand switch
Connect connector (1) for side-stand switch.
Secure the clutch cable (2) in holder (3).
Secure the cable strap (arrow).

82
Securing the relay holder
Fit relay holder (2).
Install screws (1).
Tightening torques
Relay carrier to engine
M6 x 16

8 Nm

Secure wiring harness (3) for Gear Shift Assistant and
side-stand switch and cable (4) for alternator with cable
strap (arrow).

83
Securing engine wiring harness
Secure wiring harness (1) in holders (arrows).

62

Connect connector for knock sensors (4).
Fit ground connection (3) and install bolt (2).
Tightening torques
Engine wiring harness (earth) to cylinder head
M5 x 10

5 Nm

Connect connector (1) for camshaft sensor.
Close the cable strap (arrows).

Check O-ring (1) and renew if required.
Lubricate the O-ring (1) with engine oil.
Secure crankshaft sensor (2).
Install bolt (3).
Tightening torques
Crankshaft sensor on engine housing cover
M6 x 20, Renew screw

5 Nm

Secure the cable (4) in the holder (arrow).

Connect connector (1) for coolant temperature sensor.
Secure the cable strap (arrow).

Fit connector (1) and secure cable strap (arrow).

63

with tyre pressure control (RDC) OE (0530)

Connect connector (1) for RDC control unit.
Secure the cable strap (arrow).

Connect and lock connector (1) for transmission potentiometer.
Secure the cable strap (arrow).

84
Secure the oil cooler
Clean the threads.
Make sure that the oil cooler (1) is fastened on holder (2).
Fit oil cooler (1) and install bolts (3).
Tightening torques
Oil cooler to radiator
M5 x 16, Renew screw
Thread-locking compound (micro-encapsulated)

64

5 Nm

85
Installing pinion
Fit pinion (1), with low shoulder (arrow) outward, and work
into chain (2).