Cardanshaft”.

21
Overview,measurementsetup
Overview,measurementsetup:
Rearwheelswingingarmhangscorrectlyloweredon
tensioninghook
Speedsensorinsensorbracket,distanceset
Sensorwheelwithdrivesecuredinangulargearbox
Overview,measuringwiringharness:
Speedsensorconnectedwithmeasuringwiringharness
Measuringwiringharnessconnectedwithdiagnostic
connectoranddiagnosissystem
Cordlessscrewdriver:
Accumulatorfullycharged
Setting“Drill”
Setting“Slowrunningspeed”
Cross-handlemounted
Withchuckfullypushedontohexagon.
Vehicle:
Transmissioninneutral
Ignitionswitchedon

22
CheckingCardanshaftwithdiagnosissystem
NOTICE
This check requires the exclusive use of cordless screwdrivers that are
approved for this purpose. Non-compliance can falsify the measuring
result. Use cross-handle for cordless screwdriver, high torque during
check.
Do not support cross-handle on vehicle, danger of falsification of measuring
results.

Order No.

13

RefertoServiceInformationforalistofcordlessscrewdrivers.
Drivewheelflangeadapterandsensorwheelwithcordlessscrewdriver inclockwisedirection .
Drivewheelflangeadapteronhexagon,chuckfully
pushedontohexagon.
Accumulatorfullycharged
Setting“Drill”
Setting“Clockwiserotation”
Setting“Slowrunningspeed”
Cross-handlemounted
Useonlyapredefinedcordlessdrillforthischeck!
Observetestmoduleindiagnosisprocess“ServicefunctionCardanshaft”.
Check
Result
Diagnosis result is “Cardan shaft damaged”
Measure
Replace Cardan shaft,
Result
Diagnosis result is “Cardan shaft OK”
Measure
Take down measurement setup, assemble vehicle.

ATTENTION

Order No.

23

14

Removingmeasuringdevicesfromvehicle

Measuringcableorsensorwillbedamaged
Componentdamage
Do notdisconnect plugconnectionforsensor-measuringwiringharness(plugcyclesrestricted).
Slackenknurledscrew

(1) andpushbackcarriage

Removescrew (3) andloosenspeedsensor
holder.

(2).

(4) from

Donotdisconnectconnector!

ATTENTION
Sensorwheelwillbebent,receiveslateralrunout
Componentdamage
Alwayshandlesensorwheelwithcare.
Alwayssetdownsensorwheelonaflatsurface.
Removewheelbolts (2) andremovewheelflangeadapterwithsensorwheelfromangulargearbox
(1).

Removescrews (1) andtakeoffsensorbracket.

Order No.

15

24
Disconnecting measuring wiring harness from vehicle and
diagnosis system
End service function “Check Cardan shaft” and switch off ignition.
Disconnect measuring wiring harness on vehicle analysis connector (1).
Disconnect measuring wiring harness from diagnosis system connector
(2).
Secure analysis connector (1) on vehicle.
Disconnect BMW Motorrad battery charger from batterypositive
connection point (3) and negative terminal (2).
Install cap (1).

25
Securingsuspensionstrutonrearwheel
swingingarm
Cleanthreadsforsuspensionstrutbolting.
Positionangulargearbox (1) andsuspensionstrut
withhook(331922)indrivingposition.

Alignrearwheelswingingarm
strut (2).

(1) onsuspension

Install new screw (3).
Tightening torques
Spring strut to frame
M12 x 1.5 x 60, Replace screw
Thread-locking compound (micro-encapsulated)

100 Nm

(2)

Order No.

16

26
Looseninghookfromangulargearboxand
rearframe.
Loosenhookandremove.

Makesurebreather

(1) isinstalledcorrectly.

27
Securingrearbrakecalliper

ATTENTION
Threaddamageonbrakecaliper,boltincontactwith
brakedisc
Componentdamagebyusingincorrectscrews
Bevelgearswithmodifiedthreadeddomescanalsobe
installedasareplacementforoldervehicles.
Beforeinstalling/mountingthebrakecaliper,checkthe
assignmentofthescrews.
Notethecorrectscrewallocationaccordingtothefigure.

Order No.

17

Tightening torques
Brake caliper to bevel gears
Short threaded dome to bevel
gears, M8 x 25, Replace screw

24 Nm

Thread-locking compound
(micro-encapsulated)

Long threaded dome to bevel
gears, M8 x 30, Replace screw
Thread-locking compound
(micro-encapsulated)

Cleanthethreads.
Positionbrakecalliper

(3).

Positioncablerouting

(2).

Install newscrews (1).

24 Nm

Order No.

18

28
Installtherearwheel
Cleanthewheelcentringspigotandthecontactsurfaces
ofthewheelhub.

Holdtherearwheel

(2) inposition.

Engage (1) allwheelboltslooselyfirst,thentighten.
Tightening torques
Rear wheel to wheel flange
M10 x 1.25 x 40

Tightening
sequence:
tighten in diagonally opposite sequence
60 Nm

29
with Dynamic ESAOE (0191)

Securing actuator rod for ride-height sensor to
swinging arm
Position attachment rod (3) with ball socket (1).
Clip in ball socket (1) in ball head (2).

Order No.

19

30
Installingleftcoverforspringstrut
Positiontrim (1) andpushintogrommets

31
Installingleftrearfootrestbracket
Positionfootrestbracket

(2).

Installscrews (1).
Tightening torques
Footrest plate (rear) to rear frame
M8 x 25

19 Nm

(2).

Order No.

20

32
Securing left rear trim panel
Position rear trim panel (3).
Install screw (1) and trim (2).

33
Installingrightenginespoiler
Positionenginespoiler

(4).

Press (thelugarrow ) intogrommet (3).
Installscrew(shortcollar)
Installscrew(longcollar)

(2).
(1).

withdeviationfromstandardforauthorityvehicles

Positionenginespoiler

(4).

Press (thelugarrow ) intogrommet (3).
Installscrew(shortcollar)
Installscrew(longcollar)

(2).
(1).

BU

Order No.

21

34
Installing silencer
Lightly lubricate (1)the inner face of clamp.

Lubricant
Optimoly TA

18 21 9 062 599
Slide the clamp (1) onto the silencer (2).

Push silencer (2) to limit position.
Install screw (3) and washer (4).

Tightening torques
Silencer to footrest bracket
M8 x 35

19 Nm

Positionclamp (1) withrecessinlug

(arrow).

Tightennut (2).
Tightening torques
Clamp to silencer and exhaust manifold
22 Nm

35
Installthesilencercover
Positioncover (3).
Positionscrews (1) infrontwithwasher

(2) andtighten.

36
with deviation from standard for authority vehiclesBU

Order No.

22

Installing spray guard, left
Position spray guard (2) and secure on rider footrest
(3) (arrows). Install screws (1).

37
withdeviationfromstandardforauthorityvehicles

Installingleftcasecarrier
Positioncaseholder

(4) onvehicle.

Positioncover (3).
Installscrews (2).
Tightening torques
Case carrier to rear frame
M6 x 20
Thread-locking compound (Loctite 243,
Medium strength)

8 Nm

Installscrew (1).
Tightening torques
Transverse strut on case holder
M6 x 16

Install bolts (2) and circlip (1).

8 Nm

BU

Order No.

38

23

Order No.

24

Tightening torques
Special vehicle case to case holder
M6 x 25

8 Nm

39
Finalinspectionofcompletedwork
Ensurethefollowing:
Theobjectiveofthecompletedworkwasachieved.
Alloperatingfluidshavebeenfilledinandthefluidsare
atthecorrectfilllevel.
Allloosenedscrewconnectionshavebeenretightened
correctly.
Thefuelsystemisfreeofleaks.
Thelightingandsignalsystemisfunctionalandthe
vehicleisroadworthy.
Thebrakepadsofthefrontandrearwheelbrakesare
restingagainstthebrakedisks.

Functiontest,enginestartsuppression

Install case (3) from top in locators (4). Intall screws (1) with washer (2).
extinguisher.

Order No.

1

0A01-R1200GS
33 73 503 Additional work: disconnecting propeller shaft from angular
gearbox

1

DisconnectCardanshaftfromangulargearbox

ATTENTION

Order No.

2

with pull-off device
Componentdamage
Bearinginangulargearboxisdamaged.
Observemaximumtorqueofjackscrews!
Applyjackscrewsinstagestopreventtiltingoftheextractortool.
Ifnecessary,spraytheareaofthetapersplinewithrust
removerandletitinteractbeforestartingwork.
Activeicerustremover,partnumber83192211267.
Cutthroughgaiter

(1) andwirering

(2) andremove.

Loosengaiteronangulargearboxwithrotationalmovement.

Positionhalfshells
Cardanshaft (1).

(A) fromtoolset(261930)on

Hooksengageonbottomsideofuniversaljoint(Cardan
shaftside) (arrow).
Halfshellsarepositionedtowardeachotherwith
ingpins .

retain-

Order No.

3

Insert angular gearbox (1) with attached half shells in
mount (B).
Secure angular gearbox (1) with bolts (C) and (D).
Bolt at bottom (D) can only be inserted from the right
(direction of travel).

Completely unscrew jack screw from extractor tool (E).
Attach extractor tool (E) and insert fork (F) in half shells
to limit position.

Apply jack screws (G) alternating/evenly and push
off half shells with Cardan shaft (1) from angular
gearbox (2).
Do not tilt extractor tool!
Observe maximum torque of jack screws!
Technical
Maximum

data
max 50 Nm

torque for jack
screws
Check
Result

Tighten jack screws with torque wrench.
A higher torque will damage the bearing in the angular
gearbox.

Order No.

4

Cardan shaft cannot be disconnected from angular
gearbox with nominal torque.
Measure
Replacing bevel gears
Take off half shells from Cardan shaft (1).
Remove angular gearbox (2) from mount.

Check
Check angular gearbox for tightness at shaft sealing
ring (1).
Result
Shaft sealing ring (1) is leaking.
Measure
Remove shaft sealing ring and check running
surface (arrow) of pinion nut (2) for scoring.
See 33 74 502 Replacing radial shaft seal for
bevel gear (rear bevel gears removed) Renew shaft
sealing ring.
Result
Running surface (arrow) is damaged.
Measure
Renew angular gearbox.