BMW AG Motorcycle (K1100LT, K1100RS). Manual - part 5

11.9

Piston rings

1st groove

Rectangular-section

Height

mm (in)

1.175…1.190 (0.0462…0.0469)

Wear limit

mm (in)

1.100 (0.0433)

Ring gap

mm (in)

0.20…0.40 (0.0079…0.0157)

Wear limit

mm (in)

1.50 (0.059)

Side clearance

mm (in)

0.040…0.075 (0.0016…0.0030)

Wear limit

mm (in)

0.30 (0.0118)

2nd groove Micro-chamfer

Height

mm (in)

1.178…1.190 (0.0464…0.0469)

Wear limit

mm (in)

1.100 (0.0433)

Gap

mm (in)

0.10…0.30 (0.0039…0.0118)

Wear limit

mm (in)

0.300 (0.0118)

3rd groove  Equal-chamfer ring with tubular

spring

Height

mm (in)

2.475…2.490 (0.0974…0.0980)

Gap

mm (in)

0.20…0.45 (0.0079…0.0177)

Wear limit

mm (in)

1.50 (0.0591)

Side clearance

mm (in)

0.020…0.055 (0.0008…0.0022)

Wear limit

mm (in)

0.30 (0.0118)

Installed direction of piston rings

Top marking facing up (grooves 2 and 3)

Piston pin

Piston pin dia.

mm (in)

18 (0.7087) 

-0.004 (0.0002)

Wear limit

mm (in)

17.96 (0.7071)

Bore dia. in piston

mm (in)

18.002…18.006 (0.7087…0.7089)

Play in piston

mm (in)

0.002…0.010 (0.00008…0.00039)

Play in conrod

mm (in)

0.006…0.021 (0.00024…0.00083)

Wear limit

mm (in)

0.060 (0.00236)

Technical data

K 1100 LT

K 1100 RS

11.10

11.11

Removing engine

•

Remove fuel tank.

•

Remove knee pads.

•

Remove fuel tank.

•

Remove lower section of fairing at left and right.

•

Remove radiator surround.

•

Drain coolant.

•

Remove radiator.

•

Attach hoist, BMW No. 00 1 510, to oil sump.

•

Remove rear shield plate with coolant level 
equalising tank.

•

Remove Motronic control unit.

e

 Caution:

Detach negative battery terminal first, then positive 
terminal. Connect the positive battery terminal first, 
then the negative terminal.

•

Remove the battery.

e

 Caution:

Do not allow brake fluid to come into contact with 
painted parts of the motorcycle, because brake fluid 
destroys paint.

•

Drain the brake fluid.

e

 Caution:

Avoid damage to the brake lines.

•

(ABS I) Detach both pressure modulators and 
secure them to the frame.

•

(ABS II) Remove the ABS unit.

•

Detach the brake hose fastening at the battery 
carrier.

•

Remove the left footrest plate.

•

Remove the right footrest plate together with the 
brake line and master brake cylinder.

•

Detach the engine wiring harness.

•

Separate the plug connections for the speed and 
ABS signals.

•

Detach the throttle cable.

•

Detach the choke cable.

•

Disconnect clutch cable.

•

Remove the exhaust system.

•

Remove suspension strut.

•

Detach engine mounting at frame.

•

Secure front wheel to hoist.

•

Raise the frame with telescopic fork and frame 
support, BMW No. 46 5 620, over the engine 
block, and set it down.

•

Remove the battery holder.

•

Remove the starter motor.

•

Remove the coils.

•

Remove the main (centre) stand.

•

Take out the two lower gearbox bolts.

•

Screw the main (centre) stand on hand-tight.

•

Remove the alternator cover.

•

Screw guide pins (1) und (2), BMW  No.  23 1 820, 
into the holes with the reamed sleeve; the longer 
pin (2) must be at the right.

•

Pull the gearbox off slowly.

2

1

LT110760

00 1 510

LT110830

1

2

LT110840

11.12

Dismantling engine

•

Remove air cleaner box.

•

Remove fuel injection rail.

•

Remove throttle rail.

•

Attach engine mount, BMW No. 11 0 610, to the 
engine block.

•

Lower the hoist and support the engine on as-
sembly stand, BMW No. 00 1 490.

•

Remove the hoist.

•

Drain the oil.

LT110050

LT110060

11 0 610

11.13

Removing intermediate flange

•

Remove alternator.

•

Remove coils with holder.

Removing driver

•

To remove the screw, support the driver (arrow).

•

Pull the driver off by hand.

LT110070

LT110080

11.14

Removing clutch housing

•

Install the retaining device (arrow), 
BMW No. 11 2 800, in the position illustrated.

•

Unscrew hex nut (1) and take off thrust ring (2).

•

Push O-ring (3) forwards with the clutch housing 
and remove with a hook.

•

Pull out clutch housing (4), noting the presence 
of thrust washer (5).

1

2

3

4

5

LT110090

LT110100

11 2 800

•

If necessary, pull the clutch housing off with a 
three-arm puller, BMW  No.  33 1 830.

•

Remove the intermediate flange.

LT110110

33 1 830

11.15

Stripping down and re-assembling 
intermediate flange

Removing the driver bearing

•

Bearing plate (1) 

•

Cup spring (2) 

•

Pull out ball bearing (3) with counter-support, 
BMW No. 00 8 572, and internal puller 21/2, 
BMW No. 00 8 571.

•

Seeger circlip (4)

Installing driver bearing

•

Heat the intermediate flange at the bearing seat 
to 120 °C.

•

Press the ball bearing in as far as the Seeger cir-
clip.

4

3

2

1

j

120

LT110120

•

Insert the cup spring with the larger diameter fac-
ing the bearing.

•

Install the bearing plate with the large cutout fac-
ing upwards.

•

The retaining screws must be clean and free 
from grease; insert them with Loctite 243.

X 

Tightening torque:

Bearing plate.................................................. 9 Nm

LT110130

11.16

Removing and installing shaft sealing ring for 
driver

•

If the intermediate flange has been removed, le-
ver out the sealing ring.

•

If the intermediate flange is installed, pull out the 
sealing ring with an internal puller, 
BMW No. 00 5 010, and pressure head.

•

Pre-shape the sealing ring, which must be dry, 
with the thumb and drive it in with drift, 
BMW No. 11 1 620, and handle, 
BMW No. 00 5 500.

Removing countershaft and layshaft 
with freewheel

•

Pull countershaft and layshaft out of the engine 
block together.

•

Note flat spring (1).

LT110140

00 5 010

1

LT110150