FUEL Remove filler cap slowly and fill fuel tank slowly to prevent spillage; do not overfill or fill above the bottom of the filler neck insert. In addition, leave air space to allow for fuel expansion. Expansion can cause an overfilled tank to overflow gasoline through the filler cap onto surrounding areas. After refueling, be sure filler cap is securely tightened. Inadequate safety precautions may cause an explosion or fire which could result in death or serious injury. BMW motorcycles were designed to obtain the best performance and efficiency using unleaded gasoline (91 pump octane or higher for the , 87 or higher for all other models). Pump octane is the octane number usually shown on the gas pump. Some fuel suppliers sell gasoline/alcohol blends as a fuel. The type and amount of alcohol added to the fuel is important. GASOLINE BLENDS CAUTION Using gasoline that has an alcohol additive, such as methanol, may cause fuel system rubber components’ failure and/or engine damage. BMW motorcycles are designed to give the best performance using unleaded gasoline. Some fuel suppliers sell gasoline/alcohol blends as a fuel. The type and amount of alcohol added to the fuel is important. ● DO NOT USE GASOLINES CONTAINING METHANOL. Using gasoline/methanol blends will result in starting and driveability deterioration and damage to critical fuel system components. ● ETHANOL is a mixture of 10% ethanol (Grain alcohol) and 90% unleaded gasoline. It is identified as “gasohol,” “ethanol enhanced,” or “contains ethanol.” Gasoline/ethanol blends can be used in your motorcycle if the ethanol content does not exceed 10%. ● REFORMULATED OR OXYGENATED GASOLINES (RFG): “Reformulated gasoline” is a term used to describe gasoline blends that are specifically designed to burn cleaner than other types of gasoline. Your motorcycle will run normally using this type of gas. Because of their generally higher volatility, these blends may adversely affect the starting, driveability and fuel efficiency of your motorcycle. If you experience these problems, Harley- Davidson recommends you operate your motorcycle on straight, unleaded gasoline. ENGINE OIL Use the proper grade of oil for the lowest temperature expected before the next oil change. If it is necessary to add oil and BMW oil is not available, use an oil certified for diesel engines. Acceptable diesel engine oil designations include CF, CF-4, CG-4 and CH-4. The preferred viscosities for the diesel engine oils, in descending order, are 20W-50, 15W-40 and 10W-40. At the first opportunity, see a BMW dealer to change back to 100 percent BMW oil. See 1.5 ENGINE OIL AND FILTER for all service information. ENGINE OIL AND FILTER 1.5 CHECKING AND ADDING OIL Check engine oil level in oil tank at least once every 500 miles (800 km). Check level more frequently if engine uses more oil than normal or if vehicle is operated under harsh conditions. Oil tank capacity is 3.6 quarts (U.S.) (3.4 liters). Refer to Table 1-3. on the next page for recommended engine oil viscosity. Removing and Replacing Oil Filler Cap 1. See Figure 1-1. Remove filler cap from oil tank on right side of vehicle. a. Press straight down on filler cap and release. Cap will pop up. b. Pull up on filler cap while turning counterclockwise one-quarter turn as if unscrewing filler cap. 2. Wipe attached dipstick clean. NOTE See Figure 1-2. Note that dipstick has a wide slot (1) and a narrow slot (2) and can only be inserted in oil tank one way. 3. Insert dipstick into tank. Press down on filler cap while turning clockwise one-quarter turn as if screwing filler cap into tank. When filler cap stops turning, it is fully seated. Press down on filler cap until it snaps in place, flush with top of oil tank cover. Checking Oil With Cold Engine 1. Position motorcycle so that it is leaning on jiffy stand. 2. Remove filler cap. See Removing and Replacing Oil Filler Cap above. Wipe attached dipstick clean. Reinstall oil filler cap in tank. 3. Remove oil filler cap again and check oil level on dipstick. See Figure 1-3. Dipstick has two marks. If oil level is at or below lower mark (2), add only enough oil to bring the level to a point between the two arrows on the dipstick. Replace filler cap. Checking Oil With Warm Engine 1. Run engine until engine oil is at normal operating temperature. Turn engine off. 2. Position motorcycle so that it is leaning on jiffy stand. 3. Remove filler cap. See Removing and Replacing Oil Filler Cap above. Wipe attached dipstick clean. Reinstall oil filler cap in tank. 4. Remove filler cap again and check warm oil level on dipstick. See Figure 1-3. Dipstick has two marks. If oil level in tank is at or below lower mark, add one quart (0.946 liter) of Harley-Davidson oil to tank. Replace filler cap. 5. If you added oil in step 4, remove filler cap and verify correct engine oil level in oil tank. Do not fill oil tank to the level above upper mark on dipstick. Replace filler cap. BATTERY INSPECTION 1. Battery top must be clean and dry. Dirt and electrolyte on top of the battery can cause battery to self-discharge. Clean battery top with a solution of baking soda (sodium bicarbonate) and water (5 teaspoons baking soda per quart or liter of water). When the solution stops bubbling, rinse off the battery with clean water. 2. Clean cable connectors and battery terminals using a wire brush or sandpaper. Remove any oxidation. 3. Inspect the battery screws, clamps and cables for breakage, loose connections and corrosion. Clean clamps. 4. Check the battery posts for melting or damage caused by overtightening. 5. Inspect the battery for discoloration, raised top or a warped or distorted case, which might indicate that the battery has been frozen, overheated or overcharged. 6. Inspect the battery case for cracks or leaks. BRAKES 1.7 GENERAL The front and rear brakes are fully hydraulic disc brake systems that require little maintenance. The front brake master cylinder is an integral part of the brake hand lever assembly. The rear brake master cylinder is located at the rear of the motorcycle’s frame, beneath the rear fork pivot point. INSPECTION Check the master cylinder reservoirs for proper fluid levels at the 1000 mile (1600 km) point and every 5000 miles (8000 km) thereafter. With the reservoir in a level position, add D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID (P/N 99902-77) from a sealed container until the fluid level is within approximately 1/4-inch (6 mm) below the top edge of the reservoir (front brake) or reaches the upper fluid level in the reservoir (rear brake). Do not overfill the reservoir. |
fCheck brake pads and discs for wear every 5000 miles (8000 km). Replace brake pads if friction material is worn to 0.04 in. (1.02 mm) or less. Minimum brake disc thickness is stamped on side of disc. Replace any brake disc that is worn beyond this limit. Maximum brake rotor lateral runout and warpage is 0.008 in. (0.2 mm) when measured near the outside diameter. BRAKE PADS AND DISCS 1.9 INSPECTION Check brake pads and discs: ● At every scheduled service interval. ● Whenever the components are removed from the vehicle during service procedures. Brake Pads 1WARNING Always replace brake pads in complete sets for correct brake operation. Never replace just one brake pad. Failure to install brake pads as a set could result in death or serious injury. See Figure 1-21. Replace brake pads (3) if brake pad friction material on either the front or rear caliper is worn to 0.04 in. (1.02 mm) or less above the backing plate (4). Always replace both pads in a caliper as a set. See BRAKE PAD REPLACEMENT on the next page. When checking the brake pads and discs, inspect the brake hoses for correct routing and any signs of damage. Brake Disc Thickness, Lateral Runout and Warpage The minimum brake disc (2) thickness is stamped on the side of the disc. Replace disc if worn past minimum thickness or badly scored. Maximum brake disc lateral runout and warpage is 0.008 in. (0.2 mm) when measured near the outside diameter. ● To replace front brake disc(s), see FRONT WHEEL under 2.4 WHEELS. ● To replace rear brake disc, see REAR WHEEL under 2.4 WHEELS. BRAKE PAD REPLACEMENT Front Brake Caliper CAUTION Do not remove front caliper(s) from mounting bracket unless caliper mounting pins require service. Removing caliper from mounting bracket unnecessarily increases the risk of contaminates falling into mounting pin holes and damaging caliper during vehicle operation. 1. See Figure 1-14. Position motorcycle so that front master cylinder reservoir (1) is level. 2. See Figure 1-15. Remove two screws (5), reservoir cover (4), diaphragm plate (3) and diaphragm (2) from master cylinder reservoir (1).
TIRES AND WHEELS 1.10 TIRES 1WARNING For your own personal safety, tires, rims and air valves must be correctly matched to wheel rims. See your Harley- Davidson dealer. Mismatching tires, tubes, rims and air valves may result in damage to the tire bead during mounting or may allow the tire to slip on the rim, possibly causing tire failure and resulting in death or serious injury. ● In addition, using tires other than those specified may adversely affect motorcycle handling. ● Tubeless tires fitted with the correct size inner tubes may be used on all BMW laced (wire spoked) wheels. Protective rubber rim strips must be used with tubeless tires (fitted with correct size inner tubes) when mounted on laced (wire spoked) wheels. ● Inner tubes must not be used in radial tires and radial tires must not be used on laced (wire spoked) wheels. ● Tubeless tires are used on all Harley-Davidson cast and disc wheels. ● Tire sizes are molded on the tire sidewall. Inner tube sizes are printed on the tube. Check tire pressure and tread: ● As part of the pre-ride inspection. ● At every scheduled service interval. 1. Inspect each tire for punctures, cuts, and breaks. 2. Inspect each tire for wear. Replace tires before they reach the tread wear indicator bars. 1WARNING Do not exceed the maximum inflation pressure listed on tire sidewall. Overinflating could lead to tire failure which could result in death or serious injury. 3. Check for proper front and rear tire pressures when tires are cold. Compare results against Table 1-6. TIRE WEAR INDICATORS See Figure 1-31. Tread wear indicator bars appear on tire tread surfaces when 1/32 inch (0.8 mm) or less tire tread remains. Arrows on tire sidewalls pinpoint location of wear bar indicators. Always remove tires from service before they reach the tread wear indicator bars, indicating 1/32 inch (0.8 mm) tread pattern depth remaining. New tires are needed if any of the following conditions exist. ● Tread wear indicator bars become visible on the tread surfaces. ● Tire cords or fabric become visible through cracked sidewalls, snags or deep cuts. ● A bump, bulge or split in the tire is found. ● Puncture, cut or other damage to the tire that cannot be repaired. Table 1-6. Tire Pressures ALL MODELS DUNLOP TIRES ONLY SOLO RIDER RIDER & ONE PASSENGER PSI kPA PSI kPA Front 30 207 30 207 Rear 36 248 40 276 CLUTCH 1.12 ADJUSTMENT All models feature a primary cover and a quick-release clutch cable to simplify both clutch service and adjustment. 1. See Figure 1-34. Slide rubber boot off cable adjuster. 2. Holding cable adjuster with 1/2 inch wrench, loosen jam nut using a 9/16 inch wrench. Back jam nut away from cable adjuster. Move adjuster toward jam nut to introduce a large amount of free play at hand lever. 3. models: remove left side rider footrest and mounting bracket assembly. See LEFT FOOTREST AND SHIFT LEVER ASSEMBLY under 2.31 RIDER FOOT CONTROLS: XL 883/XL 1200R for REMOVAL. 4. See Figure 1-35. Remove six screws (1) and remove clutch inspection cover (2). Exercise caution to avoid damaging or dislodging quad ring (7) in primary cover (9). 5. Slide hex lockplate with attached spring (3) from flats of adjusting screw assembly (8). Turn adjusting screw counterclockwise until resistance is felt. Back off adjusting screw 1/4 turn. 6. Slide hex lockplate with spring onto flats of adjusting screw. If necessary, turn adjusting screw clockwise slightly so that lockplate slides onto flats while also fitting within recess of outer ramp. 7. Verify that quad ring is fully seated in groove of primary cover. Install clutch inspection cover and secure with six screws. Tighten screws in a crosswise pattern to 84-108 in-lbs (9.5-12.2 Nm). |