BMW PISTONS AND RINGS INSTALLATION INSTRUCTIONS

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Filed Under (BMW) by admin on 26-10-2010

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1. Always clean the grooves before installing rings. Carbon build-up in the groove will lead to ring “bottoming” and can result in engine seizure. 2. Check the fit of rings in the groove. A maximum of .003″ side clearance is allowable. 3. Check the cylinders for taper and out-of-roundness. Any taper of out-of-roundness will have an adverse effect on the performance of an engine. Excessive piston clearance will detract from maximum performance as well. 4. Allow ample ring gap. There is far more danger of ring butting than of an appreciable compression loss through the ring gap. Gaps, if staggered, do not cause any measurable reduction of compression. Compression rings should be fitted with a minimum of .004″ end gap per inch of cylinder deglazing. 5. Always deglaze cylinder walls before installing new rings. A 400 grit stone is recommended for deglazing. 6. All parts should be spotlessly clean before installation. Dirt in any form is the worst enemy of a hi- performance engine. You may wash all parts in hot, soapy water. Ring Gap Installation 1. Do not gap oil control rings. Start with the oil control expander. Expander Ring ends butt together. Do not overlap them. 2. Install oil control rings. Set gap 90 from where expander ring butts together. Gap top oil control ring 180 from lower oil control ring gap. 3. Install 2nd and top ring also with marks up. Stagger gaps

BMW R1200GS Electronic Cruise Control Installation Manual

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Filed Under (BMW) by admin on 26-10-2010

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Undo both quick release fasteners at the rear of the panel. • Undo the quick release fastener at the lower front edge of the cover, inside the cover. The hole circled at lower right in the photo below is for this fastener. • Pull the cover outwards to disengage the fasteners. There is a grommet and post at the upper front edge of the cover, circled at upper right in the photo. Pull the cover out to disengage the post. Remove the cover. • Repeat for the cover on the other side of the bike. Remove the plastic side covers on both sides of the bike. • Pull the side covers out to disengage the mounting posts from the mounting grommets. Undo and remove the three mounting screws circled in the photo. Ease the cover out from the join with the top fuel tank cover. • Repeat for the other side cover. Disconnect the negative battery terminal. • Loosen and remove the terminal screw. Ensure the lead cannot touch the battery terminal. Remove the fuel tank. • Remove the fairing screws on both sides. • Remove the fuel pump cover

BMW R1100RT, BMW R1150RT Signal Mirror Installation Instructions

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Filed Under (BMW) by admin on 26-10-2010

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1. These instructions start with the right side mirror. Grab the mirror housing as shown and slowly push down to disengage housing from motorcycle. 2. Once you have the mirror housing removed partially, twist and remove the light bulb from mirror housing. Remove mirror housing and set it on a cloth covered surface. 3. Remove the factory mirror by inserting a slotted screwdriver against each mirror mount snaps. Slowly twist and pry each snap until it releases from motor actuator. Repeat process until factory mirror disengages. NOTE: Insert the slotted screwdriver as close to each of the snaps as possible before prying out the OE mirror. Not doing so may cause the crossbar on the motor actuator to break. Connect the two mating connectors from the adapter Signal® mirror wire harness and the new Signal® mirror wire harness. Cut a slot in the foam disc to accommodate the anti-vibration prongs on the motor adapter. Place the foam disc onto the center of the Signal® mirror motor interface. Connect the Signal® mirror mating connector to the Signal® mirror wire harness. 5. Remove Cap Sheet from two-sided adhesive disc on back of Signal ® mirror. Align the anti-rotation prongs found on the top and bottom or left and right with the corresponding slots on the motor mount. Use the palm of your hand, push down on the Signal® mirror and the mirror housing until the Signal® mirror motor mount is fully engaged. Note: Push firmly on all sides of the Signal® mirror to ensure proper engagement and travel. Not doing so could result in mirror falling off. 6. Locate the light bulb and carefully disconnect the original light blue with black stripe wire [hot wire]. Connect the red wire from the Signal® mirror wire harness to the spade terminal on the light bulb. Connect the original light blue with black stripe wire to the other spade terminal located on the red wire of the Signal® mirror wire harness. Repeat the process for the original brown wire and the black wire from the Signal® mirror wire harness [ground wires]. Insert the light bulb back into the mirror housing. 7. Align the 3-pins with their corresponding snap holes and snap the mirror housing into place. 8. Insert key into the ignition and turn to the “ON” position. Activate the right hand turn indicator to verify that the new Signal® mirror is working correctly. Replace any other accessories necess

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BMW Motorcycles Siren Speaker Mounting Bracket Installation Manual

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Filed Under (BMW) by admin on 26-10-2010

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The SA314 speaker bracket mounts on the left side crash bar of your motorcycle. If you have a light mounted here, the bracket mounting screws may share some or all of the mounting holes. 1. Secure the mounting brackets to the SA314 speaker using the provided hardware. Make sure that the brackets are properly oriented before proceeding. 2. Now secure the bracket onto the motorcycle using the supplied mounting hardware as shown below. 3. Connect the speaker to your siren as outlined in your siren installation manual. Note: Always be sure the siren is mounted so that the wires exit the bottom of the siren. This will position the siren’s drain hole on the bottom for proper drainage. IMPORTANT! Before returning the vehicle to active service, confirm the proper operation of this product, as well as all vehicle components/equipment

BMW Airhead Side Braces Installation Instructions

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Filed Under (BMW) by admin on 26-10-2010

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Figure B shows the upper end of the Airhead Side Brace where it attaches to the frame ( NOTE: Leave at least 1/2″ spacing below the bottom edge of the fuel tank ). Figure C shows how the Airhead Side Brace must clear the air inlet tubing Figure D showing how the lower edge (beveled end) fits the frame at the rear of the bike. Figure E shows one of the threaded cones properly welded to the frame, and painted. . Ensure Airhead Side Braces are fully assembled (threaded cones firmly bolted into the braces at both ends). 2. Hold Airhead Side Brace in their proper position (reference Figures A-D) to mark location where front and rear threaded cones will be welded to the frame. NOTE : The lower (rear) end of the Airhead Side Brace is beveled, for reference. NOTE : Make sure that both the left and right Airhead Side Braces are positioned equally. 3. Mark the frame and remove paint in the appropriate areas using emery cloth to prepare the frame surface for welding. NOTE : Measure and mark twice, weld once! 4. Hold assembled Airhead Side Braces in their appropriate positions and tack-weld at the top and bottom. Perform this step for both the top (front) and bottom (rear) ends of the Airhead Side Braces , on both sides of the bike. 5. Using removable tape, mark each Airhead Side Brace as either “left” or “right”, to make sure they are replaced onto the appropriate side of the bike after disassembly. 6. Remove the bolts, and the Airhead Side Braces from the tack-welded, threaded cones. Complete the welding of the threaded cone to the motorcycle frame at all 4 locations. 7. Clean/remove any weld splatter, and paint to protect threaded cone and frame from corrosion (see Figure E). 8. Re-assemble Airhead Side Braces onto threaded cones maintaining original left side/right side orientation. NOTE : The lower (rear) end of the Airhead Side Brace is beveled, for reference. 9. Torque hex bolts to 7 ft/lbs