BMW HP2 ENDURO Maintenance Instructions Manual

Brand: BMW

Model: HP2 ENDURO

Category: Motorcycles

Type: Maintenance Instructions Manual

Maintenance instructions for sporty off-roading

HP2 Enduro

Motorcycle data/dealership details

Motorcycle data

Model

Vehicle identification number

Colour code

Date of first registration

Registration number

Dealership details

Person to contact in Service depart-

ment

Ms/Mr

Phone number

Dealership address/phone number

(company stamp)

Details described or illus-

trated in this booklet may

differ from the motorcycle's

actual specification as pur-

chased, the accessories fit-

ted or the national-market

specification. No claims will

be entertained as a result of

such discrepancies.

Dimensions, weights, fuel

consumption and perform-

ance data are quoted to the

customary tolerances.

The right to modify designs,

equipment and accessories is

reserved.

Errors and omissions excep-

ted.

Not to be reproduced either

wholly or in part without writ-

ten permission from BMW

Motorrad, After Sales.

Printed in Germany.

BMW recommends

LastPage.fm Seite 0 Mittwoch, 10. August 2005 12:04 12

Maintenance in-

structions for sporty

off-roading

These maintenance instruc-

tions were compiled for riders

who want to leave metalled

roads and use their motor-

cycles for sporty off-roading.

Before you go off-roading,

BMW Motorrad recommends

installing the accessories

supplied with the motorcycle.

In this way you can effectively

protect parts of the motor-

cycle that could otherwise be

at risk.

These maintenance instruc-

tions describe the proced-

ures for installing the off-road

accessories and the proced-

ure for removing the number-

plate carrier and the mirrors.

Use the headlight guard

only when off-roading.

Riding on public roads with

the headlight guard fitted to

the motorcycle is prohibited.

Sporty off-roading inevitably

increases wear and tear on

the motorcycle, so extra

checks and maintenance

work over and above those

described in the Rider's

Manual are necessary. They

too are described in this

publication.

All the work described in

these Maintenance Instruc-

tions is supplementary to the

standard maintenance work

described in the "Service"

section of the Rider's Manual.

Please bear in mind that if the

motorcycle is used for sporty

off-roading, you must comply

with these additional mainten-

ance instructions in order to

keep the motorcycle in good

running order.

Some of the work calls for

special tools and a thorough

knowledge of motorcycles.

If you are in doubt consult a

specialist workshop, prefer-

ably your authorised BMW

Motorrad dealer.

Damage not attended

to in good time or inad-

equately repaired can result in

consequential damage to the

motorcycle.

Consult a specialist work-

shop, preferably an author-

ised BMW Motorrad dealer,

as soon as possible if you

discover that the motorcycle

is damaged.

Table of Contents

You can also consult the in-

dex at the end of this Rider's

Manual if you want to find a

particular topic or item of in-

formation.

1 General instructions . . . 3

Notes on these

Maintenance

Instructions . . . . . . . . . . . . . . 4

Abbreviations and

symbols . . . . . . . . . . . . . . . . . . 4

2 Overview . . . . . . . . . . . . . . 5

Conversion work

preparatory to

off-roading . . . . . . . . . . . . . . . 6

Maintenance work . . . . . . . . 6

3 Installing and removing

components . . . . . . . . . . . 9

Removing number-plate

carrier . . . . . . . . . . . . . . . . . . 10

Installing number-plate

carrier . . . . . . . . . . . . . . . . . . 11

Removing mirror . . . . . . . . . 12

Installing mirrors . . . . . . . . . 12

Installing headlight

guard . . . . . . . . . . . . . . . . . . . 12

Installing guard for final

drive . . . . . . . . . . . . . . . . . . . . 13

Installing cylinder

guard . . . . . . . . . . . . . . . . . . . 14

Installing deflector for

footbrake lever . . . . . . . . . . 14

Installing left and right

hand protectors . . . . . . . . . 15

Replacing left and right

hand frame-protector

strips . . . . . . . . . . . . . . . . . . . 18

4 Maintenance . . . . . . . . . 19

Work to be carried out

always before

off-roading . . . . . . . . . . . . . . 20

Work to be carried out

after five hours of riding in

sand, dust or mud . . . . . . . 20

Work to be carried out

after ten hours

off-roading . . . . . . . . . . . . . . 25

Work to be undertaken

once a year. . . . . . . . . . . . . . 29

5 Threaded fasteners . . . 31

Anchorage points, engine

and swinging arm . . . . . . . . 33

Anchorage points, frame

and mounted

components. . . . . . . . . . . . . 34

Anchorage points,

front . . . . . . . . . . . . . . . . . . . . 36

Threaded fasteners, front

wheel . . . . . . . . . . . . . . . . . . . 38

Body-panel screws . . . . . . 38

6 Technical data . . . . . . . . 39

Tightening torques for

internally mounted

components. . . . . . . . . . . . . 40

Tightening torques for

checking threading

fasteners . . . . . . . . . . . . . . . . 42

General instructions

Notes on these Maintenance

Instructions ..................... 4

Abbreviations and symbols ...... 4

General instructions

Notes on these Main-

tenance Instructions

The work explained in these

Maintenance Instructions

should be carried out in

accordance with the schedule

outlined below. Use the

operating-hours counter

described in the "Operation"

section of the Rider's Manual

to check the operating hours.

Work you must always un-

dertake before leaving sur-

faced roads for sporty off-

roading.

Work you must undertake

after five hours of riding in

mud, dust or sand.

Work you must undertake

after ten hours off-roading.

Work you must undertake

once a year.

You will find detailed informa-

tion on maintenance and re-

pair work in the Repair Manu-

al on the CD-ROM that ac-

companies your motorcycle.

Abbreviations and

symbols

Indicates warnings that

you must comply with for

reasons of your safety and the

safety of others, and to pro-

tect your motorcycle against

damage.

Specific instructions on

how to operate, control,

adjust or look after items of

equipment on the motorcycle.

Indicates the end of an

item of information.

Instruction.

Result of an activity.

Reference to a page

with more detailed in-

formation.

General instructions

Overview

Conversion work preparatory to

off-roading ...................... 6

Maintenance work ............... 6

Overview

Conversion work

preparatory to

off-roading

Removing number-plate

carrier ( 10)

Removing mirror ( 12)

Installing headlight guard

( 12)

Installing guard for final

drive ( 13)

Installing cylinder guard

( 14)

Installing deflector for foot-

brake lever ( 14)

Installing left and right hand

protectors ( 15)

Maintenance work

Work to be carried

out always before

off-roading

Checking brake disc wear

( 20)

Checking brake pads for

wear ( 20)

Checking spokes ( 20)

Work to be carried out

after five hours of riding

in sand, dust or mud

Checking alternator drive

belt ( 20)

Checking air filter for dirt

( 21)

Checking ease of move-

ment of footbrake lever

( 23)

Checking ease of move-

ment of shift lever ( 24)

Cleaning slider tubes ( 25)

Work to be carried

out after ten hours

off-roading

Checking air filter for dirt

( 21)

Checking ease of move-

ment of footbrake lever

( 23)

Checking ease of move-

ment of shift lever ( 24)

Cleaning slider tubes ( 25)

Checking steering-head

bearing ( 25)

Checking wheel bearing for

play ( 26)

Checking telescopic-fork

protector and slip-ring

( 26)

Bleeding telescopic forks

( 27)

Checking ease of move-

ment of side stand ( 27)

Check operation of side-

stand switch ( 27)

Checking spring-strut

mount for play ( 28)

Checking swinging-arm

bearings for play ( 28)

Checking flexible gaiter

( 29)

Overview

Checking Paralever bearing

for play ( 29)

Checking security of

threaded fasteners ( 29)

Work to be undertaken

once a year

Changing telescopic-fork oil

( 29)

Overview

Installing and removing components

Installing and removing

components

Removing number-plate

carrier ........................ 10

Installing number-plate

carrier ........................ 11

Removing mirror............... 12

Installing mirrors............... 12

Installing headlight guard . . .... 12

Installing guard for final drive . . . 13

Installing cylinder guard........ 14

Installing deflector for footbrake

lever . ......................... 14

Installing left and right hand

protectors . .................... 15

Replacing left and right hand

frame-protector strips ......... 18

Installing and removing components

Removing number-

plate carrier

Make sure the ground is

level and firm and place the

motorcycle on its stand.

Remove the seat.

Remove plug 1 from its

holder and disconnect the

plug.

Remove protective plug 2

from its holder.

Connect plug 1 to protect-

ive plug 2.

Push wiring-harness end

of plug 1 into the holder of

protective plug 2.

Remove screws 3 on left

and right.

Remove screws 4 and

screw 5.

Remove the number-plate

carrier and thread out the

cables.

Reinstall screws 4.

Installing and removing components

Installing number-

plate carrier

Remove screws 4.

Manoeuvre the cables into

place and hold the number-

plate carrier in position.

Install screws 4 and

screw 5.

Disconnect the number-

plate plug and the protect-

ive plug.

Install screws 3 on left and

right.

Remove wiring-harness end

of plug 1 from the holder.

Connect plug 1 and seat it

in the holder.

Installing and removing components

Seat protective plug 2 in its

holder.

Install the seat.

Removing mirror

Push back rubber sleeve 1.

Release threaded fastener 2

and remove the mirror.

Remove clamping piece 3.

Installing mirrors

Install clamping piece 3.

Clamping piece to clamping

block

30 Nm

Install the mirror and adjust

it to the correct position.

Tighten threaded fastener 2.

Mirror to clamping piece

25 Nm

Slip rubber sleeve 1 down

over the threaded fastener.

Installing headlight

guard

Use the headlight guard

only when off-roading.

Riding on public roads with

the headlight guard fitted to

the motorcycle is prohibited.

Position the headlight guard

with bore 1 against the in-

strument carrier from be-

low and secure it with cable

tie 2.

Installing and removing components

Bend the headlight guard

down at the front and use

cable ties 3 to mudguard

struts 4.

In order to avoid injury,

be sure to turn the cable

tie so that the lock is at the

back.

Installing guard for

final drive

Insert attachment 1 long

end toward the rear into

housing for final drive 2.

Position guard for final

drive 3 on the attachment

and secure it with screw 4.

Guard, final-drive housing

8Nm

Installing and removing components

Installing cylinder

guard

Remove screw 1.

Remove screws 2 and 3.

Working from the inside,

insert the front reinforcing

plate into the cylinder

guard.

Use the screws and bush-

ings provided to secure the

cylinder guard, inserting

the screws into the tapped

holes left by the screws re-

moved beforehand.

Cylinder guard to engine

Thread-locking compound:

Mechanical thread lock

8Nm

Install cable tie 3.

In order to avoid injury,

be sure to turn the cable

tie so that the lock is at the

back.

Installing deflector for

footbrake lever

Screw threaded pin 2 into

the tapped hole in the foot-

brake lever until nut 1 can

just be screwed on.

Lock the pin with nut 1.

Footbrake lever deflector to

lever

Hand-tight

Installing and removing components

Insert screw 3 through

eye 4 and install it in the

motorcycle's frame. Align

the eye as shown in the

illustration.

Footbrake lever deflector to

frame

5Nm

Remember to remove the

deflector for the footbrake

lever before you next use

the motorcycle on public

roads.

Installing left and right

hand protectors

Removing mirror ( 12)

Remove screws 1 and

remove top part of mirror

clamping block 2. Hold the

clutch fitting or handbrake

fitting, as applicable, when

removing the clamping

block.

Install screws 1 of the mirror

clamping block for the hand

protector, but do not tighten

them at this point.

Align the clamping block

so that pin 2 of the grip unit

projects into the gap in the

mirror clamping block.

Tighten screws 1 in such a

way that the gap between

the top and bottom halves

of the clamping block is

the same width at front and

rear.

Handlebar fitting to handle-

bar

Installing and removing components

Position holders 3 in such

a way that the cables pass

through recess 4. Note the

identifying marks RK for the

right hand protector and LK

for the left hand protector.

Install screws 5, but do not

tighten them at this point.

Use screws 6 and

washers to secure the

hand-protector holder to

the hand protector. Use

hand-protector holder

7 684 575 for the left side

and 7 684 576 for the right

side.

Hand protector to holder for

hand protector

3Nm

Use screw 7 and washer to

secure the hand-protector

holder to the mirror clamp-

ing block.

Holder for hand protector to

mirror clamping block

3Nm

Use screw 8 and washer to

secure the hand protector

to holder 3.

Hand protector to clamping

block

3Nm

Tighten screws 5 of the

holder in such a way that

the gap between the top

and bottom halves of the

Installing and removing components

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BMW HP2 ENDURO Maintenance Instructions Manual

Brand: BMW

Model: HP2 ENDURO

Category: Motorcycles

Type: Maintenance Instructions Manual

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BMW HP2 ENDURO Maintenance Instructions Manual

BMW HP2 ENDURO Maintenance Instructions Manual

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