34 00 095 Bleed all brake circuits, Integral ABS system

BMW R 1200  GS Adventure (0382) model code

 

 
  Preparatory work
 

Removing seat

 

Removing right side cover

 

Removing right side panel

 

Removing left side cover

 

Removing left side panel

 

Removing fuel tank

  Core activity
 
(-) Filling front control circuit
 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\warnung.gif

Warning

Mistakes can be made in repair and maintenance routines if work is carried out by persons who have not received the correct training, or in the event of non-compliance with the specified instructions.

All repair and maintenance work on the BMW Motorrad Integral ABS must be performed by trained, qualified specialists.

Comply with all maintenance and repair instructions and always work through the various steps in the correct order.

 

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\warnung.gif

Warning

Brake fluid is hygroscopic, which means that its boiling point drops once the container has been opened.

Use only new brake fluid from freshly opened containers.

 

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\warnung.gif

Warning

If bubbles of air are trapped in the brake system, rapid pumping could cause them to split into tiny bubbles and create foam in the brake fluid. This would mean that small quantities of entrained air would escape detection in the bleed test with the BMW Motorrad diagnostic system, and braking efficiency would be significantly impaired as a result.

When performing maintenance and repair work on the BMW Motorrad Integral ABS, always operate the brakes slowly. Do not pump quickly or vigorously.

 

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Turn the front wheel to a position in which the brake fluid reservoir is horizontal and secure the front wheel in this position.

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\achtung.gif

Attention

Brake fluid attacks paintwork, plastic and rubber parts.

Do not allow brake fluid to come into contact with paintwork, plastic or rubber parts.

 

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Wrap cloths around the reservoir.

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Using disengagement tool (No. 32 1 511), press back the lugs on the reservoir and open the reservoir cap.

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Remove the front reservoir cap with the diaphragm.

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Top up with fresh brake fluid to the MAX mark (arrow).

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\betriebsm.gif Fluids and lubricants

Brake fluid

Hydraulic systems

 
 
 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\warnung.gif

Warning

Air can be drawn into the system through the fluid replenishing hole if the fluid level in the reservoir is too low; the system has to be bled again if this happens.

During the fluid-change and bleeding procedure, make sure that the fluid replenishing hole is always below the level of the brake fluid.

 

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Set the handbrake lever to the position for maximum span.

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\achtung.gif

Attention

If plugs are disconnected from the pressure modulator, there is a possibility of dirt and brake fluid penetrating inside the housing and causing damage.

Do not disconnect the plugs from the pressure modulator.

 

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Connect the brake bleeding device to bleed screw (1) of the front metering cylinder, but do not switch on.

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\warnung.gif

Warning

Vacuum extraction with conventional devices does not ensure that the control circuits are adequately bled.

Do not use vacuum extraction to change the fluid in the control circuits or bleed the control circuits.

 

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

In the following sequence, bleed:

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Front metering cylinder (1)

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Front integral circuit (2)

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Front control circuit (3) and

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Front metering cylinder (1) again in accordance with instructions for bleeding and using special ring spanner (No. 34 2 532).

  Instructions for bleeding
 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

In the following sequence, bleed:

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/dash.gif

1. Slowly operate brake lever until brake light switch clicks (blow-by bore closed).

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/dash.gif

2. Open the bleed screw.

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/dash.gif

3. Slowly operate brake lever to full extent of its travel and close the bleed screw.

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/dash.gif

4. Slowly release the brake lever.

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/dash.gif

5. Repeat steps 1 to 4 until the brake fluid emerges clear and free of bubbles.

 
 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Turn the handlebars all the way to the left.

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Repeatedly and slowly pull front brake lever lightly to expel air from the handbrake cylinder.

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Fit the protective caps on the bleed screws.

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Top up with fresh brake fluid to the MAX mark (arrow).

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Wipe the rim of the reservoir, the diaphragm and the cover to remove brake fluid, and carefully re-assemble the components.

 
(-) Filling rear control circuit
 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\warnung.gif

Warning

Mistakes can be made in repair and maintenance routines if work is carried out by persons who have not received the correct training, or in the event of non-compliance with the specified instructions.

All repair and maintenance work on the BMW Motorrad Integral ABS must be performed by trained, qualified specialists.

Comply with all maintenance and repair instructions and always work through the various steps in the correct order.

 

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\warnung.gif

Warning

Brake fluid is hygroscopic, which means that its boiling point drops once the container has been opened.

Use only new brake fluid from freshly opened containers.

 

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\warnung.gif

Warning

If bubbles of air are trapped in the brake system, rapid pumping could cause them to split into tiny bubbles and create foam in the brake fluid. This would mean that small quantities of entrained air would escape detection in the bleed test with the BMW Motorrad diagnostic system, and braking efficiency would be significantly impaired as a result.

When performing maintenance and repair work on the BMW Motorrad Integral ABS, always operate the brakes slowly. Do not pump quickly or vigorously.

 

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\achtung.gif

Attention

Brake fluid attacks paintwork, plastic and rubber parts.

Do not allow brake fluid to come into contact with paintwork, plastic or rubber parts.

 

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Remove cap (1) and diaphragm (2).

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Top up the brake fluid level to the (MAX) mark.

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\betriebsm.gif Fluids and lubricants

Brake fluid

Hydraulic systems

 
 
 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\warnung.gif

Warning

Air can be drawn into the system through the fluid replenishing hole if the fluid level in the reservoir is too low; the system has to be bled again if this happens.

During the fluid-change and bleeding procedure, make sure that the fluid replenishing hole is always below the level of the brake fluid.

 

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\achtung.gif

Attention

If plugs are disconnected from the pressure modulator, there is a possibility of dirt and brake fluid penetrating inside the housing and causing damage.

Do not disconnect the plugs from the pressure modulator.

 

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Connect the brake bleeding device to bleed screw (1) of the rear metering cylinder, but do not switch on.

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\warnung.gif

Warning

Vacuum extraction with conventional devices does not ensure that the control circuits are adequately bled.

Do not use vacuum extraction to change the fluid in the control circuits or bleed the control circuits.

 

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Proceeding in the correct sequence and in accordance with the instructions for bleeding and using special ring spanner (No. 34 2 532), bleed:

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/dash.gif

Bleed screw (1) rear metering cylinder

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/dash.gif

Bleed screw (2) rear integral circuit

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/dash.gif

Bleed screw (3) rear control circuit, and

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/dash.gif

again, bleed screw (1) of the rear metering cylinder.

  Instructions for bleeding
 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

In the following sequence, bleed:

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/dash.gif

1. Slowly operate brake lever until brake light switch clicks (blow-by bore closed).

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/dash.gif

2. Open the bleed screw.

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/dash.gif

3. Slowly operate brake lever to full extent of its travel and close the bleed screw.

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/dash.gif

4. Slowly release the brake lever.

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/dash.gif

5. Repeat steps 1 to 4 until the brake fluid emerges clear and free of bubbles.

 
 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Fit the protective caps on the bleed screws.

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Top up the brake fluid level to the (MAX) mark.

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Wipe the rim of the reservoir, diaphragm (2) and cap (1) to remove brake fluid and reassemble the components.

 
(-) Filling front wheel circuit
 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\warnung.gif

Warning

Mistakes can be made in repair and maintenance routines if work is carried out by persons who have not received the correct training, or in the event of non-compliance with the specified instructions.

All repair and maintenance work on the BMW Motorrad Integral ABS must be performed by trained, qualified specialists.

Comply with all maintenance and repair instructions and always work through the various steps in the correct order.

 

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\warnung.gif

Warning

Brake fluid is hygroscopic, which means that its boiling point drops once the container has been opened.

Use only new brake fluid from freshly opened containers.

 

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\warnung.gif

Warning

If bubbles of air are trapped in the brake system, rapid pumping could cause them to split into tiny bubbles and create foam in the brake fluid. This would mean that small quantities of entrained air would escape detection in the bleed test with the BMW Motorrad diagnostic system, and braking efficiency would be significantly impaired as a result.

When performing maintenance and repair work on the BMW Motorrad Integral ABS, always operate the brakes slowly. Do not pump quickly or vigorously.

 

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\achtung.gif

Attention

Brake fluid attacks paintwork, plastic and rubber parts.

Do not allow brake fluid to come into contact with paintwork, plastic or rubber parts.

 

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\achtung.gif

Attention

If plugs are disconnected from the pressure modulator, there is a possibility of dirt and brake fluid penetrating inside the housing and causing damage.

Do not disconnect the plugs from the pressure modulator.

 

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Wrap cloths around the left and right brake calipers.

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Use piston resetting device (No. 34 1 531) and locator (No. 34 1 532) to force the pistons in the left and right brake calipers all the way back and hold them in this position.

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Connect container (No. 34 1 581) to the front wheel-circuit reservoir with threaded adapter (No. 34 1 582) and sight glass (No. 34 1 583).

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Slowly fill the container with fresh brake fluid until it is approximately 1/2 full.

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\betriebsm.gif Fluids and lubricants

Brake fluid

Hydraulic systems

 
 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Connect the brake bleeding device to the bleed screw of the right brake caliper, but do not switch on.

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Use a cable tie to secure the hose of the brake bleeding device to the bleed screw.

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Switch on the ignition.

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\achtung.gif

Attention

The front brake lever also applies the rear brakes (integral brakes). Once the brake calipers and brake pads have been removed, operating a brake lever could result in the pistons being pushed out.

Install the brake caliper with brake pads or insert the piston resetting device.

 

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Very gently pull the handbrake lever until the pump just starts up.

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Open the bleed screw, while topping up the container with new brake fluid if necessary.

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\betriebsm.gif Fluids and lubricants

Brake fluid

Hydraulic systems

 
 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\warnung.gif

Warning

Air can be drawn into the system through the fluid replenishing hole if the fluid level in the wheel-circuit reservoir is too low; the system has to be bled again if this happens.

The brake fluid must always be visible in the container, because the piston in the wheel-circuit reservoir must always be covered by the fluid.

 

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Pump out the brake fluid with virtually no pressure to begin with, then vary the brake pressure.

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\hinweis.gif

Note

The higher the brake pressure the faster the fluid is pumped through the system, which means that the level in the wheel-circuit reservoir drops all the more rapidly.


D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Continue pumping off brake fluid until it emerges clear and free from air bubbles.

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Close the bleed screw.

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\Anziehdrehmoment.gif Tightening torques

Bleed screw, brake caliper, front

 

9 Nm

 
 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Release the brake lever.

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Disconnect the brake bleeding device from the bleed screw.

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Connect the brake bleeding device to the bleed screw of the left brake caliper, but do not switch on.

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

If necessary, use a cable tie to secure the hose of the brake bleeding device to the bleed screw.

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

The procedure for changing the brake fluid in the left brake caliper is the same as that for the right caliper.

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

When the fluid exits clear and free of bubbles, continue pumping until the fluid in the container just disappears from view.

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Close the bleed screw.

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\Anziehdrehmoment.gif Tightening torques

Bleed screw, brake caliper, front

 

9 Nm

 
 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Release the brake lever and switch off the ignition.

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Disconnect the brake bleeding device from the bleed screw.

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Disconnect the container from the wheel-circuit reservoir.

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\warnung.gif

Warning

When the fluid is changed or the brakes bled, the fluid level in the wheel circuits is initially undefined. The level of fluid in the wheel circuit might be too high or too low.

After changing the fluid and/or bleeding the brakes, always bring the fluid in the wheel circuits to the correct level in accordance with the instructions.

 

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Top up the fluid in the wheel-circuit reservoir to the (MAX) mark.

  Instructions for filling front wheel circuit reservoir
 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\achtung.gif

Attention

The front brake lever also applies the rear brakes (integral brakes). Once the brake calipers and brake pads have been removed, operating a brake lever could result in the pistons being pushed out.

Install the brake caliper with brake pads or insert the piston resetting device.

 

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Make sure that the front wheel-circuit reservoir is topped up to the "MAX" mark.

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Install adapter 22 (No. 34 1 533) in piston resetting device (No. 34 1 531) and locator (No. 34 1 532) in both front brake calipers and fully compress the piston resetting device until the adapter cannot move.

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Switch on the ignition.

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Pull handbrake lever until the pistons of the front brake calipers are in contact with piston resetting device (No. 34 1 531).

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Top up the brake fluid in the wheel-circuit reservoir until the (MAX) mark in the filler neck is just touching the surface of the fluid.

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\betriebsm.gif Fluids and lubricants

Brake fluid

Hydraulic systems

 
 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Using piston resetting device (No. 34 1 531), force the brake pistons all the way back and remove, together with adapter 22 (No. 34 1 533).

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Hand-tighten the cap of the wheel-circuit reservoir.

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

If necessary, after removal replace the front brake pads with new pads.

  Installing front brake pads
 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Install the brake pads.

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Install spring (1) with the arrow (arrow) pointing in the forward direction of travel.

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Install pin (3).

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Install retainer (2).

 
 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Check operation of the brake system with the ignition switched on.

 
 
(-) Filling rear wheel circuit
 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\warnung.gif

Warning

Mistakes can be made in repair and maintenance routines if work is carried out by persons who have not received the correct training, or in the event of non-compliance with the specified instructions.

All repair and maintenance work on the BMW Motorrad Integral ABS must be performed by trained, qualified specialists.

Comply with all maintenance and repair instructions and always work through the various steps in the correct order.

 

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\warnung.gif

Warning

Brake fluid is hygroscopic, which means that its boiling point drops once the container has been opened.

Use only new brake fluid from freshly opened containers.

 

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\warnung.gif

Warning

If bubbles of air are trapped in the brake system, rapid pumping could cause them to split into tiny bubbles and create foam in the brake fluid. This would mean that small quantities of entrained air would escape detection in the bleed test with the BMW Motorrad diagnostic system, and braking efficiency would be significantly impaired as a result.

When performing maintenance and repair work on the BMW Motorrad Integral ABS, always operate the brakes slowly. Do not pump quickly or vigorously.

 

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\achtung.gif

Attention

Brake fluid attacks paintwork, plastic and rubber parts.

Do not allow brake fluid to come into contact with paintwork, plastic or rubber parts.

 

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\achtung.gif

Attention

If plugs are disconnected from the pressure modulator, there is a possibility of dirt and brake fluid penetrating inside the housing and causing damage.

Do not disconnect the plugs from the pressure modulator.

 

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Install piston resetting device (No. 34 1 531) and adapter (No. 34 1 536) and force the pistons all the way back.

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Wrap a cloth around the brake caliper.

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad/imgs/icon/bullet.gif

Connect container (No. 34 1 581) to the rear wheel-circuit reservoir with threaded adapter (No. 34 1 582) and sight glass (No. 34 1 583).

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Slowly fill the container with fresh brake fluid until it is approximately 1/3 full.

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\betriebsm.gif Fluids and lubricants

Brake fluid

Hydraulic systems

 
 
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Connect the brake bleeding device to the bleed screw, but do not switch on.

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Use a cable tie to secure the hose of the brake bleeding device to the bleed screw.

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Switch on the ignition.

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Very gently press the footbrake lever until the pump just starts up.

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Open the bleed screw, while topping up the container with new brake fluid if necessary.

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\betriebsm.gif Fluids and lubricants

Brake fluid

Hydraulic systems

 
 
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Warning

Air can be drawn into the system through the fluid replenishing hole if the fluid level in the wheel-circuit reservoir is too low; the system has to be bled again if this happens.

The brake fluid must always be visible in the container, because the piston in the wheel-circuit reservoir must always be covered by the fluid.

 

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Pump out the brake fluid with virtually no pressure to begin with, then vary the brake pressure.

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Note

The higher the brake pressure the faster the fluid is pumped through the system, which means that the level in the wheel-circuit reservoir drops all the more rapidly.


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When the emerging brake fluid is clear and free of bubbles, continue pumping until the fluid in the container just disappears from view.

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Close the bleed screw.

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\Anziehdrehmoment.gif Tightening torques

Brake caliper, rear, bleed screw

 

5 Nm

 
 
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Release the footbrake lever and switch off the ignition.

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Disconnect the brake bleeding device from the bleed screw.

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Disconnect the container from the wheel-circuit reservoir.

 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\warnung.gif

Warning

When the fluid is changed or the brakes bled, the fluid level in the wheel circuits is initially undefined. The level of fluid in the wheel circuit might be too high or too low.

After changing the fluid and/or bleeding the brakes, always bring the fluid in the wheel circuits to the correct level in accordance with the instructions.

 

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Top up the fluid in the wheel-circuit reservoir to the (MAX) mark.

  Instructions for filling rear wheel circuit reservoir
 
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Make sure that the rear wheel-circuit reservoir is topped up to the MAX mark.

 
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Fully compress piston resetting device (No. 34 1 531) and insert it together with adapter for rear brakes, (No. 34 1 536), in the rear brake caliper.

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Switch on the ignition.

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Operate the footbrake lever until the pistons of the rear brake caliper are in contact with piston resetting device (No. 34 1 531) and adapter for rear brakes(No. 34 1 536).

 
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Top up the brake fluid in the wheel-circuit reservoir until the (MAX) mark in the filler neck is just touching the surface of the fluid.

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\betriebsm.gif Fluids and lubricants

Brake fluid

Hydraulic systems

 
 
 
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Remove piston resetting device for integral brakes (No. 34 1 531) and adapter for rear brakes (No. 34 1 536).

 
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Hand-tighten the cap of the rear wheel-circuit reservoir.

 
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Replace the rear brake pads after removal, if necessary

  Installing rear brake pads
 
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Check that spring (1) is correctly seated and installed right way round.

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The engraved arrow points in the forward direction of travel.

 
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Thinly lubricate the backing plates:

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on the rear,

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at the end faces at the pad guides.

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\betriebsm.gif Fluids and lubricants

Never Seez compound (brake-pad paste)

Lubricant

83 19 2 158 852

 
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Install the brake pads.

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Manually install retaining pin (1).

  Securing rear brake caliper
 
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Hold the brake caliper in position and secure with screws (1).

D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\Anziehdrehmoment.gif Tightening torques

Brake caliper to bevel gears

M8 x 25

24 Nm

 
 
 
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Once the work has been completed, seat the pads against the brake discs and check operation of the brake system.

 
 
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Drive in retaining pin (1) until seated.

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Install retainer (2).

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Bed in the brake pads.

 
 
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Check operation of the brake system with the ignition switched on.

 
  Finishing work
 

Connecting BMW Motorrad diagnostic system to motorcycle

 

Performing bleed test with BMW Motorrad diagnostic system

 

Installing fuel tank

 

Reading fault memory with BMW Motorrad diagnostic system

 

Disconnecting BMW Motorrad diagnostic system from motorcycle

 

Installing left side panel

 

Installing left side cover

 

Installing right side panel

 

Installing right side cover

 

Installing seat

 

Final check of work performed