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TECDATA TECHNICAL DATABASE FOR MOTORCYCLES ULTRA-PRO / ONLINE 

Extensive version for detailed settings, maintenance, mechanical and electronic repairs as well as diagnosis.

LIQUIDS AND LUBRICANTS

With plug location, tightening torques and filling capacities with specifiation of the required oil.

ENGINE


Engine oil (Do not use oil additives) SAE 15W-50 API SJ
Engine oil (Do not use oil additives) SAE 15W-50 JASO MA2
Coolant (Water with 50% anti-freeze) BMW 83 51 2 445 463
• Engine sump, including filter (Dry sump) 3.1 (l)
• Plug location


• Engine oil tank 2.8 (l)
• Cooling system 1.5 (l)
• Engine oil drain plug 28 (Nm)
• Coolant drain plug 10 (Nm)

REDUCTION GEARBOX
CVTF SAE 75W-90 BMW Synthetik OSP (BMW 83 22 2 445 460)

FINAL DRIVE
Gear oil SAE 75W-90 BMW Synthetik OSP (BMW 83 22 2 445 460)
Final drive chain case  0.5 (l)

SUSPENSION
Fork oil BMW Telescopic Fork Oil Type 2 (BMW 83 19 2 408 581)
Front fork
• Left fork leg 0.39 (l)
• Right fork leg 0.39 (l)

 

ADJUSTMENT DATA

All kinds of settings and specifications for engine, cooling system, brakes, tyres and wheels.

ENGINE ( GENERAL )
Number of cylinders 1
Valves per cylinder 4

ENGINE ( SPECIFICATIONS )
Engine management ( mark and type ) BMS-E2
Throttle grip freeplay 2.0 - 3.0 (mm)
Valve clearance Cold
• Inlet 0.16 - 0.24 (mm) / Exhaust 0.34 - 0.42 (mm)
Idle speed ( Engine at operating temperature ) 1400 – 1500 (rpm)
Fuel pump pressure 3.5 (bar)
Spark plugs (mark and type) NGK LMAR8J-9E
Spark plug gap 0.8 - 1.0 (mm)
Number of spark plugs 1
Compression pressure
• Normal pressure 6.0 - 8.0 (bar) / Minimum pressure 6.0 (bar)
Oil pressure at idle speed (Engine oil temperature at least 80 °C) 0.4 (bar)
Oil pressure (Engine oil temperature at least 80 °C ) 4.0 /6000 (bar/rpm)

COOLING SYSTEM
Cap pressure 1.5 (bar)
Thermostat opening temperature 82 (°C)
Fan activation temperature 98 (°C)

BRAKES
Front disc brakes
Front disc brakes 265.0 (mm)
Disc diameter, front 265.0 (mm)
Disc thickness, front 5.0 (mm)
Disc thickness, front, minimum 4.5 (mm)
Brake pad thickness, front, minimum 1.0 (mm)
Disc run-out, maximum (front) 0.15 (mm)

Rear disc brakes
Disc diameter, rear 265.0 (mm)
Disc thickness, rear 5.0 (mm)
Disc thickness, rear, minimum 4.5 (mm)
Brake pad thickness, rear, minimum 1.0 (mm)
Disc run-out, maximum (rear) 0.15 (mm)

WHEELS AND TYRES
Tyre size and pressure
Front tyre size 120/70 R15
Front tyre pressure ( Rider only ) 2.2 (bar)
Front tyre pressure (Rider and passenger) 2.4 (bar)
Front wheel rim size 3.5x15
Rear tyre size 150/70 R14
Rear tyre pressure (Rider only) 2.4 (bar)
Rear tyre pressure (Rider and passenger) 2.9 (bar)
Rear wheel rim size 4.25x14

 

TORQUE SETTINGS

All kinds of tightening torques related to the engine and relevant drawings.

Engine
Note: Always renew stretch bolts and self-locking nuts
Cylinder head (nuts) (Threads lightly oiled)

   


Stage 1 10 (Nm)
Stage 2 30 (Nm)
Stage 3 135 (°)
Cylinder head (M6 bolts) (Threads lightly oiled) 10 (Nm)
Valve cover (Tighten the bolts in a criss-cross pattern) 10 (Nm)
Crankcase (Renew the bolts, threads lightly oiled)
Stage 1 (Pre-tighten the bolts until full surface contact is made)
Stage 2 (Bolts 1-6) 10 (Nm)
Stage 3 (Bolts 7-14) 10 (Nm)

 

  Crankcase cover

Apply thread-locking compound (M6 x 120)
Stage 1 (Pre-tighten the bolts until full surface
contact is made)
Stage 2 3 (Nm)
Stage 3 10 (Nm)
Engine oil drain plug 15(Nm)
Spark plugs 12 (Nm)
Oil filter 11(Nm)
Oxygen sensor 25(Nm)
Starter motor 10(Nm)
Camshaft gearwheel 45(Nm)
Renew the nut (Apply thread-locking compound)
Timing chain tensioner 10(Nm)
Timing cover (Renew the O-ring) (10Nm)

Exhaust manifold (Apply thread-locking compound) (14 Nm)
Inlet manifold 10 (Nm)
Coolant pump housing 10 (Nm)
(Tighten the bolts in a criss-cross pattern)
Coolant drain plug(s) 9 (Nm)
Fuel tank 8 (Nm)
Renew the bolts (Apply thread-locking compound)
Thermostat housing 10 (Nm)
Oil pump 10 (Nm)
Oil pump gearwheel 25 (Nm)
(Renew the nut)
Oil pump chain guide rail 10 (Nm)
(Apply thread-locking compound)

 

REPAIR TIMES

PRICE OFFER
The price is the starting point for fast cost estimations based on intelligent links between data, repair times and parts. The result can be easily exported in order to use when ordering parts.
Engine assembly
Lubrication system
Cooling system
Engine electrical system
Starting and charging
Air inlet system
Fuel system
Manual transmission
Drive train
CVT
Steering
Rear suspension
Axle
Wheels and tyres
Brakes (mechanical)
Brakes (electric)
Vehicle electrical system
Security system
Instrument cluster
Exterior lights
Body – Interior
Body – Exterior
...
 

 Engine assembly
Checks – adjustments

1A00003000WV0 Check the cylinder compression            OE: 11 00 539                0,33

Engine assembly

 

1A00003000WV0 Renew the engine block   
OE: 11 00 539
0,33
1A00322200NWV0 Remove/refit the engine block          OE: 11 11 514  

 Engine cover

1A00051500WV0 Remove/refit the engine cover            OE: 11 14 085 0,33
1A00051550WV0 Renew the engine cover                 OE: 11 14 085  

 

 Piston

1A00326120NWV0 Remove/refit one cylinder                  OE: 11 11 150 0,33
1A00326120N1WV0 Renew one cylinder                        OE: 11 11 150   1,00
1A04010999WV0 Remove/refit the piston                       OE: 11 11 054 0,50
1A04011000WV0 Renew the piston                                OE: 11 11 054 0,50
1A20080000MWV0 Renew all connecting rod bearings        OE: 11 24 549 0,30
1A20080000NMWV0 Remove/refit all the connecting rod bearings    OE: 11 24 549 0,30

 

 

 

Most important functions and features :

•    Combined overview of selected maintenance and repair activities.

•    Ability to add activities and parts manually.

 

 

 

 

 

TECHNICAL DRAWINGS

3D technical drawings with tighting torques and required parts for brakes, suspension, steering, etc.

REAR DISC BRAKES

 

REAR SUSPENSION

 

FUSES AND RELAYS

Location of fuses and relays with their respective function.

FUSE BOX UNDER THE DRIVER’S SEAT

           

1 [1] Main fuse (15A)
2 [2] ABS solenoid (15A)
3 [3] Main fuse (7.5A)
4 [4] Rear lights (7.5 A)
5 [5] Direction indicators (7.5 A)
6 [6] ABS control unit (7.5A)
7 [7] ABS motor (30A)
8 [8.1] Not used
9 [8.2] Not used
10 [8.3] Not used

 

 

ELEKTRICAL WIRING DIAGRAMS

Electrical wiring diagrams for electrical systems and components such as engine management,  exterior lights, safety systems, etc.
 
A1 INJECTOR
 
 
 
  
Pin number Wire colour Component Pin number Wire colour
1 Red/Blue A1 Injector 2 1 Red/Blue
1 Red/Blue E1 Engine control unit 5 Red/Blue
1 Red/Blue I1 Ignition coil 1 1  
1 Red/Blue I1 Ignition coil 2 1 Red/Black
1 Red/Blue R3 Fuel pump relay 86  
1 Red/Blue R56 Relay battery-shutdown 86 Red/Black
1 Red/Blue S314 Steering switch right 4 Red/Black
2 Red/Black E1 Engine control unit 33 Red/Black

 

COMPONENT DIAGNOSIS

 

A unique, step-by-step guided diagnosis to detect and sort out electronic malfunctions.
 
 
 
Diagnosis 1/12
1: Check the supply voltage:

Turn the ignition on. Measure the voltage on pin 1. Is it between 12 and 14.4 V?  Yes  No

2: Check the connection to ground:
3: Check the connectivity of pin 15:
4: Check the supply voltage:
5: Check the connection to ground:
6: Check the connectivity of pin 15.
7: Check the supply voltage:
8: Check the connection to ground.
9: Check the connectivity of pin 16.
10: Check the connectivity of pin 16.
11: Check the connectivity of pin 2.
12: Check the connectivity of pin 20.
 
 

KNOWN PROBLEMS AND SOLUTIONS

SMARTPACK
 
Engine does not start; Injector failure.
 
    Symptom
 
The engine does not start.
Injector failure.
 
Conditions when the symptoms appear:
After the vehicle has been stationary for 6 months or longer.

    Cause
Poor-quality fuel.

    Solution

Test the injectors one by one.
Follow the procedure.
Remove the fuel injector..

Clean the injector.
Connect the starter motor switch and the injector to the injector supply wire.
Connect the injector supply wire to the battery.
Use a fully charged battery 12 - 14 V.
Press the starter motor switch.
A clicking noise should be heard.
If no clicking noise is heard, repeat the procedure 3 times.
If the clicking noise is still not heard, renew the injector.
Repeat the procedure for the other fuel injectors.
 

 

REPAIR INSTRUCTIONS

AIR FILTER REMOVAL / INSTALLATION

Removal

Remove the fuel tank.
Remove the fuel tank lower cover.
Remove the engine control unit.
Remove the fuel tank front mounting bracket.


Remove the plug.
Remove the air filter cover.

Remove the air filter.

Installation:

Installation is in the reverse order of removal.

 

Torque settings:

Fuel tank front mounting bracket: 10 Nm 

 

RECALLS

 

Damaged gear- change forks, sliding sleeves or gearwheels.
28/10/2019 RM/2019/025 (232300)
Date 2015-09-22 - 2019-09-26

Problem
Difficult or not possible to change gear.
Number of vehicles affected: 1070

Solution
Renew the sliding sleeves for the fifth and sixth gear-change forks
Renew the sixth gear gearwheel.

 

 

LOCATION DIAGNOSTIC CONNECTOR



 

 

 

 

 CONTENT TECDATA TECHNICAL DATABASE FOR MOTORCYCLES ULTRA-PRO / ONLINE

 

The table below gives a clear summary of the subjects that are covered in the Tecdata Technical Database ULTRA-PRO / ONLINE for Adjustments and Maintenance plus Diagnostics and Repair.

 

 

ULTRA-PRO / MOTO

 

Settings and Maintenance +

Diagnostics and Repair

Vehicle identification + VIN decoder
Service schedules based on OEM V
Liquids and lubricants V
Adjustment data: Engine and Cooling system V
Brakes / Wheels and tires  V
Repair times V
Repair manuals V
Detailed technical drawings + tightening torques V
Recalls V
Fuses and relays V
Known problems and solutions V
Trouble codes V
Extensive, interactive wiring diagrams V
Component diagnosis V
Diagnosis via trouble code V

 

 

 

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