TECDATA TECHNICAL DATABASE FOR MOTORCYCLES ULTRA-PRO / ONLINE
Extensive version for detailed settings, maintenance, mechanical and electronic repairs as well as diagnosis.
We add new brands and models with each update. At the moment the following brands are available in the program:
APRILIA - BMW - DUCATI - HARLEY DAVIDSON - HERO - HONDA - HUSQVARNA - INDIAN - KAWASAKI - KTM - KYMCO - MALAGUTI - MOTO GUZZI - MV AGUSTA - PEUGEOT - PIAGGIO - POLARIS - ROYAL ENFIELD - SUZUKI - SYM - TRIUMPH - VESPA - YAMAHA - ZERO MOTORCYCLES.
LIQUIDS AND LUBRICANTS
With plug location, tightening torques and filling capacities with specifiation of the required oil.
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)
CVTF SAE 75W-90 BMW Synthetik OSP (BMW 83 22 2 445 460)
Gear oil SAE 75W-90 BMW Synthetik OSP (BMW 83 22 2 445 460)
Final drive chain case 0.5 (l)
Fork oil BMW Telescopic Fork Oil Type 2 (BMW 83 19 2 408 581)
• Left fork leg 0.39 (l)
• Right fork leg 0.39 (l)
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
• 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)
Cap pressure 1.5 (bar)
Thermostat opening temperature 82 (°C)
Fan activation temperature 98 (°C)
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
All kinds of tightening torques related to the engine and relevant drawings.
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)
Apply thread-locking compound (M6 x 120)
Exhaust manifold (Apply thread-locking compound) (14 Nm)
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 electrical system
Starting and charging
Air inlet system
Wheels and tyres
Vehicle electrical system
Body – Interior
Body – Exterior
Most important functions and features :
• Combined overview of selected maintenance and repair activities.
3D technical drawings with tighting torques and required parts for brakes, suspension, steering, etc.
REAR DISC BRAKES
FUSES AND RELAYS
Location of fuses and relays with their respective function.
FUSE BOX UNDER THE DRIVER’S SEAT
1  Main fuse (15A)
ELEKTRICAL WIRING DIAGRAMS
|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|
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
After the vehicle has been stationary for 6 months or longer.
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.
AIR FILTER REMOVAL / INSTALLATION
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 is in the reverse order of removal.
Fuel tank front mounting bracket: 10 Nm
Damaged gear- change forks, sliding sleeves or gearwheels.
28/10/2019 RM/2019/025 (232300)
Date 2015-09-22 - 2019-09-26
Difficult or not possible to change gear.
Number of vehicles affected: 1070
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||V|
|Service schedules based on OEM||V|
|Liquids and lubricants||V|
|Adjustment data: Engine and Cooling system||V|
|Brakes / Wheels and tires||V|
|Detailed technical drawings + tightening torques||V|
|Fuses and relays||V|
|Known problems and solutions||V|
|Extensive, interactive wiring diagrams||V|
|Diagnosis via trouble code||V|