Engine:
Full disassembly, inspection, repair, and reassembly of the K589 engine, including valve train, crankshaft, pistons, cylinders, lubrication system, and cooling system.
Fuel System:
Bosch Motronic fuel injection system, throttle bodies, fuel pump, fuel injectors, pressure regulator, and diagnostic procedures.
Ignition System:
Motronic ignition control, coil packs, spark plugs, timing adjustments, and diagnostic trouble codes.
Transmission:
Six-speed sequential gearbox, clutch system, shift mechanism, lubrication, and common repair procedures.
Drivetrain:
Paralever rear drive system, driveshaft, universal joints, final drive unit lubrication and maintenance.
Suspension Front:
Telescopic forks, damping adjustment, seals, springs, and fork oil specifications.
Suspension Rear:
Monolever rear suspension, shock absorber, spring preload adjustment, damping, and pivot point maintenance.
Brakes Front:
Dual disc brakes, ABS II (if equipped), brake calipers, master cylinder, brake lines, fluid specifications, and bleeding procedures.
Brakes Rear:
Single disc brake, brake caliper, master cylinder, brake lines, fluid specifications, and bleeding procedures.
Electrical System:
Complete wiring diagrams, battery, alternator, starter motor, lighting systems, fuses, relays, and diagnostic procedures.
Instrumentation:
Speedometer, tachometer, fuel gauge, warning lights, and associated sensor diagnostics.
Chassis Frame:
Frame construction, steering head bearing maintenance, and component mounting points.
Bodywork Fairings:
Removal and installation of fairings, body panels, seat, and wind deflector.
Maintenance:
Scheduled maintenance tasks, oil changes, filter replacements, spark plug changes, brake fluid flushes, coolant changes, and general inspection points.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon problems, including symptom analysis and component testing.
Repair:
Detailed, step-by-step instructions for component disassembly, repair, and reassembly for all major vehicle systems.
Rebuilds:
Complete engine and transmission rebuild procedures with torque specifications and tolerances.
Adjustments:
Valve clearance adjustments, throttle cable adjustments, clutch lever free play, and suspension settings.
Depth:
Comprehensive; covers everything from routine maintenance to full engine and transmission overhauls, including electrical system diagnostics and wiring diagrams.
Engine Type:
Four-stroke, liquid-cooled, flat-four (boxer)
Bore X Stroke:
77.6 mm x 63.7 mm
Compression Ratio:
11.0:1
Valve Train:
DOHC, 4 valves per cylinder
Horsepower Approx:
110 hp @ 7500 rpm
Torque Approx:
115 Nm (85 lb-ft) @ 6000 rpm
Fuel Delivery:
Electronic Fuel Injection (Bosch Motronic MA 2.4)
Fuel Type:
Unleaded gasoline, minimum 95 RON
Oil Type:
SAE 20W-40 or 20W-50 API SG or higher
Oil Capacity W Filter:
Approximately 4.5 liters (4.7 US quarts)
Coolant Type:
BMW approved ethylene glycol-based coolant with corrosion inhibitors.
Coolant Capacity:
Approximately 3.2 liters (3.4 US quarts)
Oil Change Interval:
Every 10,000 km (6,200 miles) or annually.
Air Filter Replacement:
Inspect every 10,000 km, replace as needed or every 20,000 km.
Spark Plug Replacement:
Replace every 20,000 km.
Brake Fluid Flush:
Every 2 years, regardless of mileage.
Coolant Flush:
Every 2 years or 30,000 km.
Valve Clearance Check:
Every 20,000 km or as specified.
Engine Oil Specification:
SAE 20W-40 or 20W-50 API SG or higher
Brake Fluid Specification:
DOT 4 brake fluid
Coolant Specification:
BMW approved ethylene glycol coolant
Final Drive Oil Specification:
SAE 90 hypoid gear oil API GL-5
Common Problem 1:
Rear main seal leaks (potential for oil seepage).
Common Problem 2:
ABS modulator failure (particularly on earlier ABS II systems).
Common Problem 3:
Stiff clutch actuation (often due to clutch slave cylinder seal issues).
Common Problem 4:
Fuel pump wear (can lead to intermittent starting or running issues).
Common Problem 5:
Electrical connector corrosion (can cause intermittent faults).
