MC130124

2/13/24, 5:21 AM
13 01 24_SERVICE ACTION: Fuel Line Hose Clamp
SIB 13 01 24
SERVICE ACTION: Fuel Line Hose Clamp
2024-02-12
MODEL
Model
K48 MU2
K48 MU2
K61 MUE
Model Description
K 1600 GT
K 1600 GTL
K 1600 B
Model Type
0F23
0F33
0F63
The affected vehicles have been marked with campaign number 0013390000 in AIR.
In order to determine if a specific motorcycle is affected by this campaign, it will be necessary to verify the
vehicle VIN in AIR (Aftersales Information Research). Based on the response of the system, either proceed
with the repair or take no further action. Please note, open campaigns or vehicle stops may not appear in
DCS Warranty Vehicle Inquiry or sales systems until 24-72 hours after they are announced, therefore AIR is
always the recommended method for determining open campaigns and vehicle stops.
SITUATION
After close inspection it has been found that the Hose clamp on the fuel line may be insufficiently crimped at
the quick connection coupling at the fuel pump.
During starting operation, a higher pressure occurs in the fuel system than while driving. Due to this
increased pressure during starting operation, the fuel line can move on the quick connection and may slip off
the quick connection completely. As a result, small amounts of fuel can leak out and the engine cannot be
started.
The affected vehicles have been placed under the delivery stop STOP130011 associated with campaign
number 0013390000, which will be lifted upon completion of this technical campaign.
Since 01/29/2024, only vehicles without this fault pattern are produced in series.
PROCEDURE
For vehicles that have not yet been delivered, the service action must be completed before vehicle
handover.
In all instances in which the vehicles have already been handed over to customers, the customers must be
made aware of the situation described above and asked to have the Technical Campaign carried out.
The position of the fuel line on the quick connection coupling must be checked according to the model
specific repair instructions “00 60 436 – Reworking hose clamp”.
1. If the position is correct, the existing hose clip only needs to be crimped tighter in accordance with the
repair instructions.
2. If the position is incorrect, the position of the fuel line must be reworked according to the repair
instructions and correctly secured with a new fuel line clamp.
Copyright ©2024 MOTORRAD USA, a division of BMW of North America, LLC. All Rights Reserved
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2/13/24, 5:21 AM
13 01 24_SERVICE ACTION: Fuel Line Hose Clamp
Correct position of the fuel hose
Specified closed size for single-eye clip (A): 2.5 –
4.0 mm
PARTS INFORMATION
Obtain and confirm the part numbers for your specific vehicle by entering the chassis number in ETK which
takes into account specific equipment and/or options.
Additional parts like gaskets, hardware and chemicals may be required for the complete repair.
Part Number (if required)
13 31 7 671 344
Fuel line clamp
CLAIM INFORMATION
Please submit claims via the normal claim process using the information below:
Defect code
00 13 39 00 00
Reworking fuel line hose clamp
Labor Operation
00 60 436
+00 60 936
00 60 436
+00 60 936
Rework fuel line hose clamp (K 1600 GT, K 1600 B)
Rework fuel line hose clamp (K1600 GT, K 1600 B)
Rework fuel line hose clamp (K 1600 GTL)
Rework fuel line hose clamp (K1600 GT)
12 FRU
11 FRU
13 FRU
12 FRU
FRUs includes all repair procedures to complete the task with allowance for necessary ancillary tasks (e.g.,
visual inspection, lubrication, cleaning parts etc.) and administrative tasks.
Labor operation code 00 60 436 is a Main labor operation. If you are using a Main labor code for another
repair, use the Plus code labor operation instead.
QUESTIONS REGARDING THIS BULLETIN
Technical inquiries
Warranty inquiries
Parts inquiries
Contact the BMW Technical Support Group via TSARA
Submit an IDS ticket to the Warranty Department
Submit an IDS ticket to the Motorrad Parts Department
Supporting Materials
picture_as_pdf RM_0060436_0F61_EN.pdf
picture_as_pdf RM_0060436_0F21_EN.pdf
picture_as_pdf RM_0060436_0F31_EN.pdf
Copyright ©2024 MOTORRAD USA, a division of BMW of North America, LLC. All Rights Reserved
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2/13/24, 5:21 AM
13 01 24_SERVICE ACTION: Fuel Line Hose Clamp
picture_as_pdf 13 01 21 Service Action - Fuel Hose Clamp.pdf
Copyright ©2024 MOTORRAD USA, a division of BMW of North America, LLC. All Rights Reserved
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2/13/24, 5:21 AM
13 01 24_SERVICE ACTION: Fuel Line Hose Clamp
Copyright ©2024 MOTORRAD USA, a division of BMW of North America, LLC. All Rights Reserved
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Order No.
1
0F21 - K 1600 GT
00 60 436 Rework hose clip
1
Removing rider’s seat
Unlock seat lock using the ignition key (1).
Lift rider's seat (2) and disconnect plug connection (3)
for seat heating.
Take off rider's seat (2).
2
Removing left bottom side panel
Remove screws (1).
Remove bottom fairing side panel (2) and detach retaining lug (arrow).
Order No.
2
3
Removing cover for left intake snorkel
Remove screw (1).
Remove cover (2).
4
Removing left side panel
ATTENTION
Scratches and damage to trim panel components
Component damage
Do not use sharp-edged or hard tools.
Use tools made of plastic, for example.
Turn slipstream deflector (1) to the side.
Remove bolt (2).
Remove expanding rivet (1) and press pin (2) down with
suitable tool.
Order No.
3
Remove screws (1).
Remove screws (1).
Loosen top fairing side panel (2), noting retaining
clip (arrow).
Pull off fairing side panel (2) from mounting pin (3) to
the top.
Remove fairing side panel (2).
5
Removing right bottom side panel
Remove screws (1).
Remove bottom fairing side panel (2) and detach retaining lug (arrow).
Order No.
4
6
Removing cover for right intake snorkel
Remove screw (1).
Remove cover (2).
7
Removing right side panel
ATTENTION
Scratches and damage to trim panel components
Component damage
Do not use sharp-edged or hard tools.
Use tools made of plastic, for example.
Turn slipstream deflector (1) to the side.
Remove bolt (2).
Remove expanding rivet (1) and press pin (2) down with
suitable tool.
Order No.
5
Remove screws (1).
Remove screws (1).
Loosen top fairing side panel (2), noting retaining
clip (arrow).
Pull off fairing side panel (2) from mounting pin (3) to
the top.
Remove fairing side panel (2).
8
Removing complete fuel-tank cover
Removing left fuel-tank cover top section
Remove screws (1).
Remove upper tank cover section (2).
Order No.
6
with audio system OE (0268)
or
with US audio system OE (0270)
Remove screws (1).
Loosen upper tank cover section (2).
with audio system OE (0268)
Disconnect pink connector (1) for DAB foil antenna and
black connector (2) for FM foil antenna.
Remove left upper tank cover section (3).
Removing right fuel-tank cover top section
Remove screws (1).
Remove upper tank cover section (2).
with audio system OE (0268)
or
with US audio system OE (0270)
Remove screws (1).
Loosen upper tank cover section (2).
Order No.
7
with audio system OE (0268)
or
with US audio system OE (0270)
Disconnect connector (1) for AM foil antenna and remove right upper tank cover section (2).
Removing left fuel-tank cover
Remove screws (1) and screw (2).
Remove screws (1).
Remove tank cover (1).
Order No.
8
Removing right fuel-tank cover
Remove screws (1) and screw (2).
Remove screws (1).
Remove tank cover (1).
Order No.
9
Removing centre fuel-tank cover
Remove screws (1) and (2).
with Keyless Ride OE (0193)
Remove the cable straps (arrows).
Remove screw (1).
Remove fuel-tank cover (2).
Order No.
10
9
Remove rear left interior trim
Remove screws (1).
Remove rear interior trim (2).
with audio system OE (0268)
or
with US audio system OE (0270)
Disconnect plug connection (1) for operating facility.
Remove screws (2).
Remove rear interior trim (3).
10
Removing rear right interior trim
Remove screws (1).
Loosen rear interior trim (2).
Disconnect plug connection (3) for the on-board socket.
Remove rear interior trim (2).
Order No.
11
11
Removing seat support
Unclip diagnostic socket (1) and hang to the side.
Remove body-bound rivets (2).
Remove screws (3).
Remove seat support (4).
12
Disengaging left intake air pipe
Loosen left intake snorkel (1) from holder (2).
13
Removing complete intake air silencer
without Japan export NV (0742)
Disconnect plug connection (1) for RDC control unit and
release cable (2) from holder (3).
Order No.
12
Disconnect plug connection (1) for secondary air valve
and disconnect cable (2).
Loosen the screw clamp (3) and pull off the vent
hose (4).
Loosen clamp (5) with pliers (17 5 571) and pull off
vent hose (6).
Remove clips (1) with washers (2) on left and right.
Disconnect plug connection (1) for intake air temperature sensor.
Remove screw (2) with contact disc (3).
Release the cable (4) from the holder (arrow).
Pull off hose (5) for secondary air system.
Remove intake silencer (6) completely and feed out
hose (7) at the same time.
with Japan export NV (0742)
Disconnect plug connection (1) for intake air temperature sensor.
Remove screw (2) with contact disc (3).
Pull off hose (4) for secondary air system.
Remove intake silencer (5) completely and feed out
hose (6) at the same time.
Order No.
13
14
Rework hose clip.
Disconnect fuel line (1).
Check that hose clip (2) and fuel line (3) are correctly
installed and not loose.
If hose clip (2) and fuel line (3) are correctly installed,
secure hose clip correctly.
If hose clip (2) and fuel line (3) are not correctly installed, install fuel line correctly and replace hose clip.
Check
Technical data
Dimension a
(distance from
end of hose to
quick-release
coupling)
0+2 mm
Dimension
b (distance
from quickrelease coupling to hose
clamp)
7+2 mm
Result
Dimension a and b are not met.
Measure
Replace hose clip.
Remove hose clip (1).
Disconnect fuel line (2) from quick-release coupling (3).
Clean and lubricate quick-release coupling (3) in the
marked area.
Use only brake cleaner or fuel for lubrication.
Do NOT use silicone spray or similar.
Push new hose clip (1) onto fuel fuel line (2).
Push fuel line (2) onto quick-release coupling (3).
After pushing on, wait for approx. 10 - 15 min until lubricating material has evaporated.
Align new hose clip (1) with quick-release coupling (3) (arrows) and secure correctly (13 1 500)to
dimension (A) using pliers.
Technical data
Dimension
b (specified
closed size
for single-eye
clip on quickrelease coupling)
2.5+1.5 mm
Order No.
14
Result
Dimension a and b are met.
Measure
Correctly secure hose clip using pliers.
Correctly secure hose clip (1) (13 1 500) to dimension (A) using pliers.
Technical data
2.5+1.5 mm
Dimension
b (specified
closed size
for single-eye
clip on quickrelease coupling)
Check O-ring (2) for damage; replace if necessary.
Connect fuel line (3) to fuel tank (4).
15
Installing complete intake air silencer
Install intake silencer (6) and insert hose (7) at the same
time.
Install bolt (2) with contact disc (3).
Tightening torques
Intake air silencer to frame
M6 x 30
Thread-locking compound (mechanical)
8 Nm
Slide on hose (5) for secondary air system.
Secure the cable (4) in the holder (arrow).
Connect plug connection (1) for intake air temperature
sensor.
with Japan export NV (0742)
Install intake silencer (5) and insert hose (6) at the same
time.
Install bolt (2) with contact disc (3).
Tightening torques
Intake air silencer to frame
M6 x 30
Thread-locking compound (mechanical)
8 Nm
Slide on hose (4) for secondary air system.
Connect plug connection (1) for intake air temperature
sensor.
Order No.
15
Install washers (2) with clips (1) on left and right.
Slide on vent hose (6) and fasten clamp (5) with pliers
(17 5 571).
Slide on vent hose (4) and fasten screw clamp (3).
Connect plug connection (1) for secondary air valve and
secure cable in holder (2).
without Japan export NV (0742)
Connect plug connection (1) for RDC control unit and
secure cable (2) in holder (3).
Order No.
16
16
Securing left intake air pipe
Secure intake snorkel (1) in holder (2).
17
Installing seat support
Install seat support (3).
Install screws (2).
Tightening torques
Seat support to frame
M6 x 16
10 Nm
Clip diagnosis plug (1) into position.
18
Installing rear right interior trim
Position rear interior trim (1), paying attention to the retaining lug (2) while doing so.
Connect plug (3) for the on-board socket.
Install screws (4).
Order No.
17
19
Install rear left interior trim
Position rear interior trim (1), paying attention to the retaining lug (2) while doing so.
Install screws (3).
with audio system OE (0268)
or
with US audio system OE (0270)
Position rear interior trim (1), paying attention to the retaining lug (2) while doing so.
Install screws (3).
Connect plug connection (4) for operating facility.
20
Installing complete fuel-tank cover
Installing centre tank cover
Hold fuel-tank cover (2) in position.
Install handlebar end plug (1).
Order No.
18
with Keyless Ride OE (0193)
Close the cable strap (arrows).
Install screws (1) and (2).
Installing right fuel-tank cover
Hold tank cover (1) in position, noting the retaining
lugs (arrows).
Install tank cover (1).
Order No.
19
Install screws (1).
Install screws (1) and screw (2).
Installing left fuel-tank cover
Hold tank cover (1) in position, noting the retaining
lugs (arrows).
Install tank cover (1).
Order No.
20
Install screws (1).
Install screws (1) and screw (2).
Installing right fuel-tank cover top section
with audio system OE (0268)
or
with US audio system OE (0270)
Position right upper tank cover section (2) and connect
connector (1) for AM foil aerial.
Position upper tank cover section (1), noting retaining
tabs (2) and retaining lugs (arrows).
Order No.
21
Install upper tank cover section (2).
Install screws (1).
Installing left fuel-tank cover top section
with audio system OE (0268)
Position left upper tank cover section (3).
Connect pink connector (1) for DAB foil antenna and
black connector (2) for FM foil antenna.
Position upper tank cover section (1), noting retaining
tabs (2) and retaining lugs (arrows).
Install upper tank cover section (2).
Install screws (1).
Order No.
22
21
Installing right side panel
Slide fairing side panel (2) onto mounting pin (3).
Secure top fairing side panel (2) with retaining
clip (arrow).
Install screws (1).
Install screws (1).
Turn slipstream deflector (1) to the side.
Install bolt (2).
Order No.
23
Install expanding rivet (1) and slide pin (2) into expanding rivet (1).
22
Installing cover for right intake snorkel
Install cover (2), paying attention to the retaining lug (3)
and engaging that correctly.
Install handlebar end plug (1).
23
Install the right bottom side panel
Install bottom fairing side panel (2) and engage retaining
lug (arrow).
Install screws (1).
Order No.
24
24
Installing left side panel
Slide fairing side panel (2) onto mounting pin (3).
Secure top fairing side panel (2) with retaining
clip (arrow).
Install screws (1).
Install screws (1).
Turn slipstream deflector (1) to the side.
Install bolt (2).
Order No.
25
Install expanding rivet (1) and slide pin (2) into expanding rivet (1).
25
Installing cover for left intake snorkel
Install cover (2), paying attention to the retaining lug (3)
and engaging that correctly.
Install handlebar end plug (1).
26
Installing left bottom side panel
Install bottom fairing side panel (2) and engage retaining
lug (arrow).
Install screws (1).
Order No.
26
27
Installing rider’s seat
Position rider's seat (2) and connect plug connection (3)
for seat heating.
Install rider's seat (2) checking that seat lock (1) locks.
28
Final check of work performed
Check the following:
The work as performed achieved the intended purpose.
All reservoirs and containers have been filled and all fluids and lubricants are at their correct levels.
All threaded fasteners released beforehand have been
correctly retightened.
The fuel system is free of leaks.
The lights and signalling equipment are fully operational
and the vehicle is roadworthy.
The brake pads of the front and rear brakes are bedded
against the brake discs.
Function test, engine start suppression
Check
Set kill switch to "ON" position.
Select neutral.
Switch on the ignition.
Neutral telltale light "N" lights up.
Select a gear.
Neutral telltale light "N" goes out.
Press the starter button.
Starter does not operate.
Extend the side stand.
Pull the clutch lever.
Press the starter button.
Starter does not operate.
Retract the side stand.
Press the starter button without releasing the clutch
lever.
Starter operates.
Order No.
27
Result
Not all test steps completed successfully.
Measure
Check the appropriate parts with the BMW Motorrad
diagnostic system.
Order No.
1
0F31 - K 1600 GTL
00 60 436 Rework hose clip
1
Removing seat
Open the seat lock with ignition key (1).
Slightly lift seat (2) and disconnect plug (3) for the seat
heating.
Remove seat (2).
2
Removing left bottom side panel
Remove screws (1).
Remove bottom fairing side panel (2), disengaging the
retaining lug (arrow).
Order No.
2
3
Removing cover for left intake snorkel
Remove screw (1).
Remove cover (2).
4
Removing left side panel
ATTENTION
Scratches and damage to trim panel components
Component damage
Do not use sharp-edged or hard tools.
Use tools made of plastic, for example.
Turn slipstream deflector (1) to one side.
Remove screw (2).
Remove expanding rivet (1), press pin (2) down using
suitable tool while doing so.
Order No.
3
Remove screws (1).
Remove screws (1).
Disengage fairing side panel (2), paying attention to retaining clip (arrow).
Pull fairing side panel (2) out of mounting pin (3) to the
top.
Remove side panel (2).
5
Removing right bottom side panel
Remove screws (1).
Remove bottom fairing side panel (2), disengaging the
retaining lug (arrow).
Order No.
4
6
Removing cover for right intake snorkel
Remove screw (1).
Remove cover (2).
7
Removing right side panel
ATTENTION
Scratches and damage to trim panel components
Component damage
Do not use sharp-edged or hard tools.
Use tools made of plastic, for example.
Turn slipstream deflector (1) to one side.
Remove screw (2).
Remove expanding rivet (1), press pin (2) down using
suitable tool while doing so.
Order No.
5
Remove screws (1).
Remove screws (1).
Disengage fairing side panel (2), paying attention to retaining clip (arrow).
Pull fairing side panel (2) out of mounting pin (3) to the
top.
Remove fairing side panel (2), paying attention to
bracket (4).
8
Removing complete fuel-tank cover
Removing left fuel-tank cover top section
Remove screws (1).
Loosen upper tank cover section (2).
Order No.
6
Remove cable strap (arrow).
Disconnect pink connector (1) for DAB foil antenna and
black connector (2) for FM foil antenna.
Remove left upper tank cover section (3).
Removing right fuel-tank cover top section
Remove screws (1).
Loosen upper tank cover section (2).
Disconnect white connector (1) for AM foil antenna and
remove right upper tank cover section (2).
Removing left fuel-tank cover
Remove screws (1) and screw (2).
Order No.
7
Remove screws (1).
Remove tank cover (1).
Removing right fuel-tank cover
Remove screws (1) and screw (2).
Remove screws (1).
Order No.
8
Remove tank cover (1).
Removing centre fuel-tank cover
Remove screws (1) and (2).
with Keyless Ride OE (0193)
Remove the cable straps (arrows).
Remove screw (1).
Remove fuel-tank cover (2).
Order No.
9
9
Remove rear left interior trim
Disconnect plug connection (1) for operating facility.
Remove screws (2).
Remove rear interior trim (3).
10
Removing rear right interior trim
Remove screws (1).
Loosen rear interior trim (2).
Disconnect plug connection (3) for the on-board socket.
Remove rear interior trim (2).
11
Removing seat support
Unclip diagnosis plug (1) and allow it to dangle to one
side.
Remove screws (2).
Remove seat support (3).
Order No.
10
12
Disengaging left intake air pipe
Loosen left intake snorkel (1) from holder (2).
13
Removing complete intake air silencer
without Japan export NV (0742)
Disconnect plug connection (1) for RDC control unit and
release cable (2) from holder (3).
Disconnect plug connection (1) for secondary air valve
and disconnect cable (2).
Loosen the screw clamp (3) and pull off the vent
hose (4).
Loosen clamp (5) with pliers (17 5 571) and pull off
vent hose (6).
Order No.
11
Remove clips (1) with washers (2) on left and right.
Disconnect plug connection (1) for intake air temperature sensor.
Remove screw (2) with contact disc (3).
Release the cable (4) from the holder (arrow).
Pull off hose (5) for secondary air system.
Remove intake silencer (6) completely and feed out
hose (7) at the same time.
with Japan export NV (0742)
Disconnect plug connection (1) for intake air temperature sensor.
Remove screw (2) with contact disc (3).
Pull off hose (4) for secondary air system.
Remove intake silencer (5) completely and feed out
hose (6) at the same time.
Order No.
12
14
Rework hose clip.
Disconnect fuel line (1).
Check that hose clip (2) and fuel line (3) are correctly
installed and not loose.
If hose clip (2) and fuel line (3) are correctly installed,
secure hose clip correctly
If hose clip (2) and fuel line (3) are not correctly installed, install fuel line correctly and replace hose clip.
Check
Technical data
Dimension a
(distance from
end of hose to
quick-release
coupling)
0+2 mm
Dimension
b (distance
from quickrelease coupling to hose
clamp)
7+2 mm
Result
Dimension a and b are not met.
Measure
Replace hose clip.
Remove hose clip (1).
Disconnect fuel line (2) from quick-release coupling (3).
Clean and lubricate quick-release coupling (3) in the
marked area.
Use only brake cleaner or fuel for lubrication.
Do NOT use silicone spray or similar.
Push new hose clip (1) onto fuel fuel line (2).
Push fuel line (2) onto quick-release coupling (3).
After pushing on, wait for approx. 10 - 15 min until lubricating material has evaporated.
Align new hose clip (1) with quick-release coupling (3) (arrows) and secure correctly (13 1 500)to
dimension (A) using pliers.
Technical data
Dimension
b (specified
closed size
for single-eye
clip on quickrelease coupling)
2.5+1.5 mm
Order No.
13
Result
Dimension a and b are met.
Measure
Correctly secure hose clip using pliers.
Correctly secure hose clip (1) (13 1 500) to dimension (A) using pliers.
Technical data
2.5+1.5 mm
Dimension
b (specified
closed size
for single-eye
clip on quickrelease coupling)
Check O-ring (2) for damage; replace if necessary.
Connect fuel line (3) to fuel tank (4).
15
Installing complete intake air silencer
Install intake silencer (6) and insert hose (7) at the same
time.
Install bolt (2) with contact disc (3).
Tightening torques
Intake air silencer to frame
M6 x 30
Thread-locking compound (mechanical)
8 Nm
Slide on hose (5) for secondary air system.
Secure the cable (4) in the holder (arrow).
Connect plug connection (1) for intake air temperature
sensor.
with Japan export NV (0742)
Install intake silencer (5) and insert hose (6) at the same
time.
Install bolt (2) with contact disc (3).
Tightening torques
Intake air silencer to frame
M6 x 30
Thread-locking compound (mechanical)
8 Nm
Slide on hose (4) for secondary air system.
Connect plug connection (1) for intake air temperature
sensor.
Order No.
14
Install washers (2) with clips (1) on left and right.
Slide on vent hose (6) and fasten clamp (5) with pliers
(17 5 571).
Slide on vent hose (4) and fasten screw clamp (3).
Connect plug connection (1) for secondary air valve and
secure cable in holder (2).
without Japan export NV (0742)
Connect plug connection (1) for RDC control unit and
secure cable (2) in holder (3).
Order No.
15
16
Securing left intake air pipe
Secure intake snorkel (1) in holder (2).
17
Installing seat support
Install seat support (3).
Install screws (2).
Tightening torques
Seat support to frame
M6 x 16
10 Nm
Clip diagnosis plug (1) into position.
18
Installing rear right interior trim
Position rear interior trim (1), paying attention to the retaining lug (2) while doing so.
Connect plug (3) for the on-board socket.
Install screws (4).
Order No.
16
19
Install rear left interior trim
Position rear interior trim (1), paying attention to the retaining lug (2) while doing so.
Install screws (3).
Connect plug connection (4) for operating facility.
20
Installing complete fuel-tank cover
Installing centre tank cover
Hold fuel-tank cover (2) in position.
Install handlebar end plug (1).
with Keyless Ride OE (0193)
Close the cable strap (arrows).
Order No.
17
Install screws (1) and (2).
Installing right fuel-tank cover
Hold tank cover (1) in position, noting the retaining
lugs (arrows).
Install tank cover (1).
Install screws (1).
Order No.
18
Install screws (1) and screw (2).
Installing left fuel-tank cover
Hold tank cover (1) in position, noting the retaining
lugs (arrows).
Install tank cover (1).
Install screws (1).
Order No.
19
Install screws (1) and screw (2).
Installing right fuel-tank cover top section
Position right upper tank cover section (2) and connect
white connector (1) for AM foil aerial.
Secure excess cable lengths with cable strap (arrow).
Position upper tank cover section (1), noting retaining
tabs (2) and retaining lugs (arrows).
Install upper tank cover section (2).
Install screws (1).
Order No.
20
Installing left fuel-tank cover top section
Position left upper tank cover section (3).
Connect pink connector (1) for DAB foil antenna and
black connector (2) for FM foil antenna.
Secure excess cable lengths with cable strap (arrow).
Position upper tank cover section (1), noting retaining
tabs (2) and retaining lugs (arrows).
Install upper tank cover section (2).
Install screws (1).
Order No.
21
21
Installing right side panel
Push fairing side panel (2) onto mounting pin (3).
Secure fairing side panel (2) with retaining clip (arrow),
noting the bracket (4).
Install screws (1).
Install screws (1).
Turn slipstream deflector (1) to one side.
Install screw (2).
Order No.
22
Install expanding rivet (1), press pin (2) into expanding
rivet (1) while doing so.
22
Installing cover for right intake snorkel
Install cover (2), paying attention to the retaining lug (3)
and engaging that correctly.
Install handlebar end plug (1).
23
Install the right bottom side panel
Install bottom fairing side panel (2), engaging the retaining lug (arrow).
Install screws (1).
Order No.
23
24
Installing left side panel
Push fairing side panel (2) onto mounting pin (3).
Secure fairing side panel (2) with retaining clip (arrow).
Install screws (1).
Install screws (1).
Turn slipstream deflector (1) to one side.
Install screw (2).
Order No.
24
Install expanding rivet (1), press pin (2) into expanding
rivet (1) while doing so.
25
Installing cover for left intake snorkel
Install cover (2), paying attention to the retaining lug (3)
and engaging that correctly.
Install handlebar end plug (1).
26
Installing left bottom side panel
Install bottom fairing side panel (2), engaging the retaining lug (arrow).
Install screws (1).
Order No.
25
27
Installing seat
Place seat (2) in position.
Connect plug (3) for the seat heating.
Install seat (2) and make sure that seat lock (1) locks.
28
Final check of work performed
Check the following:
The work as performed achieved the intended purpose.
All reservoirs and containers have been filled and all fluids and lubricants are at their correct levels.
All threaded fasteners released beforehand have been
correctly retightened.
The fuel system is free of leaks.
The lights and signalling equipment are fully operational
and the vehicle is roadworthy.
The brake pads of the front and rear brakes are bedded
against the brake discs.
Function test, engine start suppression
Check
Set kill switch to "ON" position.
Select neutral.
Switch on the ignition.
Neutral telltale light "N" lights up.
Select a gear.
Neutral telltale light "N" goes out.
Press the starter button.
Starter does not operate.
Extend the side stand.
Pull the clutch lever.
Press the starter button.
Starter does not operate.
Retract the side stand.
Press the starter button without releasing the clutch
lever.
Starter operates.
Order No.
26
Result
Not all test steps completed successfully.
Measure
Check the appropriate parts with the BMW Motorrad
diagnostic system.
Order No.
1
0F61 - K 1600 B
00 60 436 Rework hose clip
1
Removing seat
Open left case and operate unlocking (arrow) for motorcycle seat (1).
Lift seat (1) and disconnect connector (2) for seat heating.
Remove the seat (1).
with topcase OE (0696)
Open left case and operate unlocking (arrow) for motorcycle seat (1).
Lift seat (1) and disconnect connector (2) for seat heating.
Remove the seat (1).
2
Removing left bottom side panel
Remove screws (1).
Remove bottom fairing side panel (2), disengaging the
retaining lug (arrow).
Order No.
2
3
Removing cover for left intake snorkel
Remove screw (1).
Remove cover (2).
4
Removing left side panel
ATTENTION
Scratches and damage to trim panel components
Component damage
Do not use sharp-edged or hard tools.
Use tools made of plastic, for example.
Turn slipstream deflector (1) to the side.
Remove bolt (2).
Remove expanding rivet (1) and press pin (2) down with
suitable tool.
Order No.
3
Remove screws (1).
Remove screws (1).
Loosen fairing side panel (2), noting retaining
clip (arrow).
Pull off fairing side panel (2) from mounting pin (3) to
the top.
Remove fairing side panel (2).
with storage compartment OE (0152)
Remove screws (1).
Loosen fairing side panel (2), noting retaining
clip (arrow).
Pull off fairing side panel (2) from mounting pin (3) to
the top.
Remove fairing side panel (2).
Order No.
4
5
Removing right bottom side panel
Remove screws (1).
Remove bottom fairing side panel (2), disengaging the
retaining lug (arrow).
6
Removing cover for right intake snorkel
Remove screw (1).
Remove cover (2).
7
Removing right side panel
ATTENTION
Scratches and damage to trim panel components
Component damage
Do not use sharp-edged or hard tools.
Use tools made of plastic, for example.
Order No.
5
Turn slipstream deflector (1) to the side.
Remove bolt (2).
Remove expanding rivet (1) and press pin (2) down with
suitable tool.
Remove screws (1).
Remove screws (1).
Loosen fairing side panel (2), noting retaining
clip (arrow).
Pull off fairing side panel (2) from mounting pin (3) to
the top.
Remove fairing side panel (2), noting holder (4).
Order No.
6
with storage compartment OE (0152)
Remove screws (1).
Loosen fairing side panel (2), noting retaining
clip (arrow).
Pull off fairing side panel (2) from mounting pin (3) to
the top.
Remove fairing side panel (2), noting holder (4).
8
Removing complete fuel-tank cover
Removing left fuel-tank cover top section
Remove screws (1).
Remove upper tank cover section (2).
with audio system OE (0268)
or
with US audio system OE (0270)
Remove screws (1).
Loosen upper tank cover section (2).
Order No.
7
with audio system OE (0268)
Disconnect pink connector (1) for DAB foil antenna and
black connector (2) for FM foil antenna.
Remove left upper tank cover section (3).
Removing left fuel-tank cover
Remove screws (1).
Remove screws (1).
Remove bolt (2).
Pull out tank cover (3) from rubber grommet (4), noting
retaining lugs (arrows).
Removing right fuel-tank cover top section
Remove screws (1).
Remove upper tank cover section (2).
Order No.
8
with audio system OE (0268)
or
with US audio system OE (0270)
Remove screws (1).
Loosen upper tank cover section (2).
with audio system OE (0268)
or
with US audio system OE (0270)
Disconnect connector (1) for AM foil antenna and remove right upper tank cover section (2).
Removing right fuel-tank cover
Remove screws (1).
Remove screws (1).
Remove bolt (2).
Pull out tank cover (3) from rubber grommet (4), noting
retaining lugs (arrows).
Order No.
9
Removing centre fuel-tank cover
Remove screws (1) and (2).
with Keyless Ride OE (0193)
Remove the cable straps (arrows).
Remove screw (1).
Remove fuel-tank cover (2).
Order No.
10
9
Remove rear left interior trim
Remove bolt (1).
Remove rear interior trim (2).
with audio system OE (0268)
or
with US audio system OE (0270)
Disconnect plug connection (1) for operating facility.
Remove bolt (2).
Remove rear interior trim (3).
with storage compartment OE (0152)
Remove screws (1).
Remove rear interior trim (2).
Order No.
11
with audio system OE (0268)
with storage compartment OE (0152)
or
with US audio system OE (0270)
with storage compartment OE (0152)
Disconnect plug connection (1) for operating facility.
Remove screws (2).
Remove rear interior trim (3).
10
Removing rear right interior trim
Remove bolt (1).
Loosen rear interior trim (2).
Disconnect plug connection (3) for socket.
Remove rear interior trim (2).
with storage compartment OE (0152)
Remove screws (1).
Loosen rear interior trim (2).
Disconnect plug connection (3) for socket.
Remove rear interior trim (2).
Order No.
12
11
Removing seat support
Unclip diagnostic socket (1) and hang to the side.
Remove screws (2).
Remove seat support (3).
12
Disengaging left intake air pipe
Loosen left intake snorkel (1) from holder (2).
13
Removing complete intake air silencer
without Japan export NV (0742)
Disconnect plug connection (1) for RDC control unit and
release cable (2) from holder (3).
Order No.
13
Disconnect plug connection (1) for secondary air valve
and disconnect cable (2).
Loosen the screw clamp (3) and pull off the vent
hose (4).
Loosen clamp (5) with pliers (17 5 571) and pull off
vent hose (6).
Remove clips (1) with washers (2) on left and right.
Disconnect plug connection (1) for intake air temperature sensor.
Remove screw (2) with contact disc (3).
Release the cable (4) from the holder (arrow).
Pull off hose (5) for secondary air system.
Remove intake silencer (6) completely and feed out
hose (7) at the same time.
with Japan export NV (0742)
Disconnect plug connection (1) for intake air temperature sensor.
Remove screw (2) with contact disc (3).
Pull off hose (4) for secondary air system.
Remove intake silencer (5) completely and feed out
hose (6) at the same time.
Order No.
14
14
Rework hose clip.
Disconnect fuel line (1).
Check that hose clip (2) and fuel line (3) are correctly
installed and not loose.
If hose clip (2) and fuel line (3) are correctly installed,
secure hose clip correctly
If hose clip (2) and fuel line (3) are not correctly installed, install fuel line correctly and replace hose clip.
Check
Technical data
Dimension a
(distance from
end of hose to
quick-release
coupling)
0+2 mm
Dimension
b (distance
from quickrelease coupling to hose
clamp)
7+2 mm
Result
Dimension a and b are not met.
Measure
Replace hose clip.
Remove hose clip (1).
Disconnect fuel line (2) from quick-release coupling (3).
Clean and lubricate quick-release coupling (3) in the
marked area.
Use only brake cleaner or fuel for lubrication.
Do NOT use silicone spray or similar.
Push new hose clip (1) onto fuel fuel line (2).
Push fuel line (2) onto quick-release coupling (3).
After pushing on, wait for approx. 10 - 15 min until lubricating material has evaporated.
Align new hose clip (1) with quick-release coupling (3) (arrows) and secure correctly (13 1 500)to
dimension (A) using pliers.
Technical data
Dimension
b (specified
closed size
for single-eye
clip on quickrelease coupling)
2.5+1.5 mm
Order No.
15
Result
Dimension a and b are met.
Measure
Correctly secure hose clip using pliers.
Correctly secure hose clip (1) (13 1 500) to dimension (A) using pliers.
Technical data
2.5+1.5 mm
Dimension
b (specified
closed size
for single-eye
clip on quickrelease coupling)
Check O-ring (2) for damage; replace if necessary.
Connect fuel line (3) to fuel tank (4).
15
Installing complete intake air silencer
Install intake silencer (6) and insert hose (7) at the same
time.
Install bolt (2) with contact disc (3).
Tightening torques
Intake air silencer to frame
M6 x 30
Thread-locking compound (mechanical)
8 Nm
Slide on hose (5) for secondary air system.
Secure the cable (4) in the holder (arrow).
Connect plug connection (1) for intake air temperature
sensor.
with Japan export NV (0742)
Install intake silencer (5) and insert hose (6) at the same
time.
Install bolt (2) with contact disc (3).
Tightening torques
Intake air silencer to frame
M6 x 30
Thread-locking compound (mechanical)
8 Nm
Slide on hose (4) for secondary air system.
Connect plug connection (1) for intake air temperature
sensor.
Order No.
16
Install washers (2) with clips (1) on left and right.
Slide on vent hose (6) and fasten clamp (5) with pliers
(17 5 571).
Slide on vent hose (4) and fasten screw clamp (3).
Connect plug connection (1) for secondary air valve and
secure cable in holder (2).
without Japan export NV (0742)
Connect plug connection (1) for RDC control unit and
secure cable (2) in holder (3).
Order No.
17
16
Securing left intake air pipe
Secure intake snorkel (1) in holder (2).
17
Installing seat support
Install seat support (3).
Install screws (2).
Tightening torques
Seat support to frame
M6 x 16
10 Nm
Clip in diagnostic socket (1).
18
Installing rear right interior trim
Position rear interior trim (1), paying attention to the retaining lug (2) while doing so.
Connect plug connection (3) for socket.
Install bolt (4).
Order No.
18
with storage compartment OE (0152)
Position rear interior trim (1), paying attention to the retaining lug (2) while doing so.
Connect plug connection (3) for socket.
Install screws (4).
19
Install rear left interior trim
Position rear interior trim (1), paying attention to the retaining lug (2) while doing so.
Install bolt (3).
with audio system OE (0268)
or
with US audio system OE (0270)
Position rear interior trim (1), paying attention to the retaining lug (2) while doing so.
Install bolt (3).
Connect plug connection (4) for operating facility.
Order No.
19
with storage compartment OE (0152)
Position rear interior trim (1), paying attention to the retaining lug (2) while doing so.
Install screws (3).
with audio system OE (0268)
with storage compartment OE (0152)
or
with US audio system OE (0270)
with storage compartment OE (0152)
Position rear interior trim (1), paying attention to the retaining lug (2) while doing so.
Install screws (3).
Connect plug connection (4) for operating facility.
20
Installing complete fuel-tank cover
Installing centre tank cover
Hold fuel-tank cover (2) in position.
Install handlebar end plug (1).
Order No.
20
with Keyless Ride OE (0193)
Close the cable strap (arrows).
Install screws (1) and (2).
Installing right fuel-tank cover
Slide tank cover (3) into rubber grommet (4), noting retaining lugs (arrows).
Install bolt (2).
Install screws (1).
Install screws (1).
Order No.
21
Installing right fuel-tank cover top section
with audio system OE (0268)
or
with US audio system OE (0270)
Position right upper tank cover section (2) and connect
connector (1) for AM foil aerial.
Position upper tank cover section (1), noting retaining
tabs (2) and retaining lugs (arrows).
Install upper tank cover section (2).
Install screws (1).
Order No.
22
Installing left fuel-tank cover
Slide tank cover (3) into rubber grommet (4), noting retaining lugs (arrows).
Install bolt (2).
Install screws (1).
Install screws (1).
Installing left fuel-tank cover top section
with audio system OE (0268)
Position left upper tank cover section (3).
Connect pink connector (1) for DAB foil antenna and
black connector (2) for FM foil antenna.
Position upper tank cover section (1), noting retaining
tabs (2) and retaining lugs (arrows).
Order No.
23
Install upper tank cover section (2).
Install screws (1).
21
Installing right side panel
Slide fairing side panel (2) onto mounting pin (3).
Secure fairing side panel (2) with retaining clip (arrow),
noting holder (4).
Install screws (1).
with storage compartment OE (0152)
Slide fairing side panel (2) onto mounting pin (3).
Secure fairing side panel (2) with retaining clip (arrow),
noting holder (4).
Install screws (1).
Order No.
24
Install screws (1).
Turn slipstream deflector (1) to the side.
Install bolt (2).
Install expanding rivet (1) and slide pin (2) into expanding rivet (1).
Order No.
25
22
Installing cover for right intake snorkel
Install cover (2), paying attention to the retaining lug (3)
and engaging that correctly.
Install handlebar end plug (1).
23
Install the right bottom side panel
Install bottom fairing side panel (2), engaging the retaining lug (arrow).
Install screws (1).
24
Installing left side panel
Slide fairing side panel (2) onto mounting pin (3).
Secure fairing side panel (2) with retaining clip (arrow).
Install screws (1).
Order No.
26
with storage compartment OE (0152)
Slide fairing side panel (2) onto mounting pin (3).
Secure fairing side panel (2) with retaining clip (arrow).
Install screws (1).
Install screws (1).
Turn slipstream deflector (1) to the side.
Install bolt (2).
Install expanding rivet (1) and slide pin (2) into expanding rivet (1).
Order No.
27
25
Installing cover for left intake snorkel
Install cover (2), paying attention to the retaining lug (3)
and engaging that correctly.
Install handlebar end plug (1).
26
Installing left bottom side panel
Install bottom fairing side panel (2), engaging the retaining lug (arrow).
Install screws (1).
27
Installing seat
Place rear seat bench (1) in position.
Connect the connector (2) for seat heating.
Install the rear seat bench (1).
Close left case.
Order No.
28
with topcase OE (0696)
Place rear seat bench (1) in position.
Connect the connector (2) for seat heating.
Install the rear seat bench (1).
Close left case.
28
Final check of work performed
Check the following:
The work as performed achieved the intended purpose.
All reservoirs and containers have been filled and all fluids and lubricants are at their correct levels.
All threaded fasteners released beforehand have been
correctly retightened.
The fuel system is free of leaks.
The lights and signalling equipment are fully operational
and the vehicle is roadworthy.
The brake pads of the front and rear brakes are bedded
against the brake discs.
Function test, engine start suppression
Check
Set kill switch to "ON" position.
Select neutral.
Switch on the ignition.
Neutral telltale light "N" lights up.
Select a gear.
Neutral telltale light "N" goes out.
Press the starter button.
Starter does not operate.
Extend the side stand.
Pull the clutch lever.
Press the starter button.
Starter does not operate.
Retract the side stand.
Press the starter button without releasing the clutch
lever.
Starter operates.
Result
Not all test steps completed successfully.
Order No.
29
Measure
Check the appropriate parts with the BMW Motorrad
diagnostic system.