yamaha xv1700 road star warrior full service repair manual 2002 2005
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yamaha xv1700 road star warrior full service repair manual 2002 2005Get started with a FREE account. BMW 3 Series Service Manual 19.BMW 3 Series S.Introduction to Human Nutrition. Introduction to Human Nutrition: a global perspe.Get books you want. To add our e-mail address ( ), visit the Personal Document Settings under Preferences tab on Amazon. The manual is divided into ten sections: 0 GENERAL DATA AND. The next seven sections (Repair Groups 1 through 7) are repair based and organized by three digit repair groups. CAUTION! A caution calls attention to important precautions to be observed during the repair work that will help prevent accidentally damaging the car or its parts. Accidental electrical contact may damage the electrical system or cause a fire. Hydrogen gas emitted by the battery is highly flammable. Any nearby source of ignition may cause the battery to explode. Never lay tools or parts in the engine compartment or on top of the battery. Below is some important information on how to work safely, a discussion of what tools will be needed and how to use them. Make sure it stays stable and does not shift or tilt. As the car is raised, it may roll slightly and the jack may shift. Raising car safely Park car on flat, level surface. Let others know what you will be doing. CAUTION! Prior to disconnecting the battery, read the battery disconnection cautions given at the front of this manual on page viii. Watch to make sure that the jack stands do not tip or lean as the car settles on them. Observe all jacking precautions again when raising car to remove jack stands. Planning ahead To prevent getting in too deep, know what the whole job requires before starting. Genuine BMW parts should be the only replacement parts used for this purpose. Some bolts are designed to stretch during assembly and are permanently altered rendering them unreliable once removed. Note: Metric bolt classes or grades are marked on the bolt head. Do not confuse wrench size with bolt diameter. Make sure that these are installed correctly.http://erboka.org/userfiles/dm-2060-manual.xml
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This same logic applies to any part used for sealing, including rubber O-rings and copper sealing washers. In places where a shaft must pass through a. Wire repairs Repairs to a wiring harness require special care to make the repair permanent. The wire ends must be clean. Many independent repair shops make a point of using genuine BMW parts, even though they may at times be more expensive. They know the value of doing the job right with the right parts. Non-returnable parts Some parts cannot be returned, even for credit. The label on the driver’s door below the door latch will specify the month and year that the car was built. Vehicle Identification Number (VIN). This is a combination of letters and numbers that identify the particular car. Screwdrivers. The common flat-blade type and the Phillips type will handle almost all screws used on BMWs. Some have special applications. Needlenose pliers are used for gripping small and poorly accessible objects, and are useful for wiring and other electrical work.Always use jack stands to support a raised vehicle. Jack stands are available in several styles. The best ones are made of heavy material for strength, have a wide base for stability, and are equipped to positively lock in their raised positions. Several types of torque wrenches are available. An inexpensive beam-type (top) is adequate but must be read visually. A ratchet-type (bottom) can be preset to indicate (click) when the torque value has been reached. BMW special tools Many repairs covered in this manual call for the use of BMW special tools. This, however, does not automatically mean that the job is too complicated or out of reach of the do-it-yourselfer. Avoid stopping just over the crest of a hill. Turn on emergency flashers, and set out flares or emergency markers well behind car. If the engine is turning over at normal speed with the starter motor, the battery and starter are fine. If the.http://datatech-int.com/userfiles/dm-225-manual.xml Jump starting Cars with discharged or dead batteries can be jump-started using the good battery from another car. When jump-starting the engine, always note the following warnings. WARNING! Turn off ignition switch of car with discharged battery.Generally, a red warning lamp that comes on during driving should be considered serious. If you cannot immediately determine the seriousness of the warning light, stop the vehicle in a safe place and turn the engine off as soon as possible. The towing eye can be screwed into the front or rear bumper. Install towing eye into threaded hole. Standard transmission: A maximum towing distance of 20. All rights reserved. When SII detects total fuel consumption that equals the preset limits (in gallons), the instrument cluster indicates that service is required. Plug the tool (arrow) Inspection I is normally due at intervals with a maximum of 30,000 miles or 24 months. Inspection II is normally due at intervals with a maximum of 60,000 miles or 48 months. Except where noted, the maintenance items listed apply to all models and model years covered by this manual. The columns on the right side of each table give quick-reference information about the job. Check overall thickness of front and rear brake pads using special BMW tool. If replacement is necessary: Examine brake disc surfaces. Clean brake pad contact points in calipers. Grease wheel. Check thickness of parking brake linings only when replacing rear brake pads. Check operation of parking brake and adjust as necessary. Check coolant level and antifreeze protection level. Add coolant as necessary. Check aim of washer jets and adjust if necessary. Check condition and function of seat belts. Check manual transmission and clutch operation or automatic transmission operation. All rights reserved. The use of fluids that do not meet BMW's specifications may impair performance and reliability, and may void warranty coverage. Table d. Fluids and lubricants. Anti-freeze raises the boiling point and lowers the freezing point of the coolant. It also contains additives that help prevent cooling system corrosion. See Automatic Transmission. Consult an authorized BMW dealer for alternate fluid use and the most-up- to-date information regarding transmission operating fluids. Transmission fluid, manual. Engine oil, checking level Engine oil level is checked with a dipstick (arrow) in engine block. Power tools can strip the threads of the plug and the oil pan. Pull the loose plug away from the hole quickly to avoid being scalded by hot oil. It will run out quickly when the plug is removed. If possible, use gloves to protect your hands. When oil flow has diminished to. Approximate oil capacity is listed Table d. Use dipstick to check correct oil level. Start engine and check that oil pressure warning light immediately goes out. Allow engine to run for a few minutes to circulate new oil, then check for leaks at drain plug and oil filter. It is not necessary for the car to be raised and supported off the ground. Information on oil change is given earlier in this group. Use of anti-freeze containing phosphates is considered to be harmful to the cooling system. Any of conditions shown is cause for replacement. (Courtesy of Gates Rubber Company, Inc.) Engine drive belt service Drive belts and pulleys transfer power from the engine crankshaft to various accessories. WARNING! Observe care when replacing belts. Personal injury could result if a tensioner springs back into position uncontrollably. CAUTION! Mark drive belt rotation direction if removing and reusing an old belt. This allows for tighter control of the tail pipe emissions and also allows the ECM to diagnose converter problems. Level is correct if it is between MIN and MAX marks on dipstick. If level is below MIN mark, start engine and add fluid to reservoir to bring level up. Remove cover hold down bolts. Remove ignition coil grounding harnesses (arrows).https://domoticaaplicada.com/images/compare-manual-and-computerised-system.pdf Remove ignition coils: Pull up on spring clips to disconnect ignition coil harness connectors. Remove coil mounting bolts. Remove coils. Remove spark plugs. Simple maintenance of the battery and its terminal connections will ensure maximum starting performance, especially in winter when colder temperatures reduce battery power. Corrosion can be washed away with a baking soda and water solution that will neutralize acid. Apply solution carefully, though, since it will also neutralize acid inside battery.Battery condition is determined by the color of the eye: Green: Adequate charge Black: Inadequate charge;. Brake fluid, replacing BMW strictly recommends replacing the brake fluid every two years. This will help protect against corrosion and the effects of moisture in the fluid. Note: 340 Brakes for brake fluid flushing procedures. Unbolt caliper from steering arm to properly inspect: Brake pad thickness (A) Inspect unions and brake calipers for signs of fluid leaks. Inspect rigid lines for corrosion, dents, or other damage. Inspect flexible hoses for cracking. Replace faulty hoses or lines, see Brakes. Drive the car approximately 400 meters (1,300 ft.) and release the brake. To recheck the adjustment of the parking brake see Brakes. Clutch fluid, checking The hydraulic clutch and the brake system share the same reservoir and the same brake fluid. If short- distance driving predominates, the moisture and condensation in the system will not fully dry out. This will lead to early corrosion damage and more frequent replacement. Scheduled maintenance of the exhaust system is limited to inspection:. The differential should be filled with a special BMW lubricant available through an authorized BMW dealer. Note: Use a 14 mm or 17 mm Allen socket to remove the drain plug. A protective cover must be removed to access the filter. Fuel filter for M52 TU engine is shown in illustration. E46 cars with M54 engine are equipped with a fuel filter that has a built in fuel pressure regulator. Do not smoke or work near heaters or other fire hazards. Keep a fire extinguisher handy. CAUTION! Clean thoroughly around the filter connections before removing them. Note: When installing fuel filter cover, take care to reinstall foam rubber seal in front of cover correctly to prevent flooding of filter with rain splash water. Inspect ball joint and tie-rod rubber seals and boots for cracks or tears that could allow the entry of dirt, water, and other contaminants. Tires, rotating BMW does not recommend tire rotation. Due to the car's suspension design, the front tires begin to wear first at the outer shoulder and the rear tires begin to wear first at the middle of the tread or inner shoulder. Note: 320 Steering and Wheel Alignment for a more detailed discussion of alignment requirements and specifications.The body and door hinges, the hood latch, and the door check rods should be lubricated with SAE 30 or SAE 40 engine oil. Rinse using plenty of clear water. Wipe the body dry with a soft cloth towel or chamois to prevent water-spotting. Interior care Dirt spots can usually be removed with lukewarm soapy water or a dry foam cleaner. If it is necessary to clean seat belts, use a mild soap solution. Bleach and other strong cleaning agents may weaken the belt webbing and should be avoided. If cleaning the blades does not cure the problem, they should be replaced. BMW recommends replacing the wiper blades twice a year, before and after the cold season. Wiper blade chatter may be caused by dirty or worn blades, by a dirty windshield, or by bent or twisted wiper arms. Clean the blades and windshield as described above. These standards were originally mandated for California vehicles. Since 1996 they have been applied to all passenger vehicles sold in the United States. Removing the connector from the ECM or disconnecting the battery will not erase the fault memory. The extra hardware needed to operate the OBD II system consists mainly of the following:. An engine management system fault is detected for two consecutive OBD II drive cycles. A catalyst damaging fault. A component malfunction (such as catalyst deterioration) causes emissions to exceed 1.5 times OBD II standards. Two complete consecutive drive cycles with the fault present illuminate the MIL. The exception. Data from the OBD II DLC may be limited, depending on scan tool and vehicle. Professional diagnostic scan tools available at the time of this printing include the BMW factory tools (DISplus and MoDiC) and a small number of aftermarket BMW-specific tools. The CS2000 from Baum Tools Unlimited, the Retriever from Assenmacher. The ECM must recognize the loss or impairment of the signal or component and determine if a signal or sensor is faulty based on 3 conditions: Signal or component shorted to ground Signal or component shorted to. Oxygen sensor monitoring: When drive conditions allow, response rate and switching time of each oxygen sensor is monitored. Secondary air injection monitoring: Secondary air injection is used to reduce HC and CO emissions during engine warm up. If after completing the next cold start a fault is again present, the MIL will be illuminated. Fuel system monitoring: This monitors receives high priority.Drive cycle The OBD II drive cycle is an important concept in understanding OBD II requirements. The purpose of the drive. Engine coolant Input analog Signal range is checked temp. circuit. Output digital DME final stage will set flag pulse width (active whenever a short to ground, a low) short to battery voltage or a. Output digital DME final stage will set flag pulse width (active whenever a short to ground, a low) short to battery voltage or a. Change bit is monitored to indicate proper function. P0325 Knock sensor 1 Input analog Plausibility check between circuit, (Bank 1) P1542 Pedal sensor Input analog Failed signal range check potentiometer 1 (0-5V) against predefined diagnostic limits. P1542 Pedal Sensor Input analog. CAN time out (instr Input binary CAN message between. MS 43 DMTL module fault DME internal values logical P1476 EVAP: clamped Input digital Frequency of LDP pumps. P0150 Oxygen sensor Input analog Oxygen sensor signal range pre-cat (Bank 2), (0-5V) is checked to determine if short to battery electrical shorts exist on input volt. If more than two ignition signals are not recognized than there might be a problem in feedback line. P1510 Idle control valve DME internal Functional check against a. P0179 Oxygen sensor Input analog (high Checks amount of time pre-cat (Bank 2), is lean) (0-5V) oxygen sensor takes to switch switch time too. Time for each cylinder combustion is compared against avg. For specific repair procedures, refer to the appropriate repair group: 110 Engine Removal and Installation 113 Cylinder Head Removal. This engine incorporates all the technical features of the M52 TU engines with addition of fully electronic throttle control and enhanced emission controls. Table a. Engine specifications lists engine specifications for the vehicles covered by this manual. The cylinders are exposed on all sides to circulating coolant. The counterweighted crankshaft rotates in replaceable split-shell main bearings. Oilways drilled into the crankshaft provide bearing lubrication. The pistons are of the three-ring type with two upper compression rings and a lower one-piece oil scraper ring. The converters are mounted close to the engine for faster heat up. Pre- and post-catalyst oxygen sensors are a mounted in each exhaust manifold. Cooling system The cooling system circulation is. This optimizes operating temperatures in both cylinder head and block, reduces friction and thereby fuel consumption. The cooling system is designed to: Reduce operating temperatures of cylinder head. This helps achieve optimum torque throughout the entire RPM range. During engine operation, a closed resonance valve gives the intake air charge the dynamic effect of long intake runners at low to mid-range RPM (up to 3750 rpm). Routing intake air to one intake valve per cylinder causes the air charge to swirl in the cylinder. Overall improved fuel economy. 117 Camshaft Timing Chains VANOS system testing and repair information. Engine management system The Siemens engine management systems used in E46 cars combine fuel injection, ignition and other functions. It has the capability to be programmed up to 13 times. ECM outputs: Fuel injector opening duration. Intake and exhaust valve timing via the VANOS system. The radiator cooling fan and the heated coolant thermostat. Motor-driven throttle valve: MDK in MS 42.0 or EDK in MS 43.0. Fuel metering: The ECM meters pressurized fuel by changing the opening time (pulse width) of the fuel injectors. The exact amount of fuel injected is determined by the amount of time the injectors are open. Smooth idle speeds regardless of load and inputs Lower rpm range Smooth transition from acceleration. This reduces engine performance noticeably.The coils are mounted over the spark plugs and connect to the plugs via a short lead. The Siemens systems use multiple spark ignition to reduce emissions and extend spark plug life. The powerful diagnostic capabilities of these systems have the potential to. Even a fully charged battery cannot deliver power unless it is properly connected to the electrical system. Check the battery terminals for corrosion or loose cable connections. If the battery does not maintain the proper voltage, the charging system may be at fault. If a ground connection has no visible faults but is still suspect, measure the voltage drop across the connection. A large voltage drop indicates high resistance, indicating that the connection is corroded, dirty or damaged. Main fuel pump ground (arrow) behind right rear seat back rest.As an aid to installation, label all components, wires and hoses before removing them. Do not reuse gaskets, O-rings or seals during reassembly. Remove upper cover and microfilter. Open wiring harness loom cover (A) and remove wires. Unfasten screws (B) and remove lower microfilter housing. Remove intake manifold cover: Remove plastic trim covers (arrows). Working at left rear of engine compartment: Peel rubber edge seal off top of panel. Remove complete air filter housing: Detach vacuum line at intake boot (A). Disconnect electrical harness connector on mass air flow sensor (B). Release mass air flow sensor clips (C). Disconnect hose at quick disconnect fitting (arrow). Remove dipstick guide tube: Detach wiring harness brackets from tube (A). Detach fuel lines from tube (B). Remove lower guide tube mounting bolt (C). CAUTION! Fuel may be expelled under pressure. Do not smoke or work near heaters or other fire hazards. Before disconnecting fuel hoses, wrap a cloth around fuel hoses to absorb any leaking fuel. Remove intake manifold from cylinder head while carefully checking for electrical connections or hoses. CAUTION! Stuff clean rags into open intake ports to prevent any parts from falling into the engine intake. Remove cylinder head top cover: Remove plastic trim covers (arrows). Remove cover hold down bolts and lift off cover. Pets are attracted to coolant because of its sweet smell and taste. Consult a veterinarian immediately if coolant is ingested by an animal. Note: Catch and dispose of drained coolant according to local, state, and federal laws. Unbolt power steering fluid reservoir and pull aside without detaching hoses. Tie to fender with cord or stiff wire. Remove front and rear pump mounting bolts (arrows). Hang pump from body using stiff wire.Remove chassis ground strap (arrow) at right engine mounting pedestal. Install an engine lifting device (BMW 11 0 000 or equivalent) to the front and rear engine supports and raise engine until its weight is supported. Detach left and right engine mounts. Installation is reverse of removal, noting the following: Replace all gaskets, O-rings and seals. Change engine oil and filter and check all other fluid levels. Special tools Special BMW service tools are required to properly remove and install the cylinder head on engines covered by this manual. The special tools are used to time the valvetrain to the crankshaft,. Due to risk of personal injury, be sure the engine is cold before beginning the removal procedure. Cylinder head removal and installation is a complicated repair procedure. VANOS control unit, timing chain, and camshaft removal and installation all require special tools. Check for fault codes using special BMW diagnostic equipment. Remove microfilter for interior ventilation. Remove housing for interior ventilation microfilter. Open wiring harness loom cover (A) and remove wires. Disconnect VANOS solenoid electrical harness connector (A). Disconnect fuel injector electrical connectors from injectors: Use small screwdriver to pry one corner of wire lock clip on fuel injector 1 connector. Note: In this step, mass air flow sensor remains attached to rubber air duct. Loosen clamps 2 and 8 and remove mass air flow sensor and air duct. Disconnect electrical harness connector at idle speed control valve (arrow) directly above throttle housing. Working under front corner of intake manifold, disconnect electrical harness connector at fuel tank venting valve (A). Disconnect fuel lines from retaining clips (B). Remove lower dip stick guide tube mounting bolt (C). Pull out guide tube.Working underneath car, remove lower intake manifold support mounting bolt (arrow), located adjacent to left (driver's side) engine mount. Thread fuel line(s) out of rear of engine compartment while lifting fuel rail out. Remove intake manifold mounting nuts (arrows). Lift up manifold enough to disconnect positive cables from starter motor terminal (arrow). Drain radiator into a 3-gallon pail by removing plastic drain plug at lower left end of radiator (arrow). WARNING! Use caution when draining and disposing of engine coolant. Coolant is poisonous and lethal to humans and pets. Lift tank and disconnect electrical connections to pump and to washer fluid level sensor. Disconnect hoses to windshield washer and headlight washer. Tilt reservoir to prevent fluid from leaking out. Disconnect ignition coil harness connectors. Remove coil mounting fasteners. Remove coils. Remove ground straps. Set coil harness to left side of engine compartment. Remove cylinder head cover mounting fasteners and remove cylinder head cover. Use banjo bolt to attach BMW special tool 11 3 450 (compressed air fitting) to VANOS control unit. Cover oil hole (arrow) in VANOS unit with shop towel to capture oil which will spray when compressed air is applied. Secure camshafts in TDC position using BMW special tools 11 3 240 and 11 3 244. Disconnect compressed air line, leaving compressed air fitting attached to VANOS unit. Do not allow oil to run onto drive belts. Pull sealing caps straight out of VANOS unit with BMW special tool 11 6 170, or with short nose pliers. Note: Additional oil may drain from VANOS unit. Remove impulse wheel (A). Remove spring plate (A). Remove intake camshaft sprocket mounting nuts (arrows) and remove spring plate (labelled FRONT). Remove torx screws from exhaust camshaft sprocket (arrows). CAUTION! Splined shafts share the same part number for both intake and exhaust camshafts. Lift primary chain sprocket off exhaust camshaft. Remove sprocket from chain. Place timing chain on end of exhaust camshaft. Remove locating studs (arrows) from intake camshaft. Remove BMW special tools 11 3 240 and 11 3 244 from rear of cylinder head. Remove retaining nuts (arrows) and bearing cap 1 of intake camshaft. Fit BMW special tools 11 3 260 (A) and 11 3 270 (B) to cylinder head and screw long bolts (arrows) into spark plug threads. Used hydraulic lifters must be replaced into original lifter bores. Cylinder head assembly, removing Remove exhaust manifolds. See 180 Exhaust System. Remove intake camshaft position sensor (arrow) from side of cylinder head. Discard head bolts. Note: BMW special tool 11 2 250 is a thin-walled Torx E12 socket with an extended reach. The thicker gasket is available from an authorized BMW dealer. Cylinder head and valve specifications are covered in 116 Cylinder Head and Valvetrain. Please be advised that these individual jobs must be accomplished in the order in which they appear. Cylinder head assembly, installing Camshafts and valvetrain, installing VANOS control unit, installing Cylinder head cover, manifolds,. The final stages require the use of a BMW special tool 11 2 110 or a suitable protractor to tighten the bolts to a specified torque angle. Install exhaust manifolds. Install lower secondary chain guide. Tighten Torx bolts (arrows) to specifications. The bolt on the intake camshaft side is long and extends into the engine block. When the camshafts are removed, the hydraulic lifters can expand. Fit BMW special tools 11 3 260 (A) and 11 3 270 (B) to cylinder head over intake camshaft and screw long bolts (arrows) into spark plug threads. If necessary, turn camshaft so that special tools are squarely seated on cylinder head. Secure crankshaft in TDC position with BMW special tool 11 2 300 (arrow). Slide impulse wheel on intake camshaft, aligning boss with raised portion on camshaft (arrow). Recheck that arrow on top primary sprocket is aligned with upper edge of cylinder head. Keep tensioner compressed using BMW special tool 11 3 292 or suitable pin. Fit exhaust camshaft splined sleeve. Confirm that gap in sleeve splines aligns with corresponding gap in camshaft splines (arrows). Position spline gap on intake sprocket (arrow) as shown and place secondary chain on sprockets. Remove chain and sprockets from tool and slide sprockets on camshafts. Initially tighten to approx. 5 Nm (44 in-lb) and then back off by half a turn. Fit thrust spacer (A) on exhaust camshaft. Install spring plate (A) to exhaust camshaft. Make sure that F mark is visible. Install BMW special tool 11 6 150 (VANOS setup bracket) to front of cylinder head timing case. Install nuts (arrows) finger tight, then tighten down uniformly until special tool is in full contact with cylinder head. Clean sealing face and keep free of oil. If any foreign material is present on the sealing surface, the camshaft timing will be incorrect. Place BMW special tool 11 3 240 over camshafts and measure clearances. Note: If the exhaust side of the tool (A) is not flush with the head, camshaft timing is incorrect. Clean sealing face and keep free of oil. If any foreign material is present on the sealing surface, the camshaft timing will be incorrect. Check locating dowel (A) and. Insert and secure VANOS sealing plugs (arrows) with new sealing O-rings. Tightening torque Primary chain tensioner cylinder to cylinder head. Coat manifold studs with copper paste prior to installing nuts. Tightening torque Exhaust manifold. Inspect O-ring seal between mass air flow sensor and air filter housing. To facilitate reassembly, coat seal with acid-free grease. CAUTION! When reattaching throttle assembly. CAUTION! To prevent damaging engine electronic systems, install all ground wires previously removed, including the ground wires for the ignition coils. Tightening torques Coolant drain plug to cylinder block 25 Nm (18 ft-lb) The light can only be turned out using either BMW special service scan tools or an equivalent aftermarket scan tool. Disconnecting the battery will not erase the fault memory nor turn out the light. Remove housing for interior ventilation microfilter. Remove upper cover and microfilter. Install compression gauge in first cylinder's spark plug hole, tight enough to form a good seal. With parking brake set, transmission in PARK or NEUTRAL, and accelerator pedal pressed to floor, crank engine with starter. Erratic values tend to indicate valve leakage. Dramatic differences between cylinders are often the sign of a failed head gasket, burned valve, or broken piston ring. Special tools BMW special tools are required for most cylinder head service described in this repair group. Many of these tools are expensive and only available through an authorized BMW dealer. If. A cracked cylinder head must be replaced. Note:. Unfasten screws (B) and take off lower microfilter housing. Remove engine cover. Detach positive and ground connections from intake manifold and cylinder head cover, as necessary. If there is any noticeable clearance, the lifter is faulty and should be replaced. Note: When checking a hydraulic lifter, make sure the corresponding camshaft lobe is facing up so that there is no valve spring pressure on the follower. Special suction cups are available from BMW to hold the hydraulic lifters in place during carrier removal. Hydraulic cam lifters should be stored in an upright position. If necessary, use a magnetic tool to aid in removal of the lifters. If a valve guide is excessively worn, it should be reamed to accept oversized valve stems. Valve guide specifications are listed in Table Valve guides should be checked for wear using a new valve. BMW supplies oversize valves.Note: BMW special tools are available to remove the valve stem oil seals. As an alternative, standard valve seal removal tools are available from most automotive parts stores. Lubricate new seal and install using hand pressure only. Note: Valve spring specifications and wear limits are not available from BMW.