BMW R1100S repair manual

BMW Motorrad After Sales R 1150 RT Maintenance BMW Integral ABS

Published by: © BMW Motorrad After Sales UX-VS-2 All rights reserved. Not to be reprinted, translated or duplicated either wholly or in part without prior written permission. Errors and omissions excepted; subject to technical amendment. Produced in Germany 01/01

Order No. 01 71 0 029 614 UX-VS-2, 12.2000 Printed in Germany Customer Registration No. Order No. Mechanic’s signature BMW Inspection at 1,000 km (600 miles) BMW Service 10,000 km (6,000 miles) BMW Inspection every 20,000 km (12,000 miles) BMW Annual Service Read the fault code memory with the BMW MoDiTeC [Integral ABS] perform bleed test with BMW MoDiTeC Change oil while at regular operating temperature and replace the oil filter element If the motorcycle is ridden only for short distances or outside temperatures are below 0 °C: at the latest every 3,000 km (1,800 miles)* ) Change oil in gearbox while at operating temperature every 2 years* ) at the latest every 2 years Change oil in rear wheel drive while at operating temperature if necessary, clean inductive sensor on rear wheel every 40,000 km (24,000 miles) or at the latest every 2 years* ) 40,000 every 2 years Replace fuel filter * ) Normally every 40,000 km (24,000 miles), if fuel is of poor quality every 20,000 km (12,000 miles) 40,000 Check the battery fluid level, if necessary top up with distilled water Clean and grease battery poles if necessary Replace intake air filter element In very dirty and dusty operating conditions, replace every 10,000 km (6,000 miles) or even more frequently if necessary * ) Replace Poly-V belt * ) Replace the Poly-V belt every 60,000 km (36,000 miles); do not adjust it 60,000 Check brake fluid level at front and rear Check operation of brake system and freedom from leaks; repair/replace items if necessary* ) Examine brake pads and discs for wear, replace as necessary* ) [Without ABS] change brake fluid every twelve months [Integral ABS] change bake fluid in wheel circuit every 12 months [Integral ABS] change brake fluid in control circuit every 2 years* ) every 2 years [Integral ABS] perform bleed test with BMW MoDiTeC Check clutch fluid level Change the clutch fluid* ) every 2 years at the latest every 2 years Check tightness of rear wheel studs Check rear wheel bearing play by tilting wheel Check swinging arm bearings (freedom from play), adjust if necessary * ) Grease the side stand pivot Check function of side stand contact switch Check condition of spark plugs Replace spark plugs Tighten cylinder head nuts Check/adjust valve clearances Check that the throttle cable moves freely and is free of kinks and chaffing, replace if necessary * ) Check throttle-cable play check synchronisation, repair leaks if necessary * ) Final inspection with road safety and functional check: – Condition of tyres and wheels, tyre pressures – Lights and signalling equipment, telltale and warning lights, instruments, – clutch, gearshift mechanism, hand brake and foot brake, steering, – if necessary, test drive * ) Charged as an additional item BMW Motorrad Maintenance schedule R 1100 S EVO / R 1150 R / R 1150 RT

Order No. 01 71 0 029 614 UX-VS-2, 12.2000 Printed in Germany Customer Registration No. Order No. Mechanic’s signature BMW Pre-delivery check Check the shipping crate for damage Motorcycle: – unpack – install remaining items – inspect for damage – check that delivery is complete: Toolkit On-board literature Ignition keys Scope of optional extras Fill and charge the battery (mark with charging date) Check engine oil level when cold and correct if necessary. Check headlight setting and adjust if necessary. Check tightness of rear wheel studs (note correct tightening torque) Check tyre pressures Fill up with fuel [Integral ABS] perform bleed test with BMW MoDiTeC Final inspection as functional check: – Clutch, gear shift – Handbrake and foot brake – Lights and signalling equipment, telltale and warning lights, instruments, – Check operation of optional extras – If necessary, test drive Confirm pre-delivery check in “Service and Technical Booklet”. Final cleaning Motorcycle handed over on: BMW Motorrad Pre-delivery check R 1100 S EVO / R 1150 R / R 1150 RT

Order No. 01 71 0 029 621 UX-VS-2, 11.00 Printed in Germany Item Desired value Unit of measure- ment/specification Oil capacities Engine (with filter) (without filter) Transmission Initial filling Oil changes Rear wheel drive Initial filling/oil change 3.75 (6.6) 3.50 (6.15) approx. 1.0 (1.76) approx. 0.8 (1.41) of oil to bottom edge of filler neck approx. 0.25 (0.44) of oil to bottom edge of filler neck litres (Imp. pints) litres (Imp. pints) [SI 11 048 90] Engine oil grade: brand-name HD oil for four-stroke spark-ignition engines, API classes SE, SF, SG; combination with CC or CD specification litres (Imp. pints) litres (Imp. pints) Brand-name hypoid gear oil, SAE class GL 5 SAE 90 litres (Imp. pints) Brand-name hypoid gear oil, SAE class GL 5 SAE 90 Valve clearances measured cold (max. 35 °C/95 °F) Inlet: 0.15 (0.006) Exhaust: 0.30 (0.012) mm (in) mm (in) Ignition timing static setting adjust at TDC Spark plugs Electrode gap Wear limit 0.8 (0.0315) 1.0 (0.039) mm (in) mm (in) Idle speed 1,100 ±50 rpm Throttle cable setting for cold-start (increased idle) speed for throttle (twistgrip) cable for divider cable zero play approx. 0.5 (0.02) zero play mm (in) free travel Brakes Colour of identification mark on brake calipers/brake pads, front Minimum front pad thickness Minimum rear pad thickness Minimum front disc thickness Minimum rear disc thickness white 1.0 (0.039) 1.0 (0.039) (wear mark) 4.5 (0.177) 4.5 (0.177) DOT 4 brake fluid mm (in) mm (in) mm (in) mm (in) Tyre pressures depending on load front: 2.2 – 2.5 (31.9 – 36.26) rear: 2.5 – 2.9 (36.26 – 42.06) bar (psi) bar (psi) Tightening torques: Oil filter Engine oil drain plug 11 32 Nm Nm Gearbox oil filler plug Gearbox oil drain plug 30 30 Nm Nm Rear wheel drive oil filler/drain plug 23 Nm Fuel tank to rear frame Fuel pump assembly to tank 22 5 Nm Nm Poly-V belt preload Alternator to cover mount 8 20 Nm Nm Brake caliper fasteners, front Brake caliper fasteners, rear 30 40 Nm Nm Rear wheel studs 105 Nm Tightening cylinder heads Nut M 10 screw unscrew/20 180 unscrew/40 Nm ° tightening angle Nm Locknut, valve adjusting screw 8 Nm Cylinder head cover 8 Nm Spark plugs NGK BKR 7 EKC 25 Nm BMW Motorrad Service data R 1150 RT

00.1 Contents Page 00 Tightening torque ......................................................................................................................... 3 11 Engine ........................................................................................................................................... 3 12 Engine electrics ........................................................................................................................ 5 13 Fuel preparation and control ............................................................................................... 5 16 Fuel tank and lines ................................................................................................................... 5 18 Exhaust system ......................................................................................................................... 5 21 Clutch ............................................................................................................................................ 6 23 Transmission .............................................................................................................................. 6 31 Front forks ................................................................................................................................... 7 32 Steering ........................................................................................................................................ 7 33 Rear wheel drive ....................................................................................................................... 8 34 Brakes ........................................................................................................................................... 9 36 Wheels and tyres ...................................................................................................................... 9 46 Frame .......................................................................................................................................... 10 51 Equipment ................................................................................................................................. 11 61 General electrical equipment ............................................................................................ 11 Table of operating fluids ......................................................................................................... 12 00 Tightening torque Table of operating fluids

00.3 00 Tightening torque Model R 1150 RT Connection 11 Engine Cylinder head Tightening sequence: 1 Tighten cylinder head nuts (oiled) in diagonally opposite sequence 1.1 Tighten all nuts to closing torque Nm 20 1.2 Tighten all nuts to correct wrench angle ° 90 1.3 Tighten all nuts to correct wrench angle ° 90 2 M 10 screw Nm 40 3 M 6 screw Nm 9 After 1,000 km (600 miles), tighten cylinder head nuts in diagonally opposite sequence: 1 Slacken one nut 2 Tighten nut to initial torque Nm 20 3 Tighten nut to wrench angle ° 180 4 Slacken and retighten M 10 screw Nm 40 Timing gear carrier to cylinder head Nm 9 Bearing cap on rocker shaft Nm 18 Locknut, valve adjusting screw Nm 8 Cylinder head cover to cylinder head Nm 8 Camshaft end cover to cylinder head Nm 9 Air intake connection to cylinder head Nm 9 Camshaft Chain sprocket to camshaft Nm 65 Camshaft bearing cap Nm 15 Alternator mount cover M 6 screw Nm 9 M 8 screw Nm 20 Auxiliary shaft Chain sprocket to crankshaft Nm 10 Chainwheel to auxiliary shaft Nm 70 Chain tensioner housing to engine block Nm 9

00.4 Oil filter Oil filter Nm 11 Oil drain plug Nm 32 Oil pump Mesh filter basket to engine block Nm 10 Oil pump cover Nm 9 Pressure relief valve Nm 42 Oil pressure switch Nm 30 Oil cooler Cooling oil line to engine block Nm 10 Cooling oil line banjo screw with oil vent valve Nm 25 Oil cooler to bracket Nm 9 Oil cooler return line to engine block Nm 35 Oil cooler connection to crankcase Nm 9 Cylinders Tightening sequence: 1 M 8 screw Nm 20 2 M 6 screw Nm 9 3 Chain guide rail pivot screw Nm 18 Timing chain Chain tensioner Nm 32 Connecting rod Big end cap Closing torque Nm 20 Wrench angle ° 80 Crankcase Tightening sequence: M 10 screw (oiled) to initial torque Nm 25 Wrench angle ° 90 M 8 screw Nm 22 (oiled) M 6 screw Nm 9 Model R 1150 RT Connection 11 Engine

00.5 Model R 1150 RT Connection 12 Engine electrics Starter motor to engine Nm 20 Positive lead to starter motor Nm 10 Alternator to generator support cover Nm 20 Tensioning and retaining link to alternator Nm 21 Spacer to alternator Nm 21 Positive lead to alternator Nm 15 Belt pulley to alternator Nm 50 Belt pulley to crankshaft Nm 50 Poly-V belt preload Nm 8 NGK BKR 7 EKC spark plug Nm 25 Model R 1150 RT Connection 13 Fuel preparation and control Oil temperature sensor to crankcase Nm 25 Air temperature sensor to air-filter housing Nm 10 Model R 1150 RT Connection 16 Fuel tank and lines Fuel tank to rear frame Nm 22 Fuel pump assembly to tank Nm 5 Model R 1150 RT Connection 18 Exhaust system Manifold to cylinder head Nm 21 Clamp for manifold Nm 45 (apply Optimoly TA to clamp seat) Silencer to footrest plate Nm 35 Oxygen sensor to silencer Nm 45 (apply Optimoly TA to thread)

BMW R1100S repair manual

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