1999-2005 BMW R1150 R1150GS Service & Repair Manual

Repair Manual BMW Motorrad After Sales R 1150 GS

Publisher © 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. Printed in Germany 02/00 Order number 01 79 0 021 120

Introduction This Repair Manual will help you to perform all the main maintenance and repair work correctly and effi- ciently. It should be consulted regularly by workshop personnel as an addition to the practical and theoret- ical knowledge obtained in Training School courses. It is a contribution towards achieving even higher Service quality. A new issue of this repair manual will be published if amendments or additions (supplements) are needed. The latest issue date is shown in the header of the microfiche. Microfiches rendered invalid by the new issue should be destroyed without delay. All information in both text and illustrations refers to motorcycles in standard condition or with genuine BMW accessories installed, and not to motorcycles which have been modified in any way to depart from the manufacturer’s specification. ● The Repair Manual is structured in the logical sequence of the work to be performed: Removal, Disas- sembly, Repair, Assembly, Installation. ● The entire contents are divided into individual chapters, corresponding to the Construction Groups. 11 . 10 Chap. Page number within chapter ● Work to be performed during an Inspection is described in Group “00”. The various inspection routines are numbered I, II, III and IV. This numbering is repeated in the work descriptions which follow, so that work can take place without interruption. ● Use of the BMW special tools needed for certain tasks is described in the work instructions. If the need arises, repair instructions are also issued in the form of Service Information. This information is of course incorporated into the next issue of the Repair Manual. We also recommend you to consult the detailed illustrations on the Parts microfiches as an additional source of information. BMW Motorrad After Sales Published by: BMW Motorrad Hufelandstr. 6 D - 80937 München 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. Printed in Germany

UX-VS-2, 04.00 Printed in Germany Customer Licence plate No. Order No. Mechanic’s signature BMW Inspection at 1000 km (600 miles) BMW Service every 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 MoDiTeC Change oil while at regular operating temperature and renew the oil filter element if motorcycle is used only for short journeys or at outside temperatures under 0°C (32 °F), every 3 months, but at least every 3 000 km (1 800 miles) * ) Change oil in gearbox while at operating temperature at least every 2 years* ) every 2 years Change oil in rear wheel drive while at regular operating temperature; if necessary, clean inductive sensor on rear wheel every 40 000 km (24 000 miles) or at least every 2 years * ) 40 000 (24 000) every 2 years Renew fuel filter * ) normally every 40 000 km (24 000 miles), if fuel quality is poor every 20 000 km (12 000 miles) 40 000 (24 000) Check battery acid level, if necessary add distilled water Clean and grease the battery terminals, if necessary Renew intake air filter element in very dusty or dirty operating conditions, renew the intake air filter element every 10 000 km (6 000 miles) or even more often if necessary * ) Renew Poly-V belt * ) renew Poly-V belt every 60 000 km (36 000 miles); do not adjust 60 000 (36 000) Check brake fluid level at front and rear Check operation of brake system and freedom from leaks; repair/replace items if nec. * ) Examine brake pads and discs for wear, renew if necessary * ) Change the brake fluid annually Check clutch fluid level Change the clutch fluid at least every 2 years * ) every 2 years Check tightness of rear wheel studs Check rear wheel bearing play by tilting wheel Check swinging arm bearings (zero play); adjust if necessary * ) Grease the side stand pivot Check function of side stand contact switch Check condition of spark plugs Renew spark plugs Check security of cylinder head nuts Check/adjust valve clearances Check throttle cable for free movement, abrasion and kinking; renew if necessary * ) Check cable play Check synchronisation and eliminate leaks * ) Final inspection with road safety and functional check: – Condition of tyres and wheels, rims and spokes if applicable, tyre pressures – Lights and signalling equipment – Telltale and warning lights – Clutch, gear shift – Front and rear brakes, steering – Instruments – If necessary, test ride * ) Charged as an additional item BMW Motorrad Maintenance schedule R 1100 S / R 850/1200 C / R 1150 GS

UX-VS-2, 04.00 Printed in Germany Customer Licence plate 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: tools documentation keys correct optional extras Fill and charge the battery (mark with charging date) Check engine oil level when cold; add oil if necessary Check headlight beam angle, adjust if necessary Check security of rear wheel studs (comply with correct tightening torque) Check tyre pressures Fill fuel tank Final inspection as functional check: – Clutch, gear shift – Front and rear brakes – Lights and signalling equipment, telltale and warning lights, instruments – Check operation of optional extras, ABS – If necessary, test ride Confirm pre-delivery check in Service and Technical Booklet Final cleaning Motorcycle handed over on: BMW Motorrad Pre-delivery check R 1100 S / R 850/1200 C / R 1150 GS

Order No. 01 71 0 008 851 UX-VS-2, 06.99 Printed in Germany Item Desired value Unit of measurement/ specification Oil capacities Engine (with filter) (without filter) Gearbox Initial filling/oil changes Rear wheel drive Initial filling/oil changes 3.75 (6.60) 3.50 (6.16) approx. 1.0 (1.76) up to lower edge of filler hole approx. 0.25 (0.44) oil level with bottom 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) 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 (0.011) mm (in) mm (in) Ignition timing Static setting adjust at TDC Spark plugs Electrode gap Wear limit 0.8 (0.03) 1.0 (0.04) mm (in) mm (in) Idle speed 1100± 50 min -1 Throttle cable setting for cold-start (increased idle) speed for throttle (twistgrip) cable for divider cable zero play app. 0.5 (0.02) zero play mm (in) free travel Brakes Minimum front pad thickness Minimum rear pad thickness Minimum front disc thickness Minimum rear disc thickness 1.0 (0.04) wear mark 4.5 (0.18) 4.5 (0.18) DOT 4 brake fluid mm (in) mm (in) mm (in) Tyre pressures depending on load front: 2.2 – 2.5 (31.3 – 35.6) rear: 2.5 – 2.9 (35.6 – 41.2) 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 unit to tank 21 6 Nm Nm Poly-V belt preload Alternator to alternator carrier cover 8 20 Nm Nm Brake calliper mounting, front/rear 40 Nm Rear wheel studs initial torque 72 105 Nm Nm Tightening cylinder heads Nut M 10 screw slacken/20 180 slacken/40 Nm ° tightening angle Nm Locknut, valve adjusting screw 8 Nm Cylinder head cover 8 Nm Spark plugs 20 Nm BMW Motorrad Service data R 1150 GS

00 Maintenance and general instructions 11 Engine 12 Engine electrics 13 Fuel preparation and control 16 Fuel tank and lines 18 Exhaust system 21 Clutch 23 Transmission 31 Front forks 32 Steering 33 Rear wheel drive >> Next General table of contents << Back Group / Section

34 Brakes 36 Wheels and tyres 46 Frame 51 Equipment 52 Seat 61 General electrical equipment 62 Instruments 63 Lights << Back >> Next

00.1 Contents Page 00 Tightening torques ....................................................................................................................... 5 Table of operating fluids ......................................................................................................... 12 00 Maintenance and general instructions Tightening torques and table of consumables Pre-delivery check Maintenance

00.2 Contents - Pre-delivery check Page Pre-delivery check ..................................................................................................................... 13 General view of crated motorcycle ................................................................................... 13 Check the shipping crate for damage ............................................................................ 14 In case of damage in Germany ............................................................................................... 14 In case of damage in importer markets .............................................................................. 14 Unpacking the motorcycle .................................................................................................... 14 Inspecting motorcycle for damage ................................................................................... 15 Checking that delivery is complete .................................................................................. 15 Installing remaining items on motorcycle ..................................................................... 16 Install the windscreen ................................................................................................................. 16 Installing sump guard .................................................................................................................. 17 Filling and charging the battery .......................................................................................... 18 Disengaging and raising the fuel tank ................................................................................. 18 Filling and charging the battery .............................................................................................. 18 Checking engine oil when engine is cold, topping up if necessary ............... 19 Checking headlight beam angle, adjusting if necessary ...................................... 20 Checking tightness of rear wheel studs ........................................................................ 20 Checking tyre pressures ........................................................................................................ 20 Attaching adhesive label ........................................................................................................ 20 Final inspection and function check ................................................................................ 21 Final cleaning ............................................................................................................................... 21 Handing over the motorcycle ............................................................................................... 21 Pre-delivery check

1999-2005 BMW R1150 R1150GS Service & Repair Manual

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