2001-2005 BMW R1150RT Service & Repair Manual

BMW Motorrad After Sales R 1150 RT Repair Manual

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 07/2001

Introduction This repair manual will help you to perform all the main maintenance and repair work correctly and efficient- ly. If it is consulted regularly by workshop personnel it will form a useful addition to the theoretical and prac- tical knowledge acquired at the BMW Training Centre. 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. 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 complete contents are divided into individual chapters, corresponding to the unified construction groups (U.P.G., referred to here as “Group”). 11 . 10 Chapter chapter page continued If a reference is needed to a different page or chapter, an arrow symbol is shown followed by the chapter and page numbers, e.g. (a 12.5) • 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, as an additional source of information, the Electronic Parts Catalogue (ETK), which contains clear and easy-to-follow illustrations. When individual steps within an overall operation only apply to motorcycles with specific accessories or optional equipment, the options the steps refer to are identified in brackets at the beginning of the line. Ex- ample: [heated grips]. Please devote your careful attention to the following pages with their explanations describing the symbols used in the manual and their significance. BMW Motorrad After Sales Issued by BMW Motorrad After Sales UX-VS-2 D-80788 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. Produced in Germany

How to use this manual Each chapter starts with the list of contents. The list of contents is followed by the Technical Data table. Key to symbols In this Repair Manual for the R 1150 RT model, the following symbols are used; their meanings are ex- plained in the table. Special instructions aimed at improving the work procedures L Note: Specific information on operating, inspecting and adjusting work for the motorcycle as well as maintenance procedures. e Attention: Instructions and precautions specifically intended to prevent damage to the motorcycle. Failure to comply with them could invalidate the warranty. d Warning: This symbol stands for precautions and measures which are essential in order to protect the rider or other persons from possibly severe or fatal injury. Contents The titles of the tasks described in this chapter............. complete with page numbers Activities • Activities • The bullet symbol means that work steps are described in greater detail under a headline – preceding activities – A line indicates work steps described in greater detail under another headline or in another chapter If the term “undo” or “remove” is used: the fastener (e.g. screw) must be slackened off and taken out or a component (e.g. fuel rail) must be removed to the extent that other components which it conceals (e.g. throttlevalve rail) are accessible If the term “loosen” or “slacken” is used the fastener (e.g. screw) must only be slackened off but not taken out X Tightening torque: Values are stated if they differ from DIN EN 24 014 or DIN 912 ISO industrial standards.

BMW Motorrad Maintenance schedule R 1150 RT Customer Licence No. Mileage Job Order No. Date Mechanic’s signature BMW Inspection at 1,000 km/600 miles BMW Maintenance Service every 10,000 km/6,000 miles BMW Inspection every 20,000 km/ 12,000 miles BMW Annual Service Use BMW MoDiTeC to read stored error codes from fault memory [Integral ABS] Performing bleed test with BMW MoDiTeC Change engine oil, warmed to normal operating temperature, replace oil filter when used exclusively in short-distance operation, or at outside temperatures below 0°C (32 °F), or no later than every 3 months, or every 3,000 km/1,800 miles *) Change oil in gearbox, with oil warmed to normal operating temperature at least every 2 years *) Change final-drive lubricant, warmed to normal operating temperature every 40,000 km/25,000 miles, or no later than every 2 years *) Replace fuel filter *) Standard replacement interval is 40,000 km/25,000 miles, with substandard fuel quality every 20,000 km/12,000 miles Check battery electrolyte level, top up with distilled water as necessary Battery terminals, clean and grease as necessary Replace intake air filter element Replace air filter every 10,000 km/6,000 miles when vehicle is exposed to high levels of dirt and dust, or more frequently as indicated *) Check front/rear circuit brake fluid Check operation of brake system, inspect for leaks; repair/replace as indicated *) Check brake pads and discs for wear, replace as required *) [Integral ABS] Change wheel-circuit brake fluid at least once a year [Integral ABS] Change control circuit brake fluid at least every 2 years *) [Integral ABS] Perform bleed test with BMW MoDiTeC Check clutch operating fluid level Change clutch hydraulic circuit fluid *) at least every 2 years Check rear lug bolts to ensure they are tight Check rear wheel bearing play by tilting wheel Check swing arm bearings (no play), adjust as required *) Check operation of side stand switch Grease the side stand pivot Retention poly-V-belt Re-adjust new poly-V-belt one time at 10,000 km/6,000 miles Replace poly-V-belt *) Replace poly-V-belt every 60,000 km/35,000 miles Inspect spark plugs Replace spark plugs Retorque cylinder heads Check valve clearance and adjust as necessary Check throttle cable for ease of motion, inspect for abrasion and bends, replace as indicated *) Check cable free travel Check synchronisation, adjust as necessary Final inspection with operation assessment and road safety check: – Condition of wheels and tyres, tire inflation pressure – Clutch, shift mechanism, hand and foot brakes, steering – Lighting and signal indicators, warning and indicator lamps, instruments – Optional equipment – Conduct road test as required *) Write up on separate invoice; Not part of standard service procedure UX-VS-2, 07.2001 BMW recommends Castrol

BMW Motorrad Pre-delivery check R 1150 RT Customer Licence No. Job Order No. Mechanic’s signature BMW Pre-delivery check Check the shipping pallet for damage Unpack the motorcycle Inspect motorcycle for damage Check to ensure that consignment is complete: – Vehicle keys – Onboard tool kit and literature – All optional extras Installing remaining items on motorcycle Fill and charge battery (record charging date) [Integral ABS] Perform bleed test with BMW MoDiTeC Check engine oil when cold, correct as required Check tyre pressures Check tightness of rear lug bolts (note torque specification!) Fill with fuel Check headlight beam angle, adjusting if necessary Final inspection and function check – Clutch, shift mechanism – Handbrake and foot brake – Lighting and signal indicators, warning and indicator lamps, instruments – Check operation of standard and optional equipment – Road test as indicated Confirm pre-delivery check in “Service and Technical Booklet“ Final cleaning Vehicle delivered on: UX-VS-2, 07.2001 BMW recommends Castrol

BMW Motorrad Service data R 1150 RT Item Desired value Units / Specifications Oil capacities Engine (with filter) 3.75 (6.6) litres (Imp. pints) [SI 11 048 90] Engine (without filter) 3.5 (6.15) litres (Imp. pints) [SI 11 048 90] Transmission Initial filling approx. 1.0 (1.76) up to lower edge of filler hole litres (Imp. pints) Brand-name hypoid gear oil, SAE class GL 5 SAE 90 Transmission oil change approx. 0.8 (1.41) up to lower edge of filler hole litres (Imp. pints) Brand-name hypoid gear oil, SAE class GL 5 SAE 90 Rear wheel drive Initial filling/oil change approx. 0.25 (0.44) up to lower edge of filler hole 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) mm (in) Exhaust 0.30 (0.012) mm (in) Ignition timing adjust at TDC static setting Spark plugs BKR 7 EKC NGK Electrode gap 0.8 (0.0315) mm (in) Wear limit 1.0 (0.039) mm (in) Idle speed 1,100 ±50 rpm Throttle cable setting for cold-start (increased idle) speed no play for throttle (twistgrip) cable play approx. 0.5 (0.02) mm (in) for divider cable no play Brakes Brake fluid DOT 4 Colour of identification mark on brake calipers/brake pads, front white Minimum front pad thickness 1.0 (0.039) mm (in) Minimum rear pad thickness 1.0 (0.039) (wear mark) mm (in) Minimum front disc thickness 4.5 (0.177) mm (in) Minimum rear disc thickness 4.5 (0.177) mm (in) Tyre pressures depending on load front 2.2 - 2.5 (31.9 – 36.26) bar (psi) rear 2.5 - 2.9 (36.26 – 42.06) bar (psi) Tightening torques Oil filter 11 Nm Engine oil drain plug 32 Nm Gearbox oil filler plug 30 Nm Gearbox oil drain plug 30 Nm Rear wheel drive oil filler/drain plug 23 Nm Fuel tank to rear frame 22 Nm Fuel pump assembly to tank 5 Nm Poly-V belt preload 8 Nm Alternator to cover mount 20 Nm Brake caliper fasteners, front 30 Nm Brake caliper fasteners, rear 40 Nm Rear wheel studs 105 Nm Tightening cylinder heads Nut unscrew / 20 180 Nm ° tightening angle M 10 screw unscrew / 40 Nm Locknut, valve adjusting screw 8 Nm Cylinder head cover 8 Nm Spark plugs 25 Nm UX-VS-2, 07.2001 BMW recommends Castrol

00 Tightening torques, Table of operating fluids 00 Pre-delivery check 00 Maintenance 11 Motor 12 Engine electrics 13 Fuel preparation and control 16 Fuel tank and lines 18 Exhaust system 21 Clutch 23 Gearbox 31 Front forks 32 Steering 33 Rear wheel drive >> Continuation Contents << Back Group / Chapter

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

00.1 Contents Page 00 Tightening torques ....................................................................................................................... 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 torques, Table of operating fluids

2001-2005 BMW R1150RT Service & Repair Manual

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