BMW R 1150 GS Betriebsanleitung

Repair Manual

BMW Motorrad

After Sales

R 1150 GS

Publisher © BMW Motorrad

After Sales

UX-VS-2

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

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

2years

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

2years

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

2years

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)

[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)

DOT 4 brake fluid

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)

Tightening torques:

Oil filter

Engine oil drain plug 11

32 Nm

Gearbox oil filler plug

Gearbox oil drain plug 30

30 Nm

Rear wheel drive oil filler/drain plug 23 Nm

Fuel tank to rear frame

Fuel pump unit to tank 21

6Nm

Poly-V belt preload

Alternator to alternator carrier cover 8

20 Nm

Brake calliper mounting, front/rear 40 Nm

Rear wheel studs initial torque 72

105 Nm

Tightening cylinder heads Nut

M10screw

slacken/20

180

slacken/40

°tightening angle

Locknut, valve adjusting screw 8Nm

Cylinder head cover 8Nm

Spark plugs 20 Nm

BMW Motorrad

Service data

R 1150 GS

Group / Section

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

Group / Section

00.1

Contents Page

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

re-

very c

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