BMW R 1150 R Betriebsanleitung

BMW Motorrad

After Sales

R 1150 R

Repair Manual

Preface

This Repair Manual is intended to assist you in performing professional maintenance and repair operations.

In its role as a reference source for service personnel, it supplements and expands upon the theoretical

and hands-on instruction provided at our training centres to enhance the quality of our service.

A new edition of this manual will be issued in response to required revisions or the need to incorporate ad-

ditional information (supplements).

The illustrations and descriptions contained in this manual apply exclusively to standard, unmodied BMW

Motorcycles and/or BMW Motorcycles equipped with factory-approved BMW accessories and options.

•The Repair Manual’s structure reects the logical sequence in which the operations it describes will be

performed: removal, dismantling, repairs, assembly and installation.

•The individual chapters in this manual correspond to the motorcycle’s individual assembly groups.

11 . 10

deunitnocegapretpahCretpahC

A reference arrow with chapter and page (such as a 12.5) calls your attention to additional information

contained in another section of the manual

•Group"00"describestheoperationscarriedoutinthecourseofeachInspection.The variousinspectionroutines

are numberedI, II, III and IV. To help in maintaining a continuous, logical work sequence, these same numerical

designations are employed to identify the subsequent sections describing the actual repair operations.

•Use of the BMW special tools needed for certain operations is described in the work instructions.

When the need arises, repair instructions are also issued in the form of Service Information Bulletins. This infor-

mation is then incorporated into the subsequent edition of the repair manual. We also recommend that you take

advantage of the clearly illustrated Electronic Parts Catalogue as a supplementary source of information.

When individual steps within an overall operation only apply to motorcycles with specic accessories or

optional equipment, the options the steps refer to are identied in brackets at the beginning of the line.

Example: [heated grips] .

Please devote your careful attention to the following pages with their explanations describing the symbols

used in the manual and their signicance.

BMW Motorrad

After Sales

How to use this manual

Each chapter starts with a table of contents.

Following the table of contents is a table containing the techical data and specifications for the chapter’s

subject.

Explanation of symbols

This manual for the R 1150 R employss the following symbols; please refer to the table for their meanings.

Special notices for more efficient procedures

LNote:

These special notices help technicians work more efficiently when operating, inspecting, adjusting and

maintaining motorcycles.

eAttention:

Special information and precautionary notices to prevent damage to the motorcycle. Failure to observe

these mandatory precautions may invalidate the warranty.

dWarning:

Precautions intended to protect the rider and/or other individuals against injury as well as potentially fatal

hazards.

Contents

The titles of the operations described in this chapter............. together with page numbers

Operations

•Operations

•A dot or period identifies individual procedures described under a title

–previous operations

–The hyphen identifies procedures described in more detail under a different title or in another chapter

Remove means:

To completely unscrew a retaining component (such as a bolt or screw)

to detach a component (such as an injection rail) and move it enough to gain access to assemblies installed

behind it (such as a throttle-valve).

Loosen means:

To unscrew an attachment (such as a bolt or screw) without removing it entirely from its threaded socket

or retainer

X Tightening torques:

These data are indicated whenever torques deviate from the standards defined in DIN EN 24 014 and

DIN 912 ISO.

BMW Motorrad

Maintenance schedule

R 1150 R

Customer Licence No. Mileage

Job Order No. Date Mechanic’s signature

BMW Inspection at

1000 km/600 miles

BMW Maintenance

Service every

10000 km/6,000 miles

BMW Inspection

every 20000 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 *)

[Without Integral ABS] Change brake fluid annually

[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

Order No. 01 71 0 141 316 UX-VS-2, 05.2001 1st edition BMW recommends Castrol

BMW Motorrad

Pre-delivery check

R 1150 R

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 footbrake

–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:

Order No. 01 71 0 141 316 UX-VS-2, 05.2001 1st edition BMW recommends Castrol

BMW Motorrad

Service data

R 1500 R

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

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 green

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 5Nm

Poly-V belt preload 8Nm

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

°tightening angle

M 10 screw unscrew / 40 Nm

Locknut, valve adjusting screw 8Nm

Cylinder head cover 8Nm

Spark plugs NGK BKR 7 EKC 25 Nm

Order No. 01 71 0 026 973 UX-VS-2, 07.2000 1st edition BMW recommends Castrol

Gruppe / Kapitel

00 Tightening torque Table of operating fluids

00 Pre-delivery check

00 Maintenance

11 Engine

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

Gruppe / Kapitel

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

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 .........................................................................................................................6

21 Clutch ............................................................................................................................................6

23 Transmission ..............................................................................................................................7

31 Front fork ......................................................................................................................................7

32 Steering ........................................................................................................................................8

33 Rear wheel drive .......................................................................................................................8

34 Brakes ...........................................................................................................................................9

36 Wheels and tyres ....................................................................................................................10

46 Frame ..........................................................................................................................................10

51 Equipment ................................................................................................................................. 11

61 General electrical equipment ............................................................................................ 11

Table of operating fluids .........................................................................................................12

00 Tightening torque

Table of operating fluids

00.2

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