BMW R 1150 RT Betriebsanleitung

BMW Motorrad

After Sales

R 1150 RT

Repair Manual

Published by ©BMW Motorrad

After Sales

UX-VS-2

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 illus-

trations.

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

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

LNote:

Specific information on operating, inspecting and adjusting work for the motorcycle as well as maintenance

procedures.

eAttention:

Instructions and precautions specifically intended to prevent damage to the motorcycle. Failure to comply

with them could invalidate the warranty.

dWarning:

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

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 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 25 Nm

UX-VS-2, 07.2001 BMW recommends Castrol

Gruppe / Kapitel

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

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 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

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