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BMW R 1150 R Repair Manual

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Repair Manual
R 1150 R
BMW Motorrad
After Sales

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Summary of Contents for BMW R 1150 R

  • Page 1 Repair Manual R 1150 R BMW Motorrad After Sales...
  • Page 2 • 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.
  • Page 3 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 Note: These special notices help technicians work more efficiently when operating, inspecting, adjusting and maintaining motorcycles.
  • Page 4 Job Order No. Date Mechanic’s signature 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),...
  • Page 5 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!)
  • Page 6 Tightening cylinder heads unscrew / 20 ° tightening angle M 10 screw unscrew / 40 Locknut, valve adjusting screw Cylinder head cover Spark plugs NGK BKR 7 EKC Order No. 01 71 0 026 973 UX-VS-2, 07.2000 1st edition BMW recommends Castrol...

  • Page 7: 12 Engine Electrics

    Contents << Back Gruppe / Kapitel Group / Chapter 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...
  • Page 8 >> Continuation Gruppe / Kapitel Group / Chapter 34 Brakes 36 Wheels and tyres 46 Frame 51 Equipment 52 Seat 61 General electrical equipment 62 Instruments 63 Lights << Back...

  • Page 9: Table Of Contents

    00 Tightening torque Table of operating fluids 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...
  • Page 10 00.2...
  • Page 11 Tightening torque Model R 1150 R Connection 11 Engine Cylinder head Tightening sequence: 1 Tighten cylinder head nuts (oiled) in go- nally opposite sequence 1.1 Tighten all nuts to closing torque 1.2 Tighten all nuts to correct angle ° 1.3 Tighten all nuts to correct angle °...
  • Page 12 Model R 1150 R Connection 11 Engine Oil filter Oil filter Oil drain plug Oil pump Mesh filter basket to engine block Oil pump cover Pressure relief valve Oil pressure switch Oil cooler Cooling oil line to engine block Cooling oil line - banjo screw with oil vent...
  • Page 13 Model R 1150 R Connection 12 Engine electrics Starter motor to engine Starter cover to gearbox housing Positive lead to starter motor Alternator to alternator support cover Tensioning and retaining link to alternator Spacer to alternator Positive lead to alternator...

  • Page 14: 18 Exhaust System

    Model R 1150 R Connection 18 Exhaust system Manifold to cylinder head Clamp for manifold (apply Optimoly TA to clamp seat) Front silencer to manifold (apply Optimoly TA to clamp seat) Silencer to main stand lugs Silencer to rear frame at top...

  • Page 15: 23 Transmission

    Model R 1150 R Connection 23 Transmission Oil drain plug Oil filler plug Gearbox to engine block Shift lever to footrest plate Selector lever to selector shaft Housing cover to housing Frame tube to gearbox 1. to gearbox and left footrest plate (clean thread + Loctite 243) 2.

  • Page 16: 32 Steering

    Model R 1150 R Connection 32 Steering Handlebars to fork bridge, tightening se- quence: 1. Front fastener (as viewed in forward direction of travel) until seated 2. Rear fastener (as viewed in forward direction of travel) Handlebar weight to handlebars Pivot screw, handlebar lever (Tuflok Blue thread-locking compound;...
  • Page 17 Model R 1150 R Connection 33 Rear wheel drive Reaction link to rear wheel drive / gearbox (load approx. 85 kg (187 lbs) onto motorcycle and tighten loose reaction link) Spring strut to rear frame Spring strut to rear swinging arm...

  • Page 18: 36 Wheels And Tyres

    Model R 1150 R Connection 36 Wheels and tyres Quick-release axle clamp screws Quick-release axle threaded fastener Rear wheel to rear wheel drive Hand-tighten wheel studs and tighten in diagonally opposite sequence [Integral ABS] Note spacer Model R 1150 R...

  • Page 19: 51 Equipment

    Model R 1150 R Connection 46 Frame Front and rear sections of front mudguard to slider tube (Tuflok Blue thread-locking compound; screw can be released and tightened a number of times alternatively: clean thread + Loctite 243) Headlight bracket to fork bridge...

  • Page 20: Table Of Operating Fluids

    83 19 9 407 855 500 ml spray housings Crack testing agent for aluminium Developer MR 70 81 22 9 407 495 500 ml spray housings Installation aids BMW cooling spray Cooling spray 83 19 9 407 762 300 ml spray 00.12...
  • Page 21 Checking headlight beam angle, adjusting if necessary ........19 Checking tightness of rear wheel studs ................19 Checking tyre pressures ......................19 [Integral ABS] Performing bleed test with BMW MoDiTeC ........20 Final inspection and function check ................20 Final cleaning ..........................20 Handing over the motorcycle ....................21...
  • Page 22 00.14...

  • Page 23: General View Of Crated Motorcycle

    General view of crated motorcycle 00.15...

  • Page 24: Checking The Shipping Pallet For Damage

    Optional seat cover, if applicable Check for faults. • • Force off cross-struts with a suitable lever. “Express handling service” to: BMW Motorrad UX-VS-1 Attention: Fax number +49 89-382-33220 • Do not knock the cross-struts out or the motorcycle Rectify the fault.

  • Page 25: Filling And Charging The Battery

    M IN R28000020 Filling and charging the battery Filling and charging the battery 61 21 61 21 Removing the fuel tank 16 11 533 Warning: • Remove front/rear seat. Battery acid is highly caustic. • Lever off the right-hand and left-hand front trim Protect your eyes, face, hands, clothing and the sections from the tank.

  • Page 26: Checking Engine Oil When Engine Is Cold, Topping Up If Necessary

    Disconnecting the battery deletes all entries (e.g. faults, settings) stored in the Motronic control unit’s memory. Loss of settings can temporarily impair the operat- ing characteristics when the engine is restarted. Tightening torque: Fuel tank to frame ........22 Nm BMW recommends Castrol 00.18...

  • Page 27: Checking Headlight Beam Angle, Adjusting If Necessary

    Checking headlight beam Checking tightness of rear wheel 63 10 500 angle, adjusting if necessary studs Tightening torque: Securing screws for rear wheel ....105 Nm Checking tyre pressures • Check/correct tyre pressures. Tyre pressures: Solo ........front 2.2 bar (31.3 psi) ..........

  • Page 28: [Integral Abs] Performing Bleed Test With Bmw Moditec

    • BMW MoDiTeC: Clean the motorcycle. • Remove front/rear seat. • Connect the BMW MoDiTeC to the diagnostic connector. Note: Do not use a steam or high-pressure water jet. The high steam or water pressure could damage seals, Warning: the hydraulic system or electrical components.

  • Page 29: Handing Over The Motorcycle

    – controls – instruments and indicator lights – optional equipment and accessories fitted – features of BMW Integral ABS: brake servo, residual braking function, pump noises, self-diagnosis with pull-away test. • The user must be given the following information: –...
  • Page 30 00.22...
  • Page 31 Maintenance interval codes ....................27 Reading the BMW MoDiTeC fault code memory ............27 (Inspections I, II, III and IV) [Integral ABS] Performing bleed test with BMW MoDiTeC ........27 (Inspections I, II, III and IV) Changing engine oil, replacing oil filter element ............28...
  • Page 32 Contents Page Checking brake system for correct operation and freedom from leaks; repairing/replacing if necessary ...............35 (Inspection III) Checking brake pads and discs for wear/replacing ..........35 (Inspections II and III) Checking front brake pad wear ....................35 Checking rear brake pad wear ....................36 Checking brake disc wear ......................36...
  • Page 33 Contents Page Checking rear wheel bearing play by tilting wheel ..........55 (Inspection III) Checking swinging arm bearings, adjusting if necessary ........55 (Inspections I and III) Greasing the side stand pivot ....................55 (Inspections I, II and III) Checking function of side stand contact switch ............55 (Inspections I, II, III and IV) Checking/replacing spark plugs...
  • Page 34 00.26...

  • Page 35: Maintenance Interval Codes

    The codes for service and maintenance intervals in this Repair Manual are as follows: — Break-in Inspection at 1000 km/600 miles ..I — BMW Service at 10 000 km/6,000 miles ... II — BMW Inspection at 20 000 km/12,000 miles..III — BMW Annual Service ........IV...

  • Page 36: Changing Engine Oil, Replacing Oil Filter Element

    Remove oil drain plug and drain off oil. • Refit the oil drain plug with a new sealing ring. • Use the oil filter wrench, BMW No. 11 4 650, to remove the oil filter. • Coat the sealing ring on the new oil filter element with oil and install filter.

  • Page 37: Changing The Transmission Oil

    Changing the transmission Changing the oil in the rear 00 11 229 00 11 229 wheel drive (Inspections III and IV) (Inspections I, III and IV) or at least every 2 years Every 40,000 km (24,000 miles) or at the latest every 2 years •...

  • Page 38: Replacing Fuel Filter

    R28160021 Replacing fuel filter 16 12 008 (Inspection III) In normal operating conditions every 40,000 km (24,000 miles); if fuel quality is poor every 20,000 km (12,000 miles) • Remove front/rear seat. • Lever off the right-hand and left-hand front trim sections from the tank.
  • Page 39 Note correct direction of flow through fuel filter. Note: Make sure that breather lines are correctly routed. • Tighten one-time hose clips with pliers, BMW No. 13 1 500. Note: Pay attention to washers (3). Attention: Make sure that O-ring (2) is in perfect condition.

  • Page 40: Checking Battery Fluid Level And Topping Up If Necessary; Cleaning And Greasing The Battery Terminals

    M IN R28000020 Checking battery fluid level Replacing intake air filter 61 20 029 13 72 000 and topping up if necessary; clean- element ing and greasing the battery termi- (Inspection III) nals In very dirty and dusty operating conditions, replace every 10,000 km (6,000 miles) or even (Inspections III and IV) more frequently if necessary...

  • Page 41: Replacing Poly-V-Belt

    Replacing poly-V-belt 12 31 240 (Inspection III) every 60,000 km (36,000 miles) • Remove left-hand oil cooler trim. RS110490 • Remove front cover. • Slacken alternator mounting screws and nuts (1,3,4) and install a new poly-V- belt if necessary. RS110480 Poly-V-belt adjustment procedure: Poly-V-belt installation procedure: •...

  • Page 42: [Without Integral Abs] Checking Brake Fluid Level

    [Without Integral ABS] Checking • Turn the handlebars to the left. brake fluid level (Inspections II and III) Note: The volume of the brake fluid (MIN/MAX) is sufficient for lining thicknesses from new to the wear limit. It is not normally necessary to top up the fluid to ac- commodate lining wear.

  • Page 43: [Integral Abs] Checking Brake Fluid Level

    [Integral ABS] Checking brake fluid Checking brake system for correct level operation and freedom from leaks; repairing/replacing if necessary (Inspections II and III) (Inspection III) Note: • The brake fluid level in the sight glass/brake fluid Check brake system for leaks. level remains constant despite wear of the brake Checking brake pads and discs for pads.

  • Page 44: Checking Rear Brake Pad Wear

    Checking rear brake pad wear Checking brake disc wear R28000130 R28000140 • • Make sure that the brake disc is not visible Examine the brake discs carefully for cracks, through the bore (arrow) in the inner brake pad. damage, distortion, wear and score-marks. •...

  • Page 45: Replacing Brake Pads, Front Brake

    • Remove old brake pad and insert new brake pad. Note: Always wait for the BMW Integral ABS to complete its self-diagnosis after the ignition is switched on. Do not operate the brake lever until self-diagnosis is complete.

  • Page 46: Replacing Brake Pads, Rear Brake

    34 21 200 Installation is the reverse of the removal proce- dure. brake Note: Always wait for the BMW Integral ABS to complete its self-diagnosis after the ignition is switched on. Do not operate the brake lever until self-diagnosis is complete. •...

  • Page 47: [Without Integral Abs] Changing Brake Fluid And Bleeding The Brake System

    34 1 531 34 1 532 R28000180 • Use the reset device, BMW No. 34 1 531, and the positioning piece, BMW No. 34 1 532, to press back and position the brake caliper pis- tons on the left and right.

  • Page 48: [Without Integral Abs] Bleeding/Changing Brake Fluid In Rear System

    Check that the front wheel is on the ground. • Minimum fluid level Use the reset device, BMW No. 34 1 531, and Brake pads worn the adapter, BMW No. 34 1 536, to press the not less than ....the centre of the sight glass pistons completely back and to position them.
  • Page 49 • Assembly is the reverse of the disassembly pro- cedure. • Check the function of the brake system. • Recheck the brake-fluid level. Minimum fluid level Brake pads worn not less than ..............“MIN” Brake fluid ...........DOT 4 Tightening torque: Rear brake caliper bleed screw ......

  • Page 50: [Integral Abs] Changing/Bleeding Brake Fluid In Wheel Circuit

    Change brake fluid in wheel circuit once a year (Inspection IV) Attention: Only use the piston reset device, BMW No. 34 1 531, if the wheel circuit res- Warning: ervoir cover is open. All repair and maintenance work on the BMW Integral ABS should be carried out by special- ly trained personnel.
  • Page 51 Note: Always wait for the BMW Integral ABS to complete its self-diagnosis after the ignition is switched on. Note: Do not operate the brake lever until self-diagnosis is If necessary, use a cable tie to secure the bleed complete.
  • Page 52 “MAX” • • Use adapter 23, BMW No. 34 1 534, in the reset If necessary, carefully press back the pistons so device, BMW No. 34 1 531/532, on both front that the pad just fits in.
  • Page 53 BMW No. 34 2 541. • Connect the 1.5 m (4.9214 ft) silicone hose, BMW No. 34 1 561, to the right brake caliper 34 1 561 bleed screw. • The procedure for bleeding the right brake cali- per is the same as that for the left caliper.

  • Page 54: [Integral Abs]

    BMW No. 34 1 531, can be used. Attention: Only use the piston reset device, BMW No. 34 1 531, if the wheel circuit res- ervoir cover is open. 34 1 536 34 1 531 R28000170 •...
  • Page 55 R28340090 Attention: The piston in the base of the wheel circuit reservoir must always be covered by the fluid, as otherwise air can be drawn into the brake system. Bleed the system again if this happens. • Very gently press the footbrake until the pump just starts up.
  • Page 56 (arrow). • “MAX”. Remove the reset device, BMW No. 34 1 531 • Screw the reset device, BMW No. 34 1 531, to with adapter, BMW No. 34 1 536. the adapter, BMW No. 34 1 536. Warning: Attention:...
  • Page 57 Close the bleed screw. • Release the brake and switch off the ignition. • Detach the silicone hose, BMW No. 34 1 561, 34 1 561 from the bleed screw and empty it. • Remove the cover, BMW No. 34 2 541.

  • Page 58: [Integral Abs] Changing/Bleeding Brake Fluid In Control Circuit

    Change brake fluid in control circuit every 2 years (Inspection IV) Warning: All repair and maintenance work on the BMW Integral ABS should be carried out by special- ly trained personnel. Maintenance and repair procedures and processes R21000020 should be strictly observed.
  • Page 59 – again, front dosing cylinder (1) in direction of travel........21 Nm using the ring spanner, BMW No. 34 2 532, and in 2. Rear connection in direction of travel ..21 Nm accordance with rules for bleeding. Rules for bleeding: 1.

  • Page 60: [Integral Abs]

    (3) and, – again, front dosing cylinder (1) using the ring spanner, BMW No. 34 2 532, and in accordance with the rules for bleeding. Rules for bleeding: 1. Press the brake lever slowly until the brake light switch clicks (snifter hole closed).

  • Page 61: Checking Clutch Operating Fluid Level

    Attention: Once all the work has been completed, perform a R28000040 bleed test using the BMW MoDiTeC. • Performing a bleed test with BMW MoDiTeC. Required level with a new clutch liner: 00.27) ........... Half way up sight glass •...

  • Page 62: Changing The Clutch Fluid

    Changing the clutch fluid • 21 52 005 Screw the bleed screw all the way into the filler adapter (valve in filler adapter closed). (Inspection IV) at least every 2 years Attention: While bleeding the system, do not allow the brake Note: fluid level to drop below the bottom edge of the ring The description applies to a brake system filling and...

  • Page 63: Checking Tightness Of Rear Wheel Studs

    (Inspections I, II and III) 12 3 520 R21000190 • Pull off spark the plug caps using the special puller, BMW No. 12 3 520. • Remove the spark plugs using the spark plug wrench, BMW No. 12 3 510. Attention: Do not bend electrodes, there is a risk of breaking them.

  • Page 64: Tightening Cylinder Heads

    Tightening cylinder heads Checking/adjusting valve 11 12 009 11 34 004 clearances (Inspection I) (Inspections I, II and III) R21000330 R21000340 • Remove cylinder head cover. • Check valve clearance with feeler gauge and, if necessary, correct with adjusting screw. Attention: Catch escaping oil.

  • Page 65: (Inspections I, Ii And Iii)

    20 minutes. Play of throttle cable: ..approx. 2 mm (0.0787 in) • Oil temperature:....at least 90 °C (130 °F) Connect the BMW Synchro hose to the vacuum adapter and connect the cables to BMW MoDiTeC. • Adjust idle speed by turning the air bypass screws while checking that the carburettors are balanced.
  • Page 66 • • Adjust the right throttle valve in the same way. Push the rubber cap into position over the ad- justing screw. • Move the handlebars all the way from left to right Note: and check the settings. Make sure that engine If play is zero, the throttle butterflies may chatter.

  • Page 67: Final Inspection With Road Safety And Functional Check

    Final inspection with road safety and functional check (Inspections I, II, III and IV) Road safety check • Check wheels and tyres. • Check/correct tyre pressures. • Wait at least 10 minutes after the trial run/road test before checking/correcting engine oil level. Tyre pressures: Solo ........front 2.2 bar (31.3 bar) ..........
  • Page 68 11 Engine Contents Page Technical Data ..........................5 Cutaway drawing of engine ....................13 Lubricating-oil circuit ....................... 14 Cooling-oil circuit ........................15 Removing and installing engine ..................16 Removing engine .......................... 16 Installing auxiliary frame (raising frame unit clear of engine) ..................... 18 Removing auxiliary frame (lowering frame unit onto engine) .......................
  • Page 69 Contents Page Removing and installing conrods ..................34 Removing and installing alternator mount cover with engine installed ....35 Removing alternator mount cover ..................35 Replacing radial shaft seal in alternator mount cover ..........35 Removing auxiliary shaft drive ....................36 Removing oil pump ........................37 Removing radial shaft seal from crankshaft with engine installed ......38 Disassembling crankcase...
  • Page 70 Contents Page Installing piston ..........................55 Installing cylinder .........................56 Installing cylinder head .......................57 Adjusting valve clearances .......................58 Installing right cylinder head ....................59 Adjustment specification ........................59 Installing left cylinder head .......................60 Adjustment specification ........................60 Installing alternator mount cover ....................62 Installing magnetic gate/belt pulley ..................62 Timing the ignition ..........................63 Installing alternator...
  • Page 71 11.4...

  • Page 72: Technical Data

    Technical Data R 1150 R Engine, general Engine design Four-stroke flat twin, air-cooled with oil-cooled exhaust ports, installed longitudinally, 4 valves per cylinder, two overhead camshafts, electronic fuel injection. Location of engine number Crankcase Cylinder bore mm (in) 101 (3.9764) Stroke mm (in) 70.5 (2.7756)
  • Page 73 Technical Data R 1150 R Oil pump Oil pump 2 Duocentric pumps Housing depth Cooling oil mm (in) 11.02... 11.05 (0.4339...0.4350) Lubricating oil mm (in) 10.02... 10.05 (0.3945...0.3957) Height of rotor Cooling oil mm (in) 10.965... 10.98 (0.4317...0.4323) Lubricating oil mm (in) 9.965...
  • Page 74 Technical Data R 1150 R Valve seat ring Valve seat angle Inlet ° 45 Exhaust ° 45 Valve seat width ± 0.15 (0.0433 ± 0.0059) Inlet mm (in) 1.1 Wear limit mm (in) 2.5 (0.0984) ± 0.15 (0.0551 ± 0.0059) Exhaust mm (in) 1.4...
  • Page 75 Technical Data R 1150 R Rocker Bore mm (in) 16.016... 16.034 (0.6306...0.6312) Rocker shaft dia. mm (in) 15.973... 15.984 (0.6289...0.6293) Radial clearance mm (in) 0.032... 0.061 (0.0016...0.0024) Wear limit mm (in) 0.1 (0.0039) End float min. mm (in) 0.05 (0.0019) max.
  • Page 76 Technical Data R 1150 R Crankshaft Marking of main bearing and crankpin on front crank no paint mark Grinding stage 0 paint mark Grinding stage 1 (-0.25 mm/-0.0098 in) Grinding stage 0 (grinding stage 1 = —0.25 mm/—0.0098 in) Guide bearing bore dia.
  • Page 77 Technical Data R 1150 R Connecting rod Big-end bore mm (in) 51.000... 51.013 (2.0079...2.0084) Big-end bearing dia. mm (in) 48.016... 48.050 (1.8904...1.8918) Radial clearance mm (in) 0.025... 0.075 (0.0010...0.0030) Wear limit mm (in) 0.13 (0.0051) Width of big-end bearing eye mm (in) 21.883...
  • Page 78 Technical Data R 1150 R Pistons Piston dia. (Measuring plane A — see Checking pistons and cylinders) mm (in) 100.971... 100.983 (3.9753...3.9758) Wear limit mm (in) 100.895 (3.9723) mm (in) 100.983... 100.995 (3.9757...3.9763) Wear limit mm (in) 100.905 (3.9727) mm (in) 100.979... 100.987 (3.9756...3.9759) Wear limit mm (in) 100.900 (3.9725)
  • Page 79 Technical Data R 1150 R 3rd groove Coiled-spring ring Height mm (in) 1.97... 1.99 (0.0776...0.0783) Wear limit mm (in) 1.9 (0.0748) Ring gap mm (in) 0.30... 0.55 (0.0118...0.0217) Wear limit mm (in) 1.20 (0.0472) Ring float mm (in) 0.020... 0.060 (0.0008...0.0024) Wear limit mm (in) 0.15 (0.0059)

  • Page 80: Cutaway Drawing Of Engine

    Cutaway drawing of engine 11.13...

  • Page 81: Lubricating-Oil Circuit

    Lubricating-oil circuit 11.14...

  • Page 82: Cooling-Oil Circuit

    Cooling-oil circuit 11.15...

  • Page 83: Removing And Installing Engine

    Always follow the instructions in the Repair Manual. 00 1 529 34.13), Removing and installing ABS unit. R28110060 • Secure stand, BMW No. 00 1 520, to motorcycle Note: with bushes and screws, BMW No. 00 1 529. Secure the brake lines with cable ties. •...
  • Page 84 Use cable ties to secure the brake caliper to the rear frame. RS120170 • Pull off spark plug cap with special puller, BMW No. 12 3 520. • Disconnect plugs of injection valves. • Disconnect hose clamps/throttle stub pipes and push the stubs into the air filter box.

  • Page 85: Installing Auxiliary Frame (Raising Frame Unit Clear Of Engine)

    • tom bolt of the engine/frame connecting strut (1). Install adapter (7) in link/rear-frame anchorage • Place auxiliary frame, BMW No. 46 5 630, in po- and secure to auxiliary frame. • sition and secure to the rear spring-strut Secure the front spring strut at the bottom.

  • Page 86: Removing Auxiliary Frame (Lowering Frame Unit Onto Engine)

    If necessary, mask off the leading link to prevent it from being scratched. • Insert pin, BMW No. 46 5 630, from the left to align the front frame bores with the correspond- ing bores in the engine, insert the bolts from the right and tighten.

  • Page 87: Disassembling Engine

    RS110010 Disassembling and reassem- 11 00 103 bling engine Disassembling engine 11 00 • Secure engine mount, BMW No. 11 0 630, to the engine block. • Transfer engine to assembly frame. 11 4 650 RS110950 • Drain engine oil.
  • Page 88 12 3 510 RS110020 Removing cylinder head cover 11 12 • Remove spark plugs with the spark plug wrench, BMW No. 12 3 510. • Remove cylinder head cover. Attention: Catch escaping oil. 11.21...

  • Page 89: Firing Tdc

    Install locking device, BMW No. 11 5 640, to lock clutch housing. RS110461 Note: The engine can be set to top dead center by insert- ing the TDC pin, BMW No. 11 2 650, into the bores in clutch housing and the engine block. 11.22...

  • Page 90: Removing And Installing Chain Tensioner

    RS110060 Removing and installing chain 11 31 tensioner Attention: Do not mix up the chain tensioner pistons. When in- stalling, fit a new seal. Work instructions, timing-chain tensioners Removing: • Remove timing chain tensioner, then remove camshaft sprocket from camshaft. Installing: •...

  • Page 91: Removing And Installing Valve Gear Carrier

    M 6 x 60 M 6 x 30 M 6 x 30 M 6 x 30 S110110 Removing and installing valve • 11 33 Remove valve gear carrier. • Secure rockers with a rubber band (2). gear carrier Note: If no work is to be carried out on the valve gear car- rier, remove it together with the cylinder head.

  • Page 92: Disassembling And Assembling Valve Gear Carrier

    RS110080 Disassembling and assembling 11 33 valve gear carrier • Remove bearing cap. • Insert a suitable pin into the bore (arrow) of the rocker shaft, and turn the shaft back and forth to remove it from its bearing. • Remove pushrods.
  • Page 93 RS110090 • Remove camshaft bearing cap (1). • Remove camshaft and bearing (2). • Remove bucket-type tappets. Attention: Do not mix up the bucket-type tappets. • Assembly is the reverse of the disassembly pro- cedure. Attention: Note direction of installation (3) for camshaft bearing cap.

  • Page 94: Removing Cylinder Head

    M 10 x 70 M 6 x 30 M 6 x 30 M 6 x 30 RS110110 Removing cylinder head 11 12 11.27...

  • Page 95: Disassembling, Checking, Repairing And Reassembling Cylinder Head

    Do not scratch sealing face on cylinder head. Place the head on a clean, non-scratching surface. • Mount valve spring compressor, BMW No. 11 5 690, onto cylinder head. • Compress the valve springs. • Gently tap valve head to release collets from spring retainer.

  • Page 96: Checking Valves For Wear

    Checking valves for wear • Remove combustion residue from valves. • Check valve dimensions..........see Technical Data Remachining valve seat RS110890 Attention: Width (B) and diameter (D) must always be main- tained if valve seat is machined..........see Technical Data Checking and repairing cylinder head •...

  • Page 97: Replacing Valve Guides

    (approx. 20 °C/68 °F). Mount the chilled valve guide on • Examine valve guide bore for: Ø 5 mm (0.1969 in) drift, BMW No. 11 5 673. • – wear, Drive valve guides into cylinder head with no de- –...

  • Page 98: Installing Valve And Valve Stem Seal

    Shrink a short length of shrink-fit tube (arrow) on to the end of the valve stem. • Install the valve stem seal with a 5 mm (0.1969 in) dia. drift, BMW No. 11 5 602. Attention: Remove the shrink-fit tube. •...

  • Page 99: Removing Cylinder Barrel

    RS110170 Removing cylinder barrel 11 11 • Remove guide rail pivot screws (1). • Remove cylinder retaining screws, and remove cylinder. Attention: When removing cylinder, make sure that the piston does not strike the engine block. Removing and disassembling pis- 11 25 •...

  • Page 100: Checking Pistons And Cylinders

    Checking pistons and cylinders Assembling pistons 11 25 Reference temperature for measurements: ............20 ƒC (68 ƒF) R21110050 RS110180 • Carefully fit piston rings to piston in the following sequence, using piston ring pliers: • Measure cylinder bore with internal micrometer 3rd groove - coiled-spring ring at 20 mm (0.7874 in) and 100 mm (3.9370 in) 2nd groove - micro-chamfer ring...

  • Page 101: Removing And Installing Conrods

    Remove conrods. Note: When using tightening angle indicator, Note: BMW No. 11 2 500, make sure the extensions are Conrods can also be removed and installed with the of the same length. crankshaft removed. Use a 3/8“ square-drive socket wrench.

  • Page 102: Removing And Installing Alternator Mount Cover With Engine Installed

    Disconnect the Hall sensor. • Remove the starter motor. Removing alternator mount cover 11 11 • Remove the alternator. • Install locking device, BMW No. 11 5 640, to lock clutch housing. RS110240 • Remove pulley (1). • Remove magnetic gate (2). •...

  • Page 103: Removing Auxiliary Shaft Drive

    • Remove chain tensioning rail (3). • Remove chain guide rail (4). • Install locking device, BMW No. 11 5 640, to lock clutch housing. • Remove chain sprocket retaining screw (5). • Remove sprocket (6) and timing chain (7).

  • Page 104: Removing Oil Pump

    M 6 x 45 M 6 x 50 M 6 x 45 M 6 x 45 RS110410 M 6 x 50 Removing oil pump 11 41 • Remove oil pump cover (1). • Remove complete oil pump (2) together with cooling oil pipe (3), and disassemble.

  • Page 105: Removing Radial Shaft Seal From Crankshaft With Engine Installed

    Carefully lever out radial shaft seal, using a hole in the shaft sealing ring. • screwdriver. Screw the pull rod, BMW No. 00 8 581, into the pierced hole and use impact weight, BMW No. 00 8 582, to remove the shaft sealing Attention: ring.

  • Page 106: Disassembling Crankcase

    RS110261 Disassembling crankcase • Turn engine on to its side. • Remove screws on right side. 11.39...
  • Page 107 RS110260 • Turn engine on to its side. • Remove screws on left side. • Remove upper section of crankcase. 11.40...

  • Page 108: Removing Crankshaft, Auxiliary Shaft And Timing Chain Tensioning And Slide Rails

    S110050 Removing crankshaft, auxiliary shaft and timing chain tensioning and slide rails 11.41...

  • Page 109: Removing And Installing Oil Intake Strainers

    Remove conrods. • Coat the sealing face of the new oil level sight glass with tyre assembly paste and drive it in with drift, BMW No. 00 5 550. Attention: Do not mix up the conrods. Checking conrods •...

  • Page 110: Measuring Crankshaft Bearing Play

    RS110310 Measuring crankshaft bearing play Measuring radial bearing play • Measure main bearing journal with an external micrometer in two planes, A and B at right an- gles. • Enter measured values on record sheet..........See Technical Data Attention: The crankshaft can only be reground in stage 0, and must be hardened and finished afterwards.

  • Page 111: Installing Main Bearings

    00 2 510 RS110910 • Screw measuring device, BMW No. 00 2 500, with dial gauge, BMW No. 00 2 510, into tapped hole for alternator carrier cover. • Move crankshaft forwards and backwards and read end float from dial gauge.

  • Page 112: Measuring Big-End Bearing Play

    ........... See Technical Data • Install bearing shells and assemble conrods. • Using tightening angle indicator, BMW No. 11 2 500, tighten the big-end bolts. Tightening torque: Big-end bolts oiled Closing torque..........20 Nm Additional angle of rotation....... 80 °...

  • Page 113: Assembling Engine

    Clamp crankshaft in a vise with protective jaws. • Oil the big-end bolts, screw them in by hand and tighten with tightening angle indicator, BMW No. 11 2 500. Attention: Oil the bearings. Do not mix up conrods or bearing shells.

  • Page 114: Installing Crankshaft

    S110080 Installing crankshaft Installing auxiliary shaft/timing 11 21 11 31 chains • Attention: When installing the auxiliary shaft, make sure that Oil the bearings. the bore in the auxiliary shaft (2) facing the crank- shaft is in line with the crankcase mating face. Installing timing chain tensioning 11 31 Attention:...

  • Page 115: Assembling Engine Block

    RS110920 Assembling engine block • Clean and degrease sealing faces (arrow) and coat with 3-Bond 1209. • Secure the timing chain with rubber band (1) to the timing chain tensioning and slide rail. 11.48...
  • Page 116 RS110391 • Bolt the crankcase sections together. Tightening torque/tightening sequence: 1. M 10 screw (oiled) to initial torque ..25 Nm Angle of rotation..90° 2. M 8 screw (oiled) ........22 Nm 3. M 6 screw ..........9 Nm 11.49...
  • Page 117 11 5 702 11 5 703 11 5 703 11 5 703 11 5 702 11 5 703 11 5 703 11 5 701 00 5 500 00 5 500 11 5 661 11 5 661 11 5 662 11 5 662 00 5 500 11 5 661 11.50...

  • Page 118: Installing Radial Shaft Seals On Crankshaft

    • Mount sleeve complete with radial shaft seal on crankshaft (4). • Use drift, BMW No. 11 5 701, together with sleeve (5) to drive the radial shaft seal onto the crankshaft. • Remove sleeve (6). 11 11 Installing the clutch-end radial shaft seal •...

  • Page 119: Installing Clutch Housing

    Always use new screws for housing and cover. • Install clutch housing with mark (1) aligned with crankshaft mark (2). • Install locking device, BMW No. 11 5 640, to lock clutch housing. • Insert all screws by hand and tighten. Tightening torque: Clutch housing to crankshaft (threads oiled).

  • Page 120: Installing Oil Pump

    M 6 x 45 M 6 x 50 M 6 x 45 M 6 x 45 M 6 x 50 RS110411 Installing oil pump 11 41 Attention: Oil the friction faces. • Install outer rotor (1) of oil pump in pump hous- ing.

  • Page 121: Installing Auxiliary Shaft Drive

    ..........See Technical Data Tightening torque: M 6 screw ............ 10 Nm Banjo bolt for cooling oil line • Install locking device, BMW No. 11 5 640, to with oil vent valve ......... 25 Nm lock clutch housing. • Install chain sprocket (1).

  • Page 122: Installing Piston

    R21110060 Installing piston 11 25 • Turn oil scraper ring so that gap (arrow) is at top. • Install piston rings with gaps offset by 120°. Production locating point X = install on exhaust side. Attention: Make sure that retaining rings are properly seated on piston pin.

  • Page 123: Installing Cylinder

    • Oil the cylinder wall. • Compress the piston rings with a clamping strap, BMW No. 11 2 900. • Install the cylinder and at the same time pass the timing chain and the tensioner and guide rails through the timing case cavity.

  • Page 124: Installing Cylinder Head

    Fit camshaft chain sprocket in accordance with adjustment specification. • • Install cylinder head gasket. Install locking device, BMW No. 11 5 640, to • Fit cylinder head and insert correctly positioned lock clutch housing. • camshaft chain sprocket (1) and timing chain into Tighten camshaft chain sprocket.

  • Page 125: Adjusting Valve Clearances

    RS110980 Adjusting valve clearances 11 34 004 • Set piston to firing TDC on the ignition stroke. • Measure valve clearance with feeler gauge. • Correct valve clearance with adjusting screw and tighten locknut. Valve clearances with engine cold (max. 35 ƒC/95 ƒF): Inlet .........

  • Page 126: Installing Right Cylinder Head

    Note: With engine installed, set engine to TDC with dial gauge holder, BMW No. 00 2 650, and dial gauge, BMW No. 00 2 510. Right cylinder = at firing TDC: Locating pin (arrow) on right camshaft sprocket is at bottom.

  • Page 127: Installing Left Cylinder Head

    Note: With engine installed, set engine to TDC with dial gauge holder, BMW No. 00 2 650, and dial gauge, BMW No. 00 2 510. Left cylinder = at firing TDC: Locating pin (arrow) on left camshaft sprocket is at top.
  • Page 128 R110050 RS110940 • • Install the end cover with O-ring in perfect condi- Install cylinder head cover. tion. Attention: Tightening torque: Make sure that gaskets are correctly seated. Gas- M 6 screw ............9 Nm kets and sealing faces must be free from oil and grease.

  • Page 129: Installing Alternator Mount Cover

    11 5 640 11 5 680 S110090 Installing alternator mount cover 11 11 • Place assembly sleeve, BMW No. 11 5 680, on crankshaft. • Clean and de-grease sealing face (arrow) and apply 3-Bond 1209. • Install alternator mount cover.
  • Page 130 11 2 650 RS110461 12 11 004 Timing the ignition Note: With engine installed. • Using TDC locating pin, BMW No. 11 2 650, lock the clutch housing. • Connect BMW MoDiTeC with adapter cable to Hall-effect gate plate. •...

  • Page 131: Installing Alternator

    RS110480 Installing alternator 12 31 • Install alternator. Poly-V belt adjusting procedure: Poly-V belt installation procedure: • Slightly tighten hex nut (1) on adjusting screw (2) by hand (do not use tools) • Tighten adjusting screw (2) with a torque wrench and keep preload applied.

  • Page 132: Installing Engine

    Oil filter (sealing face lightly oiled) ....11 Nm Oil drain plug..........32 Nm 12 3 510 RS000010 • Install spark plugs with spark plug socket wrench, BMW No. 12 3 510. Tightening torque: Spark plug NGK BKR 7 EKC ......25 Nm 11.65...
  • Page 133 12 Engine electrics Contents Page Technical Data ..........................3 Removing and installing coil and ignition lead ............5 Checking ignition coil resistance .....................5 Removing and installing alternator ..................6 Poly-V belt adjusting procedure: ......................6 Disassembling/assembling alternator ................7 Checking alternator ........................7 Checking armature for short to ground (earth) ..............7 Removing and installing starter motor ................8...
  • Page 134 12.2...

  • Page 135: Technical Data

    Technical Data R 1150 R Starter motor Type Permanent-magnet motor with planetary gear drive Gear ratio Planetary gears 5.5 : 1 Power rating kW 1.1 Alternator Type Three-phase alternating-current generator with integrated all-electronic voltage regulator, Bosch Drive Poly-V belt Gear ratio 1 : 1.5...
  • Page 136 12.4...

  • Page 137: Removing And Installing Coil And Ignition Lead

    Disconnect plug. • Disconnect ignition lead. • Remove spark plug covers. • Pull off spark plug cap with special puller, BMW No. 12 3 520. • Remove ignition leads. • Installation is the reverse of the removal proce- dure. •...

  • Page 138: Removing And Installing Alternator

    RS110480 Removing and installing 12 31 022 Note: alternator Disconnecting the battery deletes all entries (e.g. faults, settings) stored in the Motronic control • Remove the seat. unit’s memory. • Remove fuel tank ( 16.5). Loss of settings can temporarily impair the operat- ing characteristics when the engine is restarted.

  • Page 139: Disassembling/Assembling Alternator

    RS120050 Disassembling/assembling alterna- Checking alternator 61 00 009 • Test with BMW MoDiTeC • Remove the cover retaining screws (1). Checking armature for short to • Release clips (2) and remove the cover. 61 00 009 • Remove voltage regulator (3).

  • Page 140: Removing And Installing Starter Motor

    RS120140 Removing and installing 12 41 025 starter motor Tightening torque: Starter to engine .......... 20 Nm • Remove the seat. Starter cover to gearbox casing ..... 7 Nm Positive cable to starter ....... 10 Nm Attention: Disconnect earth (ground) lead from battery. Insulate earth (ground) lead.

  • Page 141: Disassembling/Assembling Starter Motor

    61 00 009 • Remove the starter gear (10) from the shaft. • • Installation is the reverse of the removal proce- Test with BMW MoDiTeC. dure. • Coat the Bendix gear and pull-in Checking starter relay ring with grease.

  • Page 142: Removing And Installing Magnetic Gate

    Disconnecting the battery deletes all entries • Remove the starter motor. (e.g. faults, settings) stored in the Motronic control • Install locking device, BMW No. 11 5 640, to unit’s memory. lock clutch housing. Loss of settings can temporarily impair the operat- •...

  • Page 143: Timing The Ignition

    Timing the ignition 12 11 004 11 2 650 RS110461 • Using TDC locating pin, BMW No. 11 2 650, lock the clutch housing. • Connect BMW MoDiTeC with Y adapter cable to Hall-effect transmitter plug. • Set the timing, following the tester instructions.
  • Page 144 13 Fuel preparation and control Contents Page Technical Data ..........................3 Removing and installing air filter housing ..............5 Removing and installing throttle-valve stub pipe ............6 Removing and installing throttle-valve potentiometer ..........7 Removing and installing Motronic control unit ............7 13.1...
  • Page 145 13.2...
  • Page 146 Technical Data R 1150 R Fuel grade Super (premium), unleaded. 95 octane (RON) Mixture preparation Motronic MA 2.4 Throttle stub pipe intl. dia. mm (in) 45 (1.7717) Throttle angle in rest position ° 5 Air filter Round paper element 13.3...
  • Page 147 13.4...
  • Page 148 R28130020 Removing and installing air 13 72 116 filter housing Preparatory work See “Removing and installing clutch” on Page 21.5 13.5...
  • Page 149 S130020 Removing and installing throt- • 13 54 Push intake neck into air filter box and remove throttle-valve stub. tle-valve stub pipe • Disengage throttle cables (5) from right and left throttle-valve stubs. • • Press in spring keeper of multi-pin plug for throt- Installation is the reverse of the removal proce- tle-valve potentiometer (1) and disconnect plug.
  • Page 150 (basic setting is necessary — see Motronic diagnosis instructions). • Remove the throttle-valve potentiometer. • Adjust throttle-valve potentiometer with BMW MoDiTeC after installing. • Mark screws with a paint spot. R28130010 • Disconnect plug from Hall transmitter.
  • Page 151 16 Fuel tank and lines Contents Page Technical Data ..........................3 Removing and installing fuel tank ..................5 Removing and installing roll-over valve ................6 Removing and installing fuel filter and fuel pump ............7 Removing and installing fuel filter ....................7 Removing/installing fuel pump ....................7 Checking fuel pump pressure ......................7 Removing and installing fuel distributor and pressure regulator...
  • Page 152 16.2...

  • Page 153: Technical Data

    Technical Data R 1150 R Fuel tank Tank capacity (usable) l (Imp. 20.4 (4.50/5.40) gal/US gal) Including reserve of l (Imp. approx. 5 (1.10/1.30) gal/US gal) Fuel pump Type Turbine-wheel pump Make Bosch EKP-13.5 Operating voltage V 6...15 V Operating pressure bar (psi) 3.0 ±...
  • Page 154 16.4...

  • Page 155: Removing And Installing Fuel Tank

    R28160021 Removing and installing fuel 16 11 030 tank • Remove the seat. • Release the fasteners for the left and right side panels from the fuel tank. • Remove cable cover on right. • Remove oil-cooler covers. Note: Note washers (1). •...

  • Page 156: Removing And Installing Roll-Over Valve

    Remove the reducer unit with roll-over valve (1) and disconnect the hoses. • Remove the roll-over valve. • Installation is the reverse of the removal proce- dure. • Secure non-reusable hose clips with pliers, BMW No. 13 1 500. 16.6...

  • Page 157: Removing And Installing Fuel Filter And Fuel Pump

    Release hose clips at fuel filter (5). • Connect test pressure gauge, Attention: BMW No. 16 1 500 with adapter hose Note correct direction of flow through fuel filter. BMW No. 16 1 503 for quick-release coupling. • Start engine and allow to idle.
  • Page 158 18 Exhaust system Contents Page Removing and installing exhaust system ................3 Removing silencer end cap and silencer guard ...................3 Installing silencer end cap and silencer guard ..................3 Removing and installing exhaust manifold ................4 18.1...
  • Page 159 18.2...
  • Page 160 • Tighten the oxygen sensor with special socket wrench insert, • Remove rear silencer. BMW No. 11 7 020. • Remove fuel tank ( 16.5). Removing silencer end cap and silencer guard • Remove end cap. •...
  • Page 161 Removing and installing 18 11 181 exhaust manifold • Slacken the clamp holding the front silencer. • Remove fasteners securing exhaust manifold. • Remove exhaust manifold. • Installation is the reverse of the removal proce- dure. Attention: After a trial run, read out Motronic fault memory. Note position of wiring for oxygen sensor.
  • Page 162 21 Clutch Contents Page Technical Data ..........................3 Removing and installing clutch ....................5 Removing clutch ..........................5 Removing clutch from vehicle ......................5 Removing clutch from engine ......................7 Installing clutch ..........................7 Installing clutch in engine ........................7 Installing clutch in vehicle ........................7 Removing and installing clutch hydraulic line ..............8 Removing and installing clutch slave cylinder .............9...
  • Page 163 21.2...
  • Page 164 Technical Data R 1150 R Type of clutch Single dry plate with increased-leverage dia- phragm spring Actuation Hydraulic, with master and slave cylinders Master cylinder piston dia. mm (in) 13 (0.5118) Slave cylinder piston dia. mm (in) 24 (0.9449) Clutch fluid DOT 4 brake fluid Clutch plate dia.
  • Page 165 21.4...

  • Page 166: Removing And Installing Clutch

    Removing and installing 21 21 000 clutch Removing clutch 21 21 Removing clutch from vehicle • Attach stand, BMW No. 00 1 520 to motorcycle. • Remove the seat. • Remove fuel tank ( 16.5). Attention: Fuel is flammable and a hazard to health. Observe relevant safety regulations.
  • Page 167 Remove the rear wheel, rear wheel drive and swinging arm together with the gearbox. 17 5 500 R21110020 • Use hose clip pliers, BMW No. 17 5 500, to dis- connect hose from rotary breather from air-filter box. • Remove air filter box.

  • Page 168: Removing Clutch From Engine

    Install clutch housing with crankshaft pin (2) lo- ing. cated in bore (1). Diaphragm spring contact surface on pressure • Install locking device, BMW No. 11 5 640, to plate. lock clutch housing..........Optimoly MP3 paste Attention: Tightening torque: Always use new screws for housing and cover.

  • Page 169: Removing And Installing Clutch Hydraulic Line

    R28210020 Removing and installing clutch • 21 52 Disconnect the lines from the clutch slave cylin- der. hydraulic line • Remove clutch line. • Installation is the reverse of the removal proce- • Remove the seat. dure. • • Remove fuel tank ( 16.5).
  • Page 170 Removing and installing Filling and bleeding clutch 21 52 012 21 52 005 line clutch slave cylinder • Remove the seat. • Remove rear silencer. See Instructions for changing clutch fluid ( 00.54). • Remove rear brake caliper. • Remove rear wheel. Note: Place support under rear wheel drive.
  • Page 171 23 Gearbox Contents Page Technical Data ..........................3 Gearbox - sectional drawing ....................5 Removing and installing gear-shift lever .................7 Removing and installing gearbox ..................7 Replacing shaft sealing rings in gearbox housing and gearbox cover ....9 Replacing input shaft sealing ring at input end ..................9 Replacing output shaft sealing ring .....................9 Replacing input shaft sealing ring at output end ................
  • Page 172 Contents Page Assembling gearbox .........................24 Installing input, output and intermediate shafts ..............24 Installing selector shaft .......................25 Installing selector drum ......................25 Installing gearbox housing ......................26 23.2...

  • Page 173: Technical Data

    Technical Data R 1150 R Type of gearbox 6-speed gearbox with claw-action shift and inte- gral reaction damper for all gears Gear shift type Foot-operated lever and selector drum with over- shoot detent Gear ratio 1st gear 3.864 2nd gear 3.022...
  • Page 174 23.4...

  • Page 175: Gearbox - Sectional Drawing

    Gearbox - sectional drawing R21239010 23.5...
  • Page 176 23.6...

  • Page 177: Removing And Installing Gear-Shift Lever

    Tilt the rear frame up and secure it in this position terminal first, then the negative terminal. with a strap attached to the handlebars. • Use hose clip pliers, BMW No. 17 5 500, to dis- • Unscrew rear battery mount. connect hose from rotary breather from air-filter •...
  • Page 178 23 1 820 23 1 820 RS230011 • Always use oiled guide pins, BMW No. 23 1 820, when removing or installing the gearbox. Attention: Take care to keep the gearbox at its installed height until the full length of the clutch actuating rod is vis- ible, as otherwise the rod can be bent.

  • Page 179: Replacing Shaft Sealing Rings In Gearbox Housing And Gearbox Cover

    • Use puller, BMW No. 00 8 590, to remove the shaft sealing ring, or alternatively pry out carefully with a screwdriver. •...
  • Page 180 BMW No. 23 4 740. • Carefully lever out the shaft sealing ring with a screwdriver. • Install the new sealing ring with the sealing lips facing inwards, using guide, BMW No. 23 4 722, and impact driver, BMW No. 23 4 723. 23.10...

  • Page 181: Disassembling Gearbox

    R21230020 Disassembling gearbox 23 00 80 …100 Removing gearbox housing • Remove oil filler/level check screw (1). • Remove oil drain plug (2) and drain the oil from the gearbox into a suitable tray. • Remove selector lever (3). • Carefully drive back centering pins (4), from the cover side or casing side, as applicable.

  • Page 182: Removing Selector Drum

    R21230040 Removing selector drum Disassembling/assembling selec- 23 31 23 31 tor shaft • Pull the selector shafts (1) out of the selector forks. • Swing the selector forks (3/8) out towards the edge of the cover (arrows). • Remove locking pin (9). •...

  • Page 183: Removing Gearbox Shafts

    • Remove input shaft (2), output shaft (3) and Pull off the grooved ball bearings with a universal intermediate shaft (4) together from the cover. puller, BMW No. 00 7 500. • • Remove selector fork (5) from intermediate shaft.

  • Page 184: Disassembling And Assembling Input Shaft

    R21230080 Disassembling and assembling • 23 12 Use universal puller, BMW No. 00 7 500, and pressure head (arrow) to pull off grooved ball input shaft bearing (11). Disassembling input shaft 00 7 500 KR230090 • Clamp the input shaft into a vise with soft jaws.

  • Page 185: Assembling Input Shaft/Checking And Adjusting End Float Of Spring Cluster

    KR230081 • Assembling input shaft/checking and adjusting Check fully assembled length and adjust if nec- end float of spring cluster essary ( 23.21). • • Lightly oil the bearing surface for constant-speed Install spacing washer (8) of calculated thick- gear (1) on input shaft (10), and install the con- ness, and press on grooved ball bearing (9).

  • Page 186: Disassembling And Assembling Output Shaft

    Turn output shaft (6) other way round and clamp into the vise with soft jaws. • Using universal puller, BMW No. 00 7 500, pull off deep-groove ball bearing (1) together with shift gearwheel for 2nd gear (4). 00 7 500 •...

  • Page 187: Assembling Output Shaft

    1st gear 4th gear 3rd gear 2nd gear 5th gear 6th gear KR230120 • Assembling output shaft Install needle roller bearing (14). Note: Attention: Assembly starts at the shift gearwheel for 4th gear. To avoid damaging the needle roller bearing on the Before assembly, oil all friction faces lightly with gear splines of the shaft, spread it carefully at the end oil.

  • Page 188: Checking End Float

    Install sliding gearwheel for 6th gear (17) with the 23 11 recess for the selector fork facing the shift gear- • wheel for 2nd gear (3). Secure dial gauge, BMW No. 00 2 510, to dial • Install backup washer (5) and needle roller bear- gauge stand. •...

  • Page 189: Checking And Adjusting Fully Assembled Length Of Gearbox Shafts And Selector Drum

    • Take off spacing washer, grooved ball bearing • Position dial gauge, BMW No. 23 4 762, in rear and reference washer. • locating bore of stand, BMW No. 23 4 761, and Place a spacing washer (1) of the correct thick- set to 0.2 mm (0.0078 in) preload.
  • Page 190 • Place a spacing washer (1) of the correct thick- • Position dial gauge, BMW No. 23 4 762, in rear ness on the output shaft and press on the locating bore of stand, BMW No. 23 4 761, and grooved ball bearing.
  • Page 191 Take the input shaft out of the measuring fixture. • Remove the adapter disc, spacing washer, • Position dial gauge, BMW No. 23 4 762, in front grooved ball bearing and reference washer. • locating bore of stand, BMW No. 23 4 761, and Place a spacing washer (1) of the correct thick- set to 0.2 mm (0.0078 in) preload.
  • Page 192 KR230190 23 11 Checking and adjusting fully assembled length of selector drum • Place spacing washer and both thrust washers on the selector drum. • Using slide gauge, determine fully assembled length “A”. • If necessary, adjust fully assembled length “A” with a shim washer (arrow).

  • Page 193: Shimming Selector Shaft

    Shimming selector shaft 23 31 Attention: If the housing or the complete selector shaft is re- placed, the selector shaft must be measured and shimmed. KR230220 • Measure distance “C” from the shoulder on the selector shaft to the back of the sleeve. •...
  • Page 194 (2). • Align input, output and intermediate shafts so that their gear teeth mesh and the selector fork is in the position illustrated. • Push assembly sleeve, BMW No. 23 4 712, on to the input shaft splines. 23.24...
  • Page 195 R21230040 Installing selector shaft Installing selector drum 23 31 23 31 • Place a spacing washer of the correct thickness and the input-side thrust washer on selector drum (6) and secure with a small amount of grease. • Swing locking lever (8) toward the input shaft and install the selector drum.
  • Page 196 • Apply Loctite 574 sealing compound to the mat- ing face of the cover. R21230030 • Place assembly sleeve, BMW No. 23 4 732, on the output shaft. • • Place assembly sleeve, BMW No. 23 4 612, on Heat the bearing seats in the housing the selector shaft.
  • Page 197 R21230020 • Insert screws (1) and tighten in diagonally oppo- site sequence. • Drive home dowel pins (2). • Install switch of gear indicator (3) and clip cable (4) into position. • Remove metal particles from the magnet in oil drain plug (5).
  • Page 198 31 Front forks Contents Page Technical Data ..........................3 Removing and installing telescopic fork .................5 Removing and installing telescopic fork without fork bridge ........................5 Removing and installing fork bridge ..................6 Removing and installing pot-type joints ....................7 Removing and installing angular-contact ball bearing ................7 Removing and installing slider tube bridge .................8 Removing and installing ball joint in slider tube bridge .................8...
  • Page 199 31.2...

  • Page 200: Technical Data

    Technical Data R 1150 R Front suspension Type BMW Telelever with external suspension strut Telescopic fork Front wheel castor in normal position mm (in) 127 (4.9999) (with 85 kg/187 lbs rider) Steering lock angle ° 37 Total suspension travel mm (in) 120 (4.7244)
  • Page 201 31.4...

  • Page 202: Removing And Installing Telescopic Fork

    31 5 603 31 5 601 R28310020 Removing and installing tele- 31 42 scopic fork Removing and installing telescopic fork without fork bridge • Remove front wheel. • Remove mudguard. • [Integral ABS] Remove sensor and cable from slider tube. •...

  • Page 203: Removing And Installing Fork Bridge

    Installation is the reverse of the removal proce- 31 42 dure. bridge • Tighten the ball joint in the leading link using • socket, BMW No. 31 5 601, and Allen key, Remove fuel tank. • BMW No. 31 5 603. Remove windscreen. • Remove instrument carrier.

  • Page 204: Removing And Installing Pot-Type Joints

    • • Press in pot-type joint (3) with mandrel, Press out the threaded pin using a mandrel, BMW No. 31 5 661. BMW No. 31 5 651, as a support. • Install snap ring (2). • Install dust covers (1).

  • Page 205: Removing And Installing Ball Joint In Slider Tube Bridge

    Mount the slider tube bridge in retaining fixture, • Install retaining ring. BMW No. 31 5 620. • Use w/f 46 socket, BMW No. 31 5 630, to re- Removing and installing slider 31 42 lease and tighten ball joint. tube bridge •...

  • Page 206: Assembly Specification For Telescopic Fork

    • Assembly specification for telescopic fork: Secure slider tube bridge/do not tighten to spec- ified torque at this point. • Secure slider tube bridge to leading link. Attention: To ensure that the forks are installed without trapped stresses, follow the instructions below to Tightening torque: the letter and in particular, proceed exactly in ac- Leading link to ball joint...

  • Page 207: Disassembling And Assembling Telescopic Fork

    Remove wiper (3) and retaining ring (4). threaded bush, BMW No. 31 5 611, • Lever out shaft seal (5). expander, BMW No. 31 5 612, and reducing adapter, BMW No. 31 5 613. • Install retaining ring and dust wiper. • Attention: Insert bleed screw (1).

  • Page 208: Measuring Telescopic Forks

    Measuring telescopic forks 31 42 Attention: After an accident, always examine the telescopic forks for cracks and signs of damage. Examining slider tube bridge and fork bridge • Check slider tube bridge and fork bridge for sur- face irregularities. Attention: Replace slider tube bridge/fork bridge if deformed.

  • Page 209: Removing And Installing Leading Link

    Apply a light coating of grease to the shaft before installing. • Tighten the ball joint in the leading link using socket, BMW No. 31 5 601, and Allen key, BMW No. 31 5 603. Tightening torque: Leading link to engine ........ 130 Nm...

  • Page 210: Measuring The Leading Link

    Spring strut to leading link......50 Nm R28460120 • Secure the leading link with shaft (1) to leading link gauge, BMW No. 31 5 640. • Tighten the shaft until the leading link is located in the gauge with no end float.
  • Page 211 32 Steering Contents Page Technical Data ..........................3 Removing and installing left handlebar fitting .............5 Removing and installing right handlebar fitting ............6 Removing and installing brake piston in handlebar fitting ........7 Removing and installing clutch piston in handlebar fitting ........8 Adjusting blow-by clearance at handlebar fitting for brake/clutch ......9 Handlebar fitting, brake ........................9...
  • Page 212 32.2...

  • Page 213: Technical Data

    Technical Data R 1150 R Steering lock angle ° 2 x 37 Handlebar tube diameter mm (in) 22 (0.8661) Width of handlebars without weights mm (in) 785 (30.9054) Width of handlebars with weights mm (in) 825 (32.4802) 32.3...
  • Page 214 32.4...

  • Page 215: Removing And Installing Left Handlebar Fitting

    R28320010 Removing and installing left • 32 71 Loosen the retaining screw (7) for the clutch fit- ting and remove the fitting. handlebar fitting • Disconnect plug for multi-function switch, if nec- essary. • • [Heated grips] Remove the fuel tank. Disconnect plug for clutch switch, if necessary.

  • Page 216: Removing And Installing Right Handlebar Fitting

    R28320020 Removing and installing right • 32 71 Loosen the retaining screw for the brake lever fit- ting (7) and remove the fitting. handlebar fitting • Disconnect plug for multi-function switch, if nec- essary. • • [Integral ABS/heated handlebar grips] Re- Disconnect plug for brake-light switch, if neces- move the fuel tank.

  • Page 217: Removing And Installing Brake Piston In Handlebar Fitting

    R21340030 Removing and installing brake 32 72 Attention: piston in handlebar fitting Sealing lips of the boots (6) toward the pressure chamber. • Attention: Prior to installation, carefully press back the Do not allow brake fluid to come into contact with brake piston using an Allen key with T-bar han- painted parts of the motorcycle as brake fluid de- dle, for example.

  • Page 218: Removing And Installing Clutch Piston In Handlebar Fitting

    R21320050 Removing and installing clutch • 32 72 Installation is the reverse of the removal proce- dure: pay particular attention to the following. piston in handlebar fitting • Prior to installation, coat the piston and the boots (6) with brake fluid. Attention: Do not allow brake fluid to come into contact with Attention:...

  • Page 219: Adjusting Blow-By Clearance At Handlebar Fitting For Brake/Clutch

    Adjusting blow-by clearance at han- Handlebar fitting, clutch • Remove the lower section of the clutch lever fit- dlebar fitting for brake/clutch ting. • Remove the handlebar weight. • Handlebar fitting, brake Remove the grip. • • Remove cover from throttle-cable relay. [Heated grips] Release the grip and pull it out- •...

  • Page 220: Removing And Installing Handlebars

    Removing and installing han- 32 71 dlebars R28320030 • Remove left handlebar fitting ( 32.5). • Remove right handlebar fitting ( 32.6). • Remove handlebars. • Installation is the reverse of the removal proce- dure. • When installing the handlebars, always tighten the clamping blocks on the fork bridge in the cor- rect sequence: •...

  • Page 221: Removing And Installing Bowden-Cable Divider, Bowden Cable For Throttle

    R28320040 Removing and installing Bow- • 32 73 Pull Bowden-cable divider (1) out of holder in di- rection indicated by arrow. den-cable divider, Bowden cable for • Installation is the reverse of the removal proce- throttle actuation and starting- dure. speed increase •...
  • Page 222 R28320050 Disassembling Bowden-cable 32 73 divider • Remove fasteners of Bowden cables at entry to Bowden-cable divider. • Remove Bowden cable for starting-speed in- crease (1). • Remove retainer (2) for roller of Bowden-cable divider. • Remove Bowden cables. • Prior to installation, clean housing of Bowden ca- ble divider, pulley, and wedge for starting-speed increase, and do not grease.
  • Page 223 33 Rear wheel drive Contents Page Technical Data ..........................3 Removing, disassembling, reassembling and installing rear wheel drive ..5 Removing rear wheel drive ......................5 Removing and installing taper roller bearing in rear wheel drive .......5 Removing input bevel pinion ......................6 Disassembling input bevel pinion ....................7 Removing needle roller bearing for input bevel pinion ................8...
  • Page 224 Contents Page Removing and installing rear swinging arm ..............19 Removing rear swinging arm ....................19 Removing and installing taper roller bearing ..............20 Removing and installing flexible gaiter ................20 Removing drive shaft ........................20 Checking universal joint for wear .......................20 Installing drive shaft ........................20 Installing rear swinging arm ....................21...

  • Page 225: Technical Data

    Technical Data R 1150 R Rear wheel drive Gear tooth pattern Klingelnberg-Palloid spiral bevel Gear ratio 2.82 : 1 Number of teeth 31 : 11 Backlash mm (in) 0.07... 0.16 (0.0028...0.0063) Taper roller bearing preload mm (in) 0.05... 0.1 (0.0020...0.0039)
  • Page 226 33.4...

  • Page 227: Removing, Disassembling, Reassembling And Installing Rear Wheel Drive

    Remove floating bearing/fixed bearing stud Remove needle roller bearing with counter-sup- bolts. port 22/1, BMW No. 00 8 572, and internal puller 21/4, BMW No. 00 8 573, with ring support. • Heat neck of housing to 120 °C (248 °F).

  • Page 228: Removing Input Bevel Pinion

    S330030 Removing input bevel pinion • 33 12 Bolt the rear wheel drive to the retaining fixture, BMW No. 33 1 510/511. • Bolt the locking arm (1) to the retaining fixture. • Tighten grub screws until they are seated.

  • Page 229: Disassembling Input Bevel Pinion

    • Remove the input bevel pinion and the spacer. 00 7 500 KR330100 • Using puller, BMW No. 00 7 500, pull off both bearings at the same time. • Remove thrust ring (3). • Remove ball thrust bearing (4), inner race (5), roll- er bearing cage (6) and outer race (7).

  • Page 230: Assembling Input Bevel Pinion

    • Remove the outer ring of the needle roller bearing using internal puller, BMW No. 00 8 573, threaded ex- tension, BMW No. 00 8 575, and counter-sup- port, BMW No. 00 8 572. 33 12 Installing needle roller bearing for input bevel pinion •...

  • Page 231: Installing Input Bevel Pinion

    33 1 700 S330060 Installing input bevel pinion • 33 12 Clamp holder, BMW No. 33 1 510, in the vise in such a way that the input neck of the housing is pointing forward. • • Clean threads in the housing.
  • Page 232 BMW No. 33 1 760, and handle, BMW No. 00 5 500, into threaded ring (5). • Coat the cleaned threaded ring with Loctite 577 and tighten with pin wrench, BMW No. 33 1 700. • Install thrust ring (6). Note: Make sure that the lip of the shaft seal is seated cor- rectly on the thrust ring.
  • Page 233 (max. 100 °C/212 °F). KR330180 • Clamp crown wheel in vise with protective jaws. • Insert thrust block (arrow), BMW No. 00 7 511. • Use puller, BMW No. 33 1 830, to pull off the grooved ball bearing. 33.11...

  • Page 234: Assembling And Installing Crown Wheel

    Heat the housing to 80 °C (176 °F). • Insert the outer race in the bearing seat with drift, BMW No. 23 4 670, and handle, BMW No. 00 5 500. • Check that outer race is correctly seated by tap- ping gently.

  • Page 235: Shimming Input Bevel Pinion And Crown Wheel

    Shimming input bevel pinion and crown wheel • It is Attention to shim the input bevel pinion and the crown wheel if the gear set or housing has been replaced. Note: The two components of the gear set (input bevel gear and crown wheel) must have matching num- bers (1).

  • Page 236: Checking Tooth Contact Pattern

    Coat three tooth flanks of the crown wheel with marking ink. • Install measuring fixture, BMW No. 33 2 600, centre crown wheel and use the balls of your hands to press it into the housing and turn it back and forth a few times.

  • Page 237: Checking And Adjusting Backlash

    Note: • Secure measuring arm, BMW No. 33 2 603, cen- Install spacer with bevel on inside diameter toward trally to crown wheel. crown wheel. Backlash: (Setting without oil) ......

  • Page 238: Shimming Housing Cover

    Using drift, BMW No. 33 1 860, and handle, • Using depth gauge, BMW No. 00 2 550, meas- BMW No. 00 5 500, drive in the sealing ring. • ure distance “a”. Heat housing cover to 80 °C (176 °F) and install.

  • Page 239: Installing Rear Wheel Drive

    R28330010 Installing rear wheel drive • 33 10 Tighten fixed bearing stud bolt. • Tighten floating bearing stud bolt. • Firmly tighten locknut. • Note: Load approx. 85 kg (187 lbs) onto motorcycle Do not lay oil-filled rear-wheel drive on its side prior and tighten loose reaction link (3).

  • Page 240: Removing And Installing Spring Strut

    Removing and installing spring 33 53 strut Note: To remove the spring strut, support the rear axle. • Remove the seat. • Remove muffler. • Remove rear brake caliper. • Remove rear wheel. R21330060 • Remove hydraulic spring adjuster. • Remove spring strut.
  • Page 241 R28330020 Removing and installing rear 33 17 swinging arm Removing rear swinging arm • Remove rear wheel drive unit. • Remove rear spring strut. • Swinging-arm bearing studs are secured with Loctite: heat to max. 120 °C (248 °F) to release. •...
  • Page 242 BMW No. 00 8 563. necessary. • To install the bearing, heat the swinging arm to 80 °C (176 °F). • Drive in bearing with drift, BMW No. 33 5 700. Checking universal joint for wear Removing and installing flexible 33 17 gaiter KR330360 •...
  • Page 243 R28330020 Installing rear swinging arm 33 17 • Slide swinging arm over drive shaft as far as pos- Tightening torque: sible until rubber gaiter connects on housing Fixed bearing stud neck. (clean thread + Loctite 2701)...... 160 Nm • Install fixed-bearing stud bolt (1) with Loctite. Floating bearing stud (clean thread + Loctite 2701)......
  • Page 244 34 Brakes Contents Page Technical Data ..........................3 Removing and refitting front brake caliper ..............4 Disassembling and assembling front brake caliper ..........5 Removing and refitting rear brake caliper ..............6 Disassembling and assembling rear brake caliper ...........7 Dismantling rear brake caliper ....................7 Assembling rear brake caliper ....................7...
  • Page 245 Filling the front wheel circuit ......................21 Front wheel circuit reservoir filling instructions ...................22 Filling rear wheel circuit ........................23 Rear wheel circuit filling instructions ....................24 [Integral ABS] Reading fault code memory with BMW MoDiTeC .............24 [Integral ABS] Performing a bleed test with BMW MoDiTeC ............24...

  • Page 246: Technical Data

    Minimum lining thickness, rear mm (in) 1,0 (0.0393) If the brake disc is visible through the bore in the wheel-side brake pad, the brake lining is worn to its minimum permissible thickness. [ABS] Braking system BMW Integral ABS, partially integrated 34.3...

  • Page 247: Removing And Refitting Front Brake Caliper

    Removing and refitting front 34 11 brake caliper Tightening torque: Brake caliper to fork slider ......30 Nm Brake hose to brake caliper ......18 Nm Attention: Brake caliper bleed screw ......9 Nm Do not allow brake fluid to come into contact with painted motorcycle parts as brake fluid destroys paint.

  • Page 248: Disassembling And Assembling Front Brake Caliper

    • Close the bleed screw. Tightening torque: • Use the spacer, BMW No. 34 1 520, to secure Bleed screw to brake caliper ......9 Nm the two opposite brake pistons. • Place a cloth between the other pair of pistons.

  • Page 249: Removing And Refitting Rear Brake Caliper

    S340010 Removing and refitting rear 34 21 brake caliper Tightening torque: Brake caliper to rear wheel drive ....40 Nm Brake hose to brake caliper ......18 Nm Attention: Bleed screw to brake caliper ......7 Nm Do not allow brake fluid to come into contact with painted motorcycle parts as brake fluid destroys paint.

  • Page 250: Disassembling And Assembling Rear Brake Caliper

    R21340010 Disassembling and assembling Assembling rear brake caliper 34 21 rear brake caliper • Coat the new sealing rings with brake fluid and insert them into the left and right brake caliper Dismantling rear brake caliper bores. • Coat both brake caliper pistons with brake fluid •...

  • Page 251: Removing And Refitting Front Brake Discs

    Removing and refitting front 34 11 brake discs Attention: Note direction of installation for the brake disc (let- • Remove the brake caliper. tering to the outside). • Remove front wheel. Tightening torque: Brake disc to front wheel (Clean thread + Loctite 2701) ....... 21 Nm Removing and refitting rear 34 21 brake disc...

  • Page 252: [Integral Abs] Removing And Refitting Front Abs Sensor

    R28340040 [Integral ABS] Removing 34 52 044 and refitting front ABS sensor • Remove fuel tank ( 16.5). • Separate plug connector (1) in sensor line. • Remove the left brake caliper. • Remove the sensor (2). • Installation is the reverse of the removal proce- dure.

  • Page 253: [Integral Abs] Removing And Refitting Rear Abs Sensor

    R28340050 [Integral ABS] Removing 34 52 111 and refitting rear ABS sensor • Remove front/rear seat. • Separate plug connector (1) in sensor line. • Before removing/refitting, clean the sensor and bore. • Remove the sensor (2). • Installation is the reverse of the removal proce- dure.

  • Page 254: Removing And Refitting Footbrake Lever

    • is activated. Installation is the reverse of the removal proce- dure. • Tighten one-time hose clip (5) with pliers, BMW No. 13 1 500. • Tightening torque: Fill and bleed the brake system. • Brake pedal to footrest plate [Integral ABS] Bleed/fill the rear control circuit (Clean thread + Loctite 2701) .......

  • Page 255: Removing And Refitting Brake Piston In Handlebar Fitting

    Checking and adjusting piston rod Removing and refitting brake piston play in handlebar fitting ( 32.7) R21340040 • Set the adjusting screw of the footbrake lever to distance A. Distance A:... 14 +/- 0.5 mm (0.5512 +/- 0.1969 in) (Top edge of footbrake lever to top edge of adjusting screw.) •...

  • Page 256: Removing/Installing The Abs Pressure Modulator

    Do not allow brake fluid to come into contact with Warning: painted motorcycle parts as brake fluid destroys All repair and maintenance work on the paint. BMW Integral ABS should be carried out by special- • ly trained personnel. Drain the brake system ( 34.15).

  • Page 257: Installing The Abs Pressure Modulator

    34.18). • Once all the work on the brake system has been completed, read the fault code memory and per- form a bleed test using BMW MoDiTeC 34.24). Note: Disconnecting the battery deletes all entries (e.g. faults, settings) stored in the Motronic control unit’s memory.

  • Page 258: [Integral Abs] Draining Brake System

    All repair and maintenance work on the Only use the piston reset BMW Integral ABS should be carried out by special- device, BMW No. 34 1 531, if the wheel circuit res- ly trained personnel. ervoir cover is open. Maintenance and repair procedures and processes should be strictly observed.
  • Page 259 Draw off the old brake fluid from the wheel circuit reservoir. • Remove rear brake pads. Attention: Only use the piston reset device, BMW No. 34 1 531, if the wheel circuit res- ervoir cover is open. 34 1 536 34 1 531 R28000170 •...
  • Page 260 Draw off old brake fluid and clean the reservoir. R28340110 • Draw off the brake fluid in accordance with the sequence, using the ring spanner, BMW No. 34 2 532. – Rear dosing cylinder (4), – rear integral circuit (5) and –...

  • Page 261: [Integral Abs] Filling The Brake System

    All repair and maintenance work on the into the brake system. BMW Integral ABS should be carried out by special- ly trained personnel. Maintenance and repair procedures and processes should be strictly observed.
  • Page 262 (3) and – again, front dosing cylinder (1) using the ring spanner, BMW No. 34 2 532, and in accordance with the rules for bleeding. Rules for bleeding: 1. Pull the brake lever slowly until the brake light switch clicks (snifter hole closed).

  • Page 263: Filling The Rear Control Circuit

    – front control circuit (3) and, – again, rear dosing cylinder (1) using the ring spanner, BMW No. 34 2 532, and in accordance with the rules for bleeding. R28000050 Rules for bleeding: 1. Press the brake lever slowly until the brake light •...

  • Page 264: Filling Wheel Circuits

    The procedure for topping up the brake fluid in the right brake caliper is the same as that for the • Use the reset device, BMW No. 34 1 531, and left caliper. • the positioning piece, BMW No. 34 1 532, to Release the brake and switch off the ignition.

  • Page 265: Front Wheel Circuit Reservoir Filling Instructions

    • “MAX” Remove the reset device, • Use adapter 23, BMW No. 34 1 534, in the reset BMW No. 34 1 531/532, with device, BMW No. 34 1 531/532, on both front adapter, BMW No. 34 1 534. brake calipers , and screw on the reset device until the adapter is secure.

  • Page 266: Filling Rear Wheel Circuit

    R28000170 can be drawn into the brake system. • • Use the adapter, BMW No. 34 1 536, instead of Gently press the footbrake until the pump just the external brake pad. starts up. •...

  • Page 267: Rear Wheel Circuit Filling Instructions

    • Top up fluid in rear wheel circuit reservoir to Install front/rear seat. “MAX”. • Screw the reset device, BMW No. 34 1 531, to Brake fluid ...........DOT 4 the adapter, BMW No. 34 1 536. Tightening torque: Attention: Rear brake caliper bleed screw ...... 7 Nm The piston in the base of the wheel circuit reservoir Brake caliper to rear wheel drive ....
  • Page 268 R28340121 [Integral ABS] 34 51 Removing/installing wheel circuit reservoir bleed lines • Remove the cover of the wheel circuit reservoir with bleed lines. • Install in reverse order, ensuring that: • the bleed lines are not kinked, • bleed lines which have been shortened and bleed line ends are cut on the diagonal.
  • Page 269 • such that it is not chafed or bent when the handle- Carefully remove the quad rings (3) using the dis- bars are turned. mantling tool, BMW No. 34 2 561. • Install the quad rings with brake lines. •...
  • Page 270 Removing and refitting front brake line 34.27...
  • Page 271 Removing and refitting rear brake line 34.28...
  • Page 272 36 Wheels and tyres Contents Page Technical Data ..........................3 Removing and installing front wheel .................5 Removing front wheel ........................5 Installing the front wheel ......................5 Removing and installing wheel bearings ................6 Removing wheel bearings ......................6 Installing wheel bearings ......................7 Removing and installing rear wheel ...................8 Removing rear wheel ........................8...
  • Page 273 36.2...
  • Page 274 Technical Data R 1150 R Wheels Rim size Front 3.50 x 17 MT H 2 Rear 5.00 x 17 MT H 2 Max. radial/lateral runout Front mm (in) 0.5 (0.0197) Rear mm (in) 0.3 (0.0118) Tyres Tyre size Front 120/70 ZR 17 Tubeless...
  • Page 275 36.4...
  • Page 276 Note: [Integral ABS] After switching on the ignition, al- Do not apply handbrake lever with brake calipers re- ways wait for the BMW Integral ABS to complete its moved/front wheel removed. self-diagnosis. Do not operate the brake lever until self-diagnosis •...
  • Page 277 36 6 640 36 5 511 R28360020 • Clamp a drift, BMW No. 36 5 511, into the vise and place the wheel on it with the wide bearing down. • Place a spacing ring, BMW No. 36 6 640 , be- tween the wheel hub at the right and the claws of the internal puller.
  • Page 278 00 5 500 36 5 512 36 5 511 R360028 • Clamp a drift, BMW No. 36 5 511, into the vise and place the wheel on it with the wide bearing (1) down. S360090 • Install spacer tube (2).
  • Page 279 Do not operate the brake pedal when the brake cal- [Integral ABS] After switching on the ignition, al- iper is removed. ways wait for the BMW Integral ABS to complete its [Integral ABS] Do not actuate handbrake lever or self-diagnosis.
  • Page 280 Tighten nut to slightly preload bearing. • At the rear wheel, secure mounting device, BMW No. 36 3 618, to the centering collar side with wheel studs and taper rings. • Install balancing shaft, BMW No. 36 3 607, and nut, BMW No.
  • Page 281 • At the rear wheel, secure mounting device, BMW No. 36 3 618, to the centering collar side with wheel studs and taper rings. • Install balancing shaft, BMW No. 36 3 607, and nut, BMW No.
  • Page 282 46 Frame Contents Page Technical Data ..........................3 Overall view, frame ........................5 Removing and installing main (centre) stand ...............6 Removing and installing side stand ...................7 Removing and installing front mudguard ................8 Removing and installing luggage rack/case holder ..........9 Removing and installing rear side panels ..............
  • Page 283 46.2...
  • Page 284 Technical Data R 1150 R Location of manufacturer’s type plate/frame number On frame, at right Length, overall mm (in) 2,170 (85.4329) Max. height without mirrors mm (in) 1,165 (45.8660) Width of handlebars with weights mm (in) 825 (32.4803) Width across rear footrests mm (in) 734 (28.8976)
  • Page 285 46.4...

  • Page 286: Overall View, Frame

    Overall view, frame R28460110 46.5...

  • Page 287: Removing And Installing Main (Centre) Stand

    R21460150 Rs46170 Note: When installing the springs, make sure that the thick • Attach stand, BMW No. 00 1 520 to motorcycle. spring is on the inside and the thin spring on the • Disconnect retract springs. outside (arrow). •...
  • Page 288 Removing and installing side 46 53 Tightening torque: stand Pivot mount of main stand, M 8 (stud (3)) (clean thread + Loctite 243)......21 Nm Pivot mount of main stand, M 8 (cheesehead screw) ........21 Nm Carrier plate to engine block M 12 (socket-head screw) (clean thread + Loctite 2701)......

  • Page 289: Removing And Installing Front Mudguard

    R28460030 Removing and installing front 46 61 mudguard • Remove holder (1) for speedometer drive. • Remove front section of front mudguard. • Remove front wheel. • Remove holder (2) for speedometer drive. • Remove the rear section of the front mudguard. •...

  • Page 290: Removing And Installing Luggage Rack/Case Holder

    R28460090 Removing and installing lug- 46 63 gage rack/case holder Tightening torque: Case holder to frame M 6 screw ............8 Nm (clean thread + Loctite 243) M 8 screw ............ 20 Nm (clean thread + Loctite 243) 46.9...

  • Page 291: Removing And Installing Rear Side Panels

    R28460101 Removing and installing rear 46 63 side panels • Remove the seat. • If necessary, remove the case holder. • Remove rear side panel. • Installation is the reverse of the removal proce- dure. Note: Make sure that assembly is correct (arrow). Note washers (1).

  • Page 292: Removing And Installing Rear Trim

    R28460042 Removing and installing rear 46 62 trim • Remove the seat. • Remove case holder with luggage rack, if neces- sary. • Remove rear side panels. • Remove the tail light. • Remove screw (1). • Remove screws (2) and (3) on right and left and pull the tail section to the rear.

  • Page 293: Removing And Installing Rear Mudguard And Rear Carrier

    R28460041 Removing and installing rear • 46 62 Remove the seat lock and and disengage the Bowden cable. mudguard and rear carrier • Remove screws (5) and remove the rear carrier. • Installation is the reverse of the removal proce- •...
  • Page 294 R28460070 Removing and installing front foot- rest plate Removing and installing left foot- 46 71 rest plate • Remove retaining clip (arrow). • Disconnect selector lever from gearshift linkage. • Remove hydraulic spring-strut adjuster. • Remove the footrest plate. • Installation is the reverse of the removal proce- dure.
  • Page 295 R28460060 Removing and installing right 46 71 footrest plate • Remove stud (arrow). • Detach the master cylinder from the footrest plate. • Take out the screws of the footrest plate. • Remove the footrest plate and disconnect the brake-light switch. •...

  • Page 296: Removing And Installing Rear Footrest Plate

    R28460050 Removing and installing rear 46 71 footrest plate Tightening torque: Footrest plate to rear frame ......21 Nm 46.15...

  • Page 297: Removing And Installing Frame

    Insulate earth (ground) lead. Disconnect the horn and remove it complete with the bracket. • • Attach stand, BMW No. 00 1 520, to motorcycle. Release the cable ties at the frame. • • Remove fuel tank. Release the fasteners securing the fixed tubes in •...
  • Page 298 • Secure the fork bridge with handlebars to the as- sembly crane, BMW No. 46 5 640. • Remove fastener securing fork bridge to frame. Note: The screw pin is a press fit in the angular-contact ball bearing: remove as a complete unit.
  • Page 299 Release the plug for the fuel pump from the rear Attention: frame. • Switch off ignition. Secure the rear frame to the assembly crane, Disconnect earth (ground) lead from battery. BMW No. 46 5 640. Insulate earth (ground) lead. • Remove the seat. Attention: • Remove fuel tank.

  • Page 300: Checking Running Gear

    Place the motorcycle on its main (centre) stand on a flat, level surface. • Place the track offset gauge, BMW No. 36 3 920, against the left or right side of the motorcycle. Note: In order to use the track alignment gauge on either the left or right side, simply screw the supports in on the other side.
  • Page 301 • Calculate wheel track offset “S”: EXAMPLE: – Wheel track offset “S” is the distance to left or   right between the longitudinal axes of the front Formula - - - - - – - - - -  ...
  • Page 302 51 Equipment Contents Page Removing and installing ignition switch/steering lock ...........3 Removing and installing ignition/light switch ..............3 Removing and installing lock barrel ..................3 Drilling out lock barrel ..........................3 Removing and installing lock barrel for fuel tank filler cap ........4 Drilling out lock barrel ..........................4 Removing and installing seat lock/helmet lock ............5 51.1...
  • Page 303 51.2...
  • Page 304 • Install steering lock with non-removable socket Drilling out lock barrel • wrench insert, BMW No. 51 0 531. Use a 4-5 mm (0.1575-0.1969 in) dia. drill bit to drill the full length of the lock barrel. • Repeat with drill bits of successively larger diam- Tightening torque: eter until the lock barrel can be removed.
  • Page 305 GS510040 Removing and installing lock 51 25 barrel for fuel tank filler cap Note: Make sure that screws do not fall into fuel tank: cov- er fuel tank filler neck with cloth. • Open cap and remove lower part of cap (1). •...
  • Page 306 Removing and installing seat 51 25 lock/helmet lock R28510010 • Open the retainer. • Remove fastener securing seat lock/helmet lock. • Use a screwdriver to pry off the cap on the in- side. • Remove the spring and the hook. •...
  • Page 307 52 Seat Contents Page Disassembling/assembling seat ..................3 52.1...
  • Page 308 52.2...
  • Page 309 R28520010 Disassembling/assembling seat 52 51 52.3...
  • Page 310 61 General electrical equipment Contents Page Technical Data ..........................3 Removing and installing central electrical equipment box ........5 Disassembling/assembling central electrical equipment box ......5 Relay positions/fuse assignments (central electrical equipment box) ...6 Fuse assignments ..........................6 Wiring-harness routing, frame [Integral ABS] ..........................7 Wiring-harness routing/connection in central electrical equipment box ....8...
  • Page 311 61.2...
  • Page 312 Technical Data R 1150 R Battery A/h 19 61.3...
  • Page 313 61.4...

  • Page 314: Removing And Installing Central Electrical Equipment Box

    RS610062 Removing and installing central • 61 13 After installation, shorten the middle rubber lug of the anti-spray fastener (arrow) to electrical equipment box 10 mm (0.3937 in). • Switch on the ignition. • Without starting the engine, fully open the throttle Attention: once or twice so that the Motronic control unit Switch off ignition.

  • Page 315: Relay Positions/Fuse Assignments (Central Electrical Equipment Box)

    Relay positions/fuse assignments Fuse assignments (No. 1 on left, looking forwards) (central electrical equipment box) Relay positions R28610080 1. Instrument cluster, indicator damping, R28610080 brake light (without Integral ABS only) ..4 A 2. Parking light, tail light ........4 A 1.

  • Page 316: Wiring-Harness Routing, Frame [Integral Abs]

    Wiring-harness routing, frame [Integral ABS] Attention: Use (yellow) galvanized screws for the ground (earth) connection to the engine. Screws with unsuitable corrosion proofing can cause the electrical resistance to rise as high Ω as 80 Run wiring without kinking and avoid risk of abrasion. Note the number and position of the cable ties.
  • Page 317 R28610070 Wiring-harness routing/connection in central electrical equipment box 61.8...
  • Page 318 RS610110 Wiring-harness routing, central electri- cal equipment box/output Note: The white mark (arrow) must be covered by the grommet. 61.9...

  • Page 319: Wiring-Harness Routing/Connection In Central Electrical Equipment Box

    Wiring-harness routing View from left 61.10...
  • Page 320 R28619021 61.11...
  • Page 321 R28619022 61.12...

  • Page 322: Wiring-Harness Routing

    Wiring-harness routing View from right 61.13...
  • Page 323 R28619011 61.14...
  • Page 324 R28619013 61.15...
  • Page 325 R28619012 61.16...

  • Page 326: Wiring Harness

    Wiring harness Front R28610010 61.17...

  • Page 327: Removing And Installing Battery Holder

    Removing and installing bat- 61 21 tery holder R28610090 • Remove fuel tank. • Remove the battery. Attention: Disconnect the negative battery terminal first, then the positive terminal. Connect the positive battery terminal first, then the negative terminal. • Motronic control unit. •...
  • Page 328 62 Instruments Contents Page Technical Data ..........................3 Removing and installing instrument cluster ..............5 Removing and installing bracket of instrument carrier ...........6 62.1...
  • Page 329 62.2...
  • Page 330 Technical Data R 1150 R Instrument cluster Instrument lighting / telltales A 12 V 1.7 W [ABS] ABS warning light/brake failure A 14 V 3 W Speedometer drive Speedometer drive ratio I = 2.6 62.3...
  • Page 331 62.4...
  • Page 332 R28620011 Removing and installing instru- 62 11 ment cluster Attention: Switch off ignition. Disconnect earth (ground) lead from battery. Insulate earth (ground) lead. • Remove speedster windscreen with holder, if ap- plicable. • Remove headlight. • Disconnect speedometer drive (1). •...
  • Page 333 R28630010 Removing and installing • 46 63 Installation is the reverse of the removal proce- dure. bracket of instrument carrier Attention: Attention: Do not secure the ignition-cable harness to the horn Switch off ignition. bracket together with the cable package, in order to Disconnect earth (ground) lead from battery.
  • Page 334 63 Lights Contents Page Technical Data ..........................3 Removing and installing headlight ..................5 Adjusting headlight ........................5 Removing and installing front indicators ................5 63.1...
  • Page 335 63.2...
  • Page 336 Technical Data R 1150 R Headlight Circular, with halogen Bulbs High/low (dipped) beam headlight H4 halogen bulb 12 V 60/55 W Parking light 12 V/ 4 W Standard designation T 8/4 Brake/rear light 12 V/ 21/5 W Standard designation P 25-2...
  • Page 337 63.4...
  • Page 338 R28630010 Removing and installing head- Removing and installing front 63 12 63 13 light indicators Attention: Attention: Switch off ignition. Switch off ignition. Disconnect earth (ground) lead from battery. Disconnect earth (ground) lead from battery. Insulate earth (ground) lead. Insulate earth (ground) lead. •...

Table of Contents