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BMW R 1150 GS Repair Manual

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Repair Manual
R 1150 GS
BMW Motorrad
After Sales

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  • Page 1 Repair Manual R 1150 GS BMW Motorrad After Sales...
  • Page 2 Publisher © BMW Motorrad After Sales UX-VS-2 All rights reserved. Not to be reprinted, translated or duplicated either wholly or in part without prior written permission. Errors and omissions excepted; subject to technical amendment. Printed in Germany 02/00 Order number 01 79 0 021 120...
  • Page 3 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.
  • Page 4 BMW Motorrad Maintenance schedule R 1100 S / R 850/1200 C / R 1150 GS Customer Licence plate No. Order No. Mechanic’s signature Read the fault code memory with the MoDiTeC Change oil while at regular operating temperature and renew the oil filter element if motorcycle is used only for short journeys or at outside temperatures under 0°C (32 °F), every...
  • Page 5 BMW Motorrad Pre-delivery check R 1100 S / R 850/1200 C / R 1150 GS Customer Licence plate No. Pre-delivery check Order No. Mechanic’s signature Check the shipping crate for damage Motorcycle: – unpack – install remaining items – inspect for damage –...
  • Page 6 BMW Motorrad Service data R 1150 GS Item Desired value Unit of measurement/ specification Oil capacities Engine (with filter) 3.75 (6.60) litres (Imp. pints) (without filter) 3.50 (6.16) litres (Imp. pints) [SI 11 048 90] Engine oil grade: brand-name HD oil for four-stroke spark-ignition engines, API classes SE, SF , SG;...
  • Page 7 General table of contents << Back Group / Section Group / Section 00 Maintenance and general instructions 11 Engine 12 Engine electrics 13 Fuel preparation and control 16 Fuel tank and lines 18 Exhaust system 21 Clutch 23 Transmission 31 Front forks 32 Steering 33 Rear wheel drive >>...
  • Page 8 >> Next Group / Section Group / Section 34 Brakes 36 Wheels and tyres 46 Frame 51 Equipment 52 Seat 61 General electrical equipment 62 Instruments 63 Lights << Back...
  • Page 9 00 Maintenance and general instructions Tightening torques and table of consumables Pre-delivery check Maintenance Contents Page Tightening torques ........................5 Table of operating fluids ......................12 00.1...

  • Page 10: Table Of Contents

    Pre-delivery check Contents - Pre-delivery check Page Pre-delivery check ........................13 General view of crated motorcycle ................... 13 Check the shipping crate for damage ................14 In case of damage in Germany ....................14 In case of damage in importer markets ................
  • Page 11 Maintenance Contents - Maintenance Page Maintenance ..........................22 Key to maintenance intervals ....................22 Reading out MoDiTeC fault memory ................22 (Inspections I, II, III and IV) Changing engine oil, replacing oil filter element ............22 (Inspections I, II, III and IV) Changing oil in gearbox ......................23 (Inspections III and IV) or at the latest every 2 years...
  • Page 12 Contents - Maintenance Page Changing brake fluid and bleeding brake system ............31 Change the brake fluid annually (Inspection IV) Bleeding front brake circuit/changing brake fluid ............31 Additional information for [ABS] Bleeding rear brake circuit/changing brake fluid ............33 Checking clutch operating fluid level ................34 (Inspections II and III) Changing the clutch fluid...

  • Page 13: Tightening Torques

    Tightening torques Model R 1150 GS Connection 11 Engine Cylinder head Tightening sequence: 1. Tighten cylinder head nuts (oiled) in diagonally opposite sequence 1.1 Tighten all nuts to closing torque 1.2 Tighten all nuts to correct angle 90° 1.3 Tighten all nuts to correct angle 90°...
  • Page 14 Model R 1150 GS Connection 11 Engine 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 valve...
  • Page 15 Model R 1150 GS Connection 12 Engine electrics Spacer to alternator Positive lead to alternator Belt pulley to alternator Standard alternator 560 W Do not release Special alternator 700 W Belt pulley to crankshaft Poly-V belt preload Spark plug 13 Fuel preparation and control...
  • Page 16 Model R 1150 GS 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 42 (clean thread + Loctite 243) 2.
  • Page 17 Model R 1150 GS Connection 33 Rear wheel drive Oil filler plug Oil drain plug Threaded ring 160 (clean thread + Loctite 577) Hexagon nut, input bevel gear 200 (clean thread + Loctite 2701) Cover to rear-wheel drive housing Fixed bearing stud, swinging arm to...
  • Page 18 Model R 1150 GS Connection 34 Brakes Front brake caliper bleed screw Rear brake caliper bleed screw Pressure modulator bleed screw Filler adapter in brake caliper 18 (clean thread + Loctite 243 or new filler adapter) Grub screw in filler adapter...
  • Page 19 Model R 1150 GS Connection 46 Frame Footrest plate to gearbox/ Rear footrest plate to rear frame M 8 screws Fairing bracket to front frame Front carrier to fairing bracket Mudguard at bottom to slider tube 4 (clean thread + Loctite 2701)

  • Page 20: Table Of Operating Fluids

    83 19 9 407 855 500 ml spray housings Crack testing agent for aluminum 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: Pre-Delivery Check

    Pre-delivery check General view of crated motorcycle 00.13...

  • Page 22: Check The Shipping Crate For Damage

    Check the shipping crate for Unpacking the motorcycle damage • Lever off the cover. • • When the motorcycle arrives, check the packing Take out the separate pack of items: material immediately for damage and, if neces- – Documentation sary, examine the contents for consequential –...

  • Page 23: Inspecting Motorcycle For Damage

    Inspecting motorcycle for damage • Check for defects. • Use the “express handling service” to notify BMW Motorrad, UX-VS-1 Fax: +49 (0)89 382 33220 • Rectify the fault. • If parts are needed, order them through the usual channel. •...

  • Page 24: Installing Remaining Items On Motorcycle

    R21000070 Installing remaining items on motorcycle Install the windscreen • Carefully tighten the securing screws by hand. 00.16...

  • Page 25: Installing Sump Guard

    R21000080 Installing sump guard • Install the spacer bushing at the front left. Tightening torque: Bushing to engine block....... 20 Nm • Install the front rubber mounts with the long thread down. • Install the rear rubber mounts. • Install the inner plate with the outer guard. 00.17...

  • Page 26: Filling And Charging The Battery

    R21000100 Filling and charging the battery Note: Disengaging and raising the fuel tank Follow the instructions for use supplied with the bat- tery charger. • Remove seat. • Remove right side trim. Charge current (amps) Caution: ......10 % of rated battery capacity (Ah) Fuel is flammable and a hazard to health.

  • Page 27: Checking Engine Oil When Engine Is Cold, Topping Up If Necessary

    • Switch on the ignition. Checking engine oil when engine is • Without starting the engine, fully open the throttle cold, topping up if necessary once or twice so that the Motronic control unit can register the throttle-valve positions. Note: Disconnecting the battery deletes all entries (e.g.

  • Page 28: Checking Headlight Beam Angle, Adjusting If Necessary

    Checking headlight beam angle, Checking tightness of rear wheel adjusting if necessary studs Tightening torque: Rear wheel studs ........105 Nm Checking tyre pressures • Check/correct tyre pressures. Tyre pressures: Solo ........front 2.2 bar (31.3 psi) ..........rear 2.5 bar (35.6 psi) Two-up ........

  • Page 29: Final Inspection And Function Check

    Final inspection and function check Handing over the motorcycle • Clutch This is the ideal opportunity to familiarise the cus- • Check gear shift action. tomer with the motorcycle in order to ensure the • Handbrake and foot brake customer’s satisfaction and safety. •...

  • Page 30: Maintenance

    Read out the fault memory. ring. • • Perform all requisite repair work. Use oil filter wrench, BMW No. 11 4 650, to re- move the oil filter. • Coat sealing ring on new oil filter element with oil Changing engine oil, replacing oil and install filter.

  • Page 31: Changing Oil In Gearbox

    Changing oil in gearbox Changing the oil in the rear wheel drive (Inspections III and IV) or at the latest every 2 years (Inspections I, III and IV) Every 40,000 km (24,000 miles) or at the latest • Change the gearbox oil at operating tempera- every 2 years ture.

  • Page 32: Replacing Fuel Filter

    Fuel is flammable and a hazard to health. Observe relevant safety regulations. • Seal the fuel feed and return lines with hose clips, BMW No. 13 3 010, and disconnect. • Disconnect breather lines. • Pull the plug connector off the fuel pump unit.
  • Page 33 Note correct direction of flow through fuel filter. Make sure that breather lines are correctly routed. • Secure non-reusable hose clips with pliers, BMW No. 13 1 500. Caution: Make sure O-ring (2) is in perfect condition. Tightening torque: Fuel pump unit ..........6 Nm...

  • Page 34: Checking Battery Fluid Level And Topping Up If Necessary; Cleaning And Greasing The Battery Posts

    R21000100 Checking battery fluid level and Replacing intake air filter element topping up if necessary; cleaning and (Inspection III) greasing the battery posts 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 35: Replacing Poly-V Belt

    Poly-V belt tensioning procedure: • Pull off spark plug caps with special puller, 1. Slightly tighten hex nut (1) on adjusting screw (2) BMW No. 12 3 520. by hand (do not use tools). • Remove spark plugs with the spark plug wrench, 2.

  • Page 36: Checking Brake System For Correct Operation And Freedom From Leaks; Repairing/Replacing If Necessary

    Checking brake system for correct Rear brake operation and freedom from leaks; • The motorcycle must be upright. repairing/replacing if necessary (Inspection III) • Check brake system for leaks. Checking 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.

  • Page 37: Checking Brake Pads And Discs For Wear/Replacing

    Checking brake pads and discs for Checking brake disc wear wear/replacing (Inspections II and III) Checking front brake pad wear R21000220 • Examine the brake discs carefully for cracks, damage, distortion, wear and score-marks. Brake disc wear limit: R21000200 front:..........4.5 mm (0.18 in) rear:..........

  • Page 38: Replacing Brake Pads, Front Brake

    Installation is the reverse of the removal proce- dure. • Before installing the brake caliper, force the pis- tons fully back with resetting tool, BMW No. 34 1 500. Tightening torque: Brake caliper to fork slider tube....40 Nm 00.30...

  • Page 39: Changing Brake Fluid And Bleeding Brake System

    Draw off brake fluid until it emerges clear and R21000270 free from air bubbles. • Use resetting tool, BMW No. 34 1 500, to force Caution: the pistons of the right-hand brake caliper fully While bleeding the system, do not allow the brake back.

  • Page 40: Additional Information For [Abs]

    Additional information for [ABS] Caution: The motorcycle is not permitted on the road without the grub screw in place and secure in the filler adapter. • Connect the brake bleeding device to the bleed screw of the left-hand brake caliper. •...

  • Page 41: Bleeding Rear Brake Circuit/Changing Brake Fluid

    Remove the inner brake pad. • Move the brake caliper to a horizontal position. 34 1 500 R21000300 • Using resetting tool, BMW No. 34 1 500, force the pistons fully back. • Connect the brake bleeding device and open the bleed screw. •...

  • Page 42: Checking Clutch Operating Fluid Level

    Checking clutch operating fluid Changing the clutch fluid level (Inspections IV) (Inspections II and III) at the latest every 2 years • Place the motorcycle on its centre stand. Caution: Do not allow brake fluid to come into contact with painted parts of the motorcycle as brake fluid de- stroys paint.

  • Page 43: Checking Tightness Of Rear Wheel Studs

    • Disconnect the brake bleeding device from the Checking tightness of rear wheel bleed screw. studs • Reinstall socket-head grub screw (2) in the filler adapter. (Inspection I) • Tighten the rear wheel studs with a torque Caution: wrench. The motorcycle is not permitted on the road without the grub screw in place and secure in the filler adapter.

  • Page 44: Greasing The Side Stand Pivot

    • • Check free movement of side stand and grease Pull off spark plug caps with special puller, if necessary. BMW No. 12 3 520. • • Grease pivot point (arrow). Remove spark plugs with the spark plug wrench, BMW No. 12 3 510.

  • Page 45: Tightening Cylinder Heads

    Tightening cylinder heads Checking/adjusting valve clearances (Inspection I) (Inspections I, II and III) R21000330 R21000340 • Remove cylinder head cover. • Check valve clearance with feeler gauge and, if Caution: necessary, correct with adjusting screw. Catch escaping oil. Valve clearances with engine cold (max.

  • Page 46: Replacing If Necessary

    • Checking freedom of throttle cable, Connect hose of BMW Synchro to vacuum adapter and connect cables to BMW MoDiTeC. checking for chaffing and kinks, • Adjust idle speed by turning the air bypass replacing if necessary screws while checking that the carburettors are Checking throttle-cable play balanced.

  • Page 47: 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 ........
  • Page 48 11 Engine Contents Page Technical Data ..........................5 Cutaway drawing of engine ....................12 Lubricating-oil circuit ....................... 13 Cooling-oil circuit ........................14 Removing engine ........................15 Installing auxiliary frame (Raising frame unit clear of engine) ....................17 Removing auxiliary frame (Lowering frame unit onto engine) ......................
  • Page 49 Contents Page Removing alternator mount cover ..................34 Replacing radial shaft seal in alternator mount cover ..........34 Removing auxiliary shaft drive ....................35 Removing oil pump ........................36 Removing radial shaft seal from crankshaft with engine installed ......37 Disassembling crankcase ......................38 Removing crankshaft, auxiliary shaft and timing chain tensioning and slide rails ..............................40 Removing and installing oil intake strainers...
  • Page 50 11.3 Conte ntsPageIn s t alling...
  • Page 51 11.4...

  • Page 52: Technical Data

    Technical Data R 1150 GS 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 (3.97) Stroke mm (in) 70.5 (2.78)
  • Page 53 Technical Data R 1150 GS Valves Included angle between valves ° 41 Valve clearances with engine cold (max. 35 °C/95 °F) Inlet valve mm (in) 0.15 (0.006) Exhaust valve mm (in) 0.30 (0.012) Valve timing without valve clearance, 3 mm (0.12 in) valve lift Inlet opens °...
  • Page 54 Technical Data R 1150 GS Valve guide Valve guide Extl. dia. mm (in) 12.533 ... 12.544 (0.4934 ... 0.4939) Bore in cylinder head mm (in) 12.500 ... 12.518 (0.4921 ... 0.4928) Overlap mm (in) 0.015 ... 0.044 (0.0006 ... 0.0017) Repair stages Replacement valve guide Extl.
  • Page 55 Technical Data R 1150 GS Bucket-type tappet Extl. dia. mm (in) 23.947 ... 23.960 (0.9428 ... 0.9433) Bore dia. in cylinder head mm (in) 24.000 ... 24.021 (0.9449 ... 0.9457) Radial clearance mm (in) 0.040 ... 0.074 (0.0016 ... 0.0029) Wear limit mm (in) 0.18 (0.0070)
  • Page 56 Technical Data R 1150 GS 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 (0.010 ... 0.0030) Wear limit mm (in) 0.13 (0.005)
  • Page 57 Technical Data R 1150 GS 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)
  • Page 58 Technical Data R 1150 GS Piston pins Piston pin dia. mm (in) 21.995 ... 22.000 (0.8664 ... 0.8662) Wear limit mm (in) 21.960 (0.8646) Bore in piston mm (in) 22.005 ... 22.011 (0.8664 ... 0.8666) Radial clearance in piston mm (in) 0.005 ... 0.016 (0.0002 ... 0.0006) Wear limit mm (in) 0.070 (0.0028)

  • Page 59: Cutaway Drawing Of Engine

    Cutaway drawing of engine 11.12...

  • Page 60: Lubricating-Oil Circuit

    Lubricating-oil circuit 11.13...

  • Page 61: Cooling-Oil Circuit

    Cooling-oil circuit 11.14...

  • Page 62: Removing Engine

    R21110030 • Remove actuating cable for starting-speed in- crease. • • Secure stand, BMW No. 00 1 520, to motorcycle Disengage throttle cable. • with overlength bushes and screws, Remove Bowden-cable cover from fitting for BMW No. 00 1 527.
  • Page 63 Use cable ties to secure the brake caliper to the rear frame. 12 3 520 RS120170 • Pull off spark plug cap with special puller, BMW No. 12 3 520. • Disconnect plugs of injection valves. R21610050 • Disconnect hose clamps/throttle stub pipes and push the stubs into the air filter box.

  • Page 64: Installing Auxiliary Frame (Raising Frame Unit Clear Of Engine)

    (1). Caution: • Place auxiliary frame, BMW No. 46 5 630, in po- When raising the frame unit, take care not to sition and secure to the rear spring-strut damage the oil line on the engine at the front.

  • Page 65: 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 66: Disassembling Engine

    11 0 630 RS110010 Disassembling engine • Secure engine mount, BMW No. 11 0 630, to the engine block. • Transfer engine to assembly frame. 11 4 650 RS110950 • Drain engine oil. • Remove the oil filter, using oil filter wrench, BMW No.

  • Page 67: Removing Cylinder Head Cover

    12 3 510 RS110020 Removing cylinder head cover • Remove spark plugs with the spark plug wrench, BMW No. 12 3 510. • Remove cylinder head cover. Caution: Catch escaping oil. 11.20...

  • Page 68: Locking The Engine At Tdc

    Install locking device, BMW No. 11 5 640, to lock clutch housing. RS110461 Note: The engine can be locked at TDC by inserting locat- ing pin, BMW No. 11 2 650, through the hole in the clutch housing and the engine block. 11.21...

  • Page 69: Removing And Installing Chain Tensioner

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

  • Page 70: Remove Valve Gear Carrier

    M6 x 60 M6 x 30 M6 x 30 M6 x 30 S110110 Remove valve gear carrier • Remove valve gear carrier. • Secure rockers with a rubber band (2). Note: If no work is to be carried out on the valve gear car- rier, remove it together with the cylinder head.

  • Page 71: Disassembling/Assembling Valve Gear Carrier

    RS110080 Disassembling/assembling 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. Caution: Do not mix up the rocker shafts and pushrods. 11.24...
  • Page 72 RS110090 • Remove camshaft bearing cap (1). • Remove camshaft and bearing (2). • Remove bucket-type tappets. Caution: Do not mix up the bucket-type tappets. • Assembly is the reverse of the disassembly pro- cedure. Caution: Note direction of installation (3) for camshaft bearing cap.

  • Page 73: Removing Cylinder Head

    M10 x 70 M6 x 30 M6 x 30 M6 x 30 RS110110 Removing cylinder head 11.26...

  • Page 74: 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 75: Checking Valves For Wear

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

  • Page 76: 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 77: Installing Valve And Valve Stem Seal

    Shrink a short length of 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. Caution: Remove the shrink-fit tube. •...

  • Page 78: Removing Cylinder

    RS110170 Removing cylinder • Remove guide rail bearing screws (1). • Remove cylinder retaining screws, and remove cylinder. Caution: When removing cylinder, make sure that the piston does not strike the engine block. Removing and disassembling piston • Remove both retaining rings from piston pin. •...

  • Page 79: Checking Pistons And Cylinders

    Checking pistons and cylinders Assembling pistons Reference temperature for measurements: ......... 20 °C (68 °F) R21110050 RS110180 • Carefully fit piston rings to piston in the following • Measure cylinder bore with internal probe at sequence, using piston ring pliers: 20 mm (0.79 in) and 100 mm (3.94 in) from the 3rd groove - coiled-spring ring top in direction of piston pin, and again at a right...

  • Page 80: Removing And Installing Conrod

    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. Use a 3/8“ square-drive socket crankshaft removed. wrench.

  • Page 81: Removing And Installing Alternator Mount Cover With Engine Installed

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

  • Page 82: 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 83: Removing Oil Pump

    M6 x 45 M6 x 50 M6 x 45‹ M6 x 45 RS110410 M6 x 50 Removing oil pump • Remove oil pump cover (1). • Remove complete oil pump (2) together with cooling oil pipe (3), and disassemble. Caution: Check installed positions of parts which have al- ready been run together.

  • Page 84: Removing Radial Shaft Seal From Crankshaft With Engine Installed

    Using awl, BMW No. 00 8 583, carefully punch a hole in the shaft sealing ring. • Screw the pull rod, BMW No. 00 8 581, into the pierced hole and use impact weight, S110040 BMW No. 00 8 582, to remove the shaft sealing ring.

  • Page 85: Disassembling Crankcase

    RS110261 Disassembling crankcase • Turn engine on to its side. • Remove screws on right side. 11.38...
  • Page 86 RS110260 • Turn engine on to its side. • Remove screws on left side. • Remove upper section of crankcase. 11.39...

  • Page 87: Removing Crankshaft, Auxiliary Shaft And Timing Chain Tensioning And Slide

    S110050 Removing crankshaft, auxiliary shaft and timing chain tensioning and slide rails 11.40...

  • Page 88: Removing And Installing Oil Intake Strainers

    • Coat the sealing face of the new oil level sight glass with engine oil and drive it in with drift, BMW No. 00 5 550. Removing and installing oil thermostat S110070 •...

  • Page 89: 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 Caution: The crankshaft can only be reground in grinding stage 0;...

  • Page 90: Installing Main Bearings

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

  • Page 91: 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 Tightening angle..........80° 11.44...

  • Page 92: 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. Caution: Oil the bearings. Do not mix up conrods or bearing shells.

  • Page 93: Installing Crankshaft

    S110080 Installing crankshaft Installing auxiliary shaft/timing chains • When installing the auxiliary shaft, make sure that Caution: the bore in the auxiliary shaft (2) facing the crank- Oil the bearings. shaft is in line with the crankcase mating face. Caution: Installing timing chain tensioning and Timing chains (3) must mesh fully with auxiliary shaft sprockets.

  • Page 94: 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 tensioner and slide rail. 11.47...
  • Page 95 RS110391 • Bolt the crankcase sections together. Tightening torque/tightening sequence: 1. M 10 screw (oiled) Initial torque ..25 Nm Wrench angle ..... 90° 2. M 8 screw (oiled) ........22 Nm 3. M 6 screw ..........9 Nm 11.48...
  • Page 96 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 11.49...

  • Page 97: Installing Radial Shaft Seals On Crankshaft

    • Using assembly sleeve, BMW No. 11 5 662, mount the radial shaft seal with the closed side toward the clutch onto drift, BMW No. 11 5 661, with handle, BMW No. 00 5 500, (8). • Remove assembly sleeve (9).

  • Page 98: 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 (screw threads oiled) ........

  • Page 99: Installing Oil Pump

    M6 x 45 M6 x 50 M6 x 45 M6 x 45 M6 x 50 RS110411 Installing oil pump Caution: Oil the friction faces. • Install outer rotor (1) of oil pump in pump hous- ing. • Install oil pump housing with cooling oil pipe (2). Caution: O-ring (3) must be in perfect condition.

  • Page 100: Installing Auxiliary Shaft Drive

    ..........See Technical Data M6 screw ............. 10 Nm Banjo bolt for cooling oil line with oil vent valve ......... 25 Nm • Install locking device, BMW No. 11 5 640, to lock clutch housing. • Install chain sprocket (1). Tightening torque: M 6 screw ............

  • Page 101: Installing Piston

    R21110060 Installing piston • 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. Caution: Make sure that retaining rings are properly seated on piston pin.

  • Page 102: 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 103: 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 104: Adjusting Valve Clearances

    RS110980 Adjusting valve clearances • 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 °C/95 °F): Inlet .........

  • Page 105: 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 106: 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 107 RS110050 RS110940 • • Install the end cover with O-ring in perfect condi- Install cylinder head cover. tion. Caution: 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 108 11 5 640 11 5 680 S110090 Installing alternator mount cover • 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. Tightening torque: M 8 screw ............
  • Page 109 11 2 650 RS110461 Timing the ignition • Using TDC locating pin, BMW No. 11 2 650, lock the clutch housing. • Connect BMW MoDiTeC with adapter cable to Hall-effect gate plate. • Set the timing, following the tester instructions.

  • Page 110: Installing Alternator

    RS110480 Installing alternator • 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. Tighten upper retain- ing nut (3), then remove torque wrench from ad- justing screw.
  • Page 111 Tightening torque: 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............ 20 Nm 11.64...
  • Page 112 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 Disassembling/assembling alternator (Option 50 A)
  • Page 113 12.2...

  • Page 114: Technical Data

    Technical Data R 1150 GS 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 Standard: Denso, Option: Bosch Drive...
  • Page 115 12.4...

  • Page 116: Removing And Installing Coil And Ignition Lead

    • Disengage fuel tank. ing characteristics when the engine is restarted. • Seal the fuel feed and return lines with hose clips, BMW No. 13 0 010, and disconnect. • Checking ignition coil resistance Disconnect breather lines. • Disconnect plug for fuel pump.

  • Page 117: Removing And Installing Alternator

    • Seal the fuel feed and return lines with hose Place the Poly-V belt in position, tension it and clips, BMW No. 13 3 010, and disconnect. turn the engine over once, then relieve belt ten- • Disconnect breather lines.

  • Page 118: Disassembling/Assembling Alternator

    S120020 Disassembling/assembling Checking alternator alternator • Test with BMW MoDiTeC. • Remove the cover retaining screws (1). Checking armature for short to ground • Unscrew nut (2) and remove sleeve (3). (earth) • Remove the cover. • Remove voltage regulator (4).

  • Page 119: Checking Alternator

    RS120050 Disassembling/assembling Checking alternator alternator • Test with BMW MoDiTeC. (Option 50 A) Checking armature for short to ground • Remove the cover retaining screws (1). (earth) • Release clips (2) and remove the cover. • Remove voltage regulator (3).

  • Page 120: Removing And Installing Starter Motor

    RS120140 Removing and installing starter motor • Remove the seat. Caution: Disconnect earth (ground) lead from battery. Insulate earth (ground) lead. • Remove cover (1) for the starter motor and dis- connect cable (2) for the power socket. • Disconnect lead (3). •...

  • Page 121: Disassembling/Assembling Starter Motor

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

  • Page 122: Removing And Installing Magnetic Gate

    Loss of settings can temporarily impair the operat- • Remove the starter motor. ing characteristics when the engine is restarted. • Install locking device, BMW No. 11 5 640, to lock clutch housing. • Remove Poly-V belt pulley (3) with rotor gate from Tightening torque: crankshaft.

  • Page 123: Timing The Ignition

    Timing the ignition 11 2 650 RS110461 • Using TDC locating pin, BMW No. 11 2 650, lock the clutch housing. • Connect BMW MoDiTeC with adapter cable to Hall-effect gate plate. • Set the timing, following the tester instructions.

  • Page 124: Fuel Preparation And Control

    13 Fuel preparation and control Contents Page Technical Data ..........................3 Removing and installing air filter housing ..............5 Removing and installing trottle-valve stub pipe ............6 Removing and installing throttle-valve potentiometer ..........7 Removing and installing Motronic control unit ............7 13.1...
  • Page 125 13.2...

  • Page 126: Technical Data

    Technical Data R 1150 GS Super (premium), unleaded. 95 octane (RON) Fuel grade Motronic MA 2.4 Mixture preparation Throttle stub pipe intl. dia. mm (in) 45 (1.771) Throttle angle in rest position ° 5 Air filter Round paper element 13.3...
  • Page 127 13.4...

  • Page 128: Removing And Installing Air Filter Housing

    RS130090 Removing and installing air filter housing Preparatory work ..........See Group 23 (removal of transmission) 13.5...

  • Page 129: Removing And Installing Trottle-Valve Stub Pipe

    S130020 Removing and installing trottle- • Push intake neck into air filter box and remove throttle-valve stub. 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 130: Removing And Installing Throttle-Valve Potentiometer

    (basic setting is necessary — from battery and insulate it. see Motronic diagnosis instructions). • Remove the throttle-valve potentiometer. • Adjust throttle-valve potentiometer with BMW MoDiTeC after installing. • Mark screws with a paint spot. RS130010 • Disconnect plug from Hall sensor. •...

  • Page 131: Fuel Tank And Lines

    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, fuel pump and fuel level sensor ....7 Removing and installing fuel filter ....................7 Removing and installing fuel pump and fuel level sensor ..........7...
  • Page 132 16.2...

  • Page 133: Technical Data

    Technical Data R 1150 GS Fuel tank Tank capacity (usable) l (Imp.gal/ US gal) 22 (4.8/5.81) Including reserve of l (Imp.gal/ US gal) approx. 4 (0.88/1.06) Fuel pump Type Turbine-wheel pump Make VDO type HPI-3.0 Operating voltage V 7...15V Fuel pressure bar (psi) 3±0.2 (42.69±2.85)
  • Page 134 16.4...

  • Page 135: Removing And Installing Fuel Tank

    Remove side panel. • Remove screw securing fuel tank. • Seal the fuel feed and return lines with hose clips, BMW No. 13 3 010, and disconnect. • Disconnect breather and overflow hoses. • Disconnect the plug of the fuel pump.

  • Page 136: 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 137: Removing And Installing Fuel Filter, Fuel Pump And Fuel Level Sensor

    Note correct direction of flow through fuel filter. • Connect test pressure gauge, • Remove/install fuel filter. BMW No. 16 1 500, on the pressure side. • • Secure non-reusable hose clips with pliers, Start engine and allow to idle.

  • Page 138: Removing And Installing Fuel Distributor And Pressure Regulator

    Removing and installing fuel distributor and pressure regulator • Remove air filter box....See Group 23, removing transmission. R21160030 • Remove the fuel distributor with pressure regula- tor from the holder. • Installation is the reverse of the removal proce- dure.

  • Page 139: Exhaust System

    18 Exhaust system Contents Page Removing and installing exhaust system ................3 Removing and installing silencer and front silencer ............3 Removing silencer end cap and silencer guard ...................3 Installing silencer end cap and silencer guard ..................3 Removing and installing exhaust manifolds ................4 18.1...
  • Page 140 18.2...

  • Page 141: Removing And Installing Exhaust System

    Installation is the reverse of the removal proce- system dure. • Secure the oxygen sensor with special socket Removing and installing silencer and wrench insert, BMW No. 11 7 020. front silencer Removing silencer end cap and silencer guard • • Remove rear silencer.

  • Page 142: Removing And Installing Exhaust Manifolds

    Removing and installing exhaust manifolds • Slacken the clamp holding the front silencer. • Remove fasteners securing exhaust manifold. • Remove exhaust manifold. • Installation is the reverse of the removal proce- dure. Caution: After a trial run, read out Motronic fault memory. Note position of wiring for oxygen sensor.
  • Page 143 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 .............8...
  • Page 144 21.2...

  • Page 145: Technical Data

    Technical Data R 1150 GS 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 (0.51) Slave cylinder piston dia. mm (in) 24 (0.94) Clutch fluid DOT 4 brake fluid Clutch plate dia.
  • Page 146 21.4...

  • Page 147: Removing And Installing Clutch

    • Remove the sump guard. When installing the footrest plates, use the long • Secure stand, BMW No. 00 1 520, to motorcycle screws on the right and the short screws on the left. with overlength bushes and screws, •...
  • Page 148 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. • Remove the fuel distributor. • Remove clutch slave cylinder. •...

  • Page 149: Removing Clutch From Engine

    Install clutch housing with crankshaft pin (2) lo- Tightening torque: cated in bore (1). Housing cover to flywheel ......12 Nm • Install locking device, BMW No. 11 5 640, to lock clutch housing. Installing clutch in vehicle • Installation is the reverse of the removal proce- Caution: dure.

  • Page 150: Removing And Installing Clutch Hydraulic Line

    R21210010 Removing and installing clutch Removing and installing clutch hydraulic line slave cylinder • • Remove the seat. Remove the seat. • • Remove fuel tank. Remove rear brake caliper. • • Remove rear brake caliper. Remove rear wheel. • •...

  • Page 151: Filling/Bleeding Clutch Line

    Filling/bleeding clutch line Tightening torque: Clutch slave cylinder to gearbox ....9 Nm ............See Group 00 Tightening sequence: Connecting pipe/gearbox 1. to gearbox and left footrest plate (clean thread + Loctite 243)...... 42 Nm 2. clamp block, connecting tube to gearbox .. 9 Nm 3.
  • Page 152 23 Transmission Contents Page Technical Data ..........................3 Gearbox - sectional drawing ....................5 Removing and installing gear-shift lever .................7 Removing/installing gearbox ....................7 Replacing the shaft sealing rings in the gearbox housing and gearbox cover ...9 Replacing the input shaft sealing ring at input end ................9 Replacing output shaft sealing ring .....................9 Replacing input shaft sealing ring at output end ................
  • Page 153 Contents Page Assembling gearbox .........................23 Installing input, output and intermediate shafts ..............24 Installing selector shaft .......................25 Installing selector drum ......................25 Installing gearbox housing ......................26 23.2...

  • Page 154: Technical Data

    Technical Data R 1150 GS Type of gearbox 6-speed gearbox with claw-action shift and integral reaction damper for all gears Gear shift type Foot-operated lever and selector drum with over- shoot detent Gear ratios 1st gear 3.864 2nd gear 3.022 3rd gear 2.393...
  • Page 155 23.4...

  • Page 156: Gearbox - Sectional Drawing

    Gearbox - sectional drawing R21239010 23.5...
  • Page 157 23.6...

  • Page 158: Removing And Installing Gear-Shift Lever

    Gear shift pedal to footrest plate ....35 Nm Removing/installing gearbox • Remove the sump guard. • Secure stand, BMW No. 00 1 520, to motorcycle with overlength bushes and screws, BMW No. 00 1 527. Note: Mount a washer on the screw on the right as viewed R21610050 in the forward direction of travel.
  • Page 159 Remove cable ties/wiring harness from air filter • box. Installation is the reverse of the removal proce- • Use hose clip pliers, BMW No. 17 5 500, to dis- dure. connect hose from rotary breather from air-filter box. Caution: •...

  • Page 160: Replacing The Shaft Sealing Rings In The 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 161: Replacing Input Shaft Sealing Ring At Output End

    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 162: Disassembling Gearbox

    R21230020 Disassembling gearbox 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 163: Removing Selector Drum

    R21230040 Removing selector drum Disassembling/assembling selector 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). • Press guide plate (5) in the opposite direction to the spring loading (arrow).

  • Page 164: Removing Gearbox Shafts

    If the grooved ball bearings are replaced, the fully assembled length must be re-adjusted. • Pull off the grooved ball bearings with a universal puller, BMW No. 00 7 500. • Press the output-side grooved ball bearing on to the intermediate shaft.

  • Page 165: Disassembling/Assembling Input Shaft

    (3), thrust block (2) and constant-speed gear (1). • Clamp input shaft (10) other way round in vise. • Use universal puller, BMW No. 00 7 500, and 00 7 500 pressure head (arrow) to pull off grooved ball bearing (11). KR230090 •...

  • Page 166: Assembling Input Shaft/Checking And Adjusting Axial Play Of Spring Cluster

    KR230081 • Assembling input shaft/checking and adjusting Install spacing washer (8) of calculated thick- axial play of spring cluster ness, and press on grooved ball bearing (9). • Lightly oil the bearing surface for constant-speed gear (1) on input shaft (10), and install the con- Endplay: stant-speed gear.

  • Page 167: Disassembling/Reassembling 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 168: Assembling Output Shaft

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

  • Page 169: Checking Endplay

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

  • Page 170: Checking/Adjusting Fully Assembled Length Of Gearbox Shafts And Selector

    • 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 (0.008 in) preload.

  • Page 171: Checking/Adjusting Fully-Assembled Length Of Output Shaft

    Caution: The maximum deviation from zero must not be ex- • Position dial gauge, BMW No. 23 4 762, in rear ceeded. locating bore of stand, BMW No. 23 4 761, and • set to 0.2 mm (0.008 in) preload.

  • Page 172: Checking/Adjusting Fully-Assembled Length Of Input Shaft

    Caution: The maximum deviation from zero must not be ex- • Position dial gauge, BMW No. 23 4 762, in front ceeded. locating bore of stand, BMW No. 23 4 761, and • set to 0.2 mm (0.008 in) preload.

  • Page 173: Checking/Adjusting Fully Assembled Length Of Selector Drum

    KR230190 Checking/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). Fully assembled length: Selector drum ............

  • Page 174: Shimming Selector Shaft

    Shimming selector shaft Caution: 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 175: Assembling Gearbox

    Installing input, output and • Push assembly sleeve, BMW No. 23 4 712, on intermediate shafts to the input shaft splines. Note: This is necessary only if the shaft sealing ring is in- stalled.

  • Page 176: Installing Selector Shaft

    R21230040 Installing selector shaft Installing selector drum • 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 177: Installing Gearbox Housing

    • Apply Loctite 574 sealing compound to the mat- ing face of the cover. • Place assembly sleeve, BMW No. 23 4 732, on R21230030 the output shaft. • Place assembly sleeve, BMW No. 23 4 612, on •...
  • Page 178 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 179 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 180 31.2...

  • Page 181: Technical Data

    Technical Data R 1150 GS Front suspension Type BMW Telelever with external suspension strut Telescopic fork Front wheel caster in normal-load position (85 kg/187 lbs rider) mm (in) 115 (4.528) Steering lock angle ° 42 Total suspension travel mm (in) 190 (7.48)
  • Page 182 31.4...

  • Page 183: Removing And Installing Telescopic Fork

    31 5 603 31 5 601 R21310020 Removing and installing telescopic fork Removing and installing telescopic fork without fork bridge • Remove front wheel. • Remove mudguard. • [ABS] Remove sensor. • Remove brake line retainer. • Place a support beneath the telescopic fork. •...

  • Page 184: Removing And Installing Fork Bridge

    • Tighten the ball joint in the leading link using Disengage fuel tank and pull to the rear. • socket, BMW No. 31 5 601, and Allen key, Disconnect plug of ignition lock. • BMW No. 31 5 603. Attach the handlebar to a crane and release the fastener securing the handlebar to the fork bridge.

  • Page 185: Removing And Installing Pot-Type Joints

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

  • Page 186: Removing And Installing Slider Tube Bridge

    Mount the slider tube bridge in retaining fixture, • Install retaining ring. BMW No. 31 5 670. • Use w/f 46 socket, BMW No. 31 5 630, to re- Removing and installing slider tube lease and tighten ball joint. bridge Tightening torque: Ball joint to slider tube bridge •...

  • Page 187: Disassembling/Assembling Telescopic Fork

    Remove wiper (3) and retaining ring (4). BMW No. 31 5 611, expander, • Lever out shaft seal (5). BMW No. 31 5 612, and reducing adapter, BMW No. 31 5 613. • Caution: Install retaining ring and dust wiper.

  • Page 188: Measuring Telescopic Fork

    Measuring telescopic fork Caution: After an accident, always examine the telescopic fork for cracks and signs of damage. Examining slider tube bridge and fork bridge • Check slider tube bridge and fork bridge for sur- face irregularities. Caution: Replace slider tube bridge/fork bridge if deformed. Checking runout of fixed tube RS310061 •...

  • Page 189: 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 on right ..... 73 Nm Left screw cap (coat thread lightly with Never Seeze)....
  • Page 190 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 Checking and adjusting operating clearance at front brake/clutch levers ....9 Front brake ............................9...
  • Page 191 32.2...

  • Page 192: Technical Data

    Technical Data R 1150 GS Steering lock angle ° 2 x 42 Steering head tube dia. mm (in) 22 (0.866) Width of handlebar with weights mm (in) 903 (35.551) 32.3...
  • Page 193 32.4...

  • Page 194: Removing And Installing Left Handlebar Fitting

    R21320010 Removing and installing left Note: handlebar fitting Align the clamp joint line with the punch mark on the handlebar. • Disengage fuel tank and pull to the rear. • • Remove securing screw (1) and remove handle- Fill and bleed the clutch operating system. bar weight.

  • Page 195: Removing And Installing Right Handlebar Fitting

    R21320020 Removing and installing right handlebar fitting Note: Align the clamp joint line with the punch mark on the • Disengage fuel tank and pull to the rear. handlebar. • Remove securing screw (1) and remove handle- bar weight. • •...

  • Page 196: Removing And Installing Brake Piston In Handlebar Fitting

    R21340030 Removing and installing brake piston • Prior to installation, carefully press back the in handlebar fitting brake piston using an Allen key with T-bar han- dle, for example. • • Drain the brake system. Use cranked-tip snap-ring pliers to install the re- taining ring.

  • Page 197: Removing And Installing Clutch Piston In Handlebar Fitting

    R21320050 Removing and installing clutch piston in handlebar fitting Caution: Sealing lips of the boots (6) toward the pressure • Drain the clutch operating system. chamber. • Prior to installation, carefully press back the Caution: clutch piston using an Allen key with T-bar han- Do not allow brake fluid to come into contact with dle, for example.

  • Page 198: Checking And Adjusting Operating Clearance At Front Brake/Clutch Levers

    Checking and adjusting operating Note: Thread is secured with Loctite, if necessary heat clearance at front brake/clutch levers slightly prior to facilitate removal. Front brake • Remove cover from throttle-cable relay. • • Remove the lower section of the brake lever fit- Remove the pivot screw of lever and remove the ting.

  • Page 199: Removing And Installing Handlebar

    Removing and installing handlebar R21320030 • Remove left and right handlebar fittings. • Remove handlebar. • Installation is the reverse of the removal proce- dure. Caution: Make sure that all lines and cables are correctly routed. Align the punch mark on the handlebar with the gap between the clamp blocks.

  • Page 200: Removing And Installing Bowden-Cable Divider, Bowden Cable For Throttle Actuation And Starting-Speed Increase

    R21320040 Removing and installing Bowden- ............ see Group 00 cable divider, Bowden cable for throttle actuation and starting-speed increase • Disengage fuel tank and pull to the rear. • Remove actuating cable for starting-speed in- crease. • Disengage Bowden cable (A). •...

  • Page 201: Disassembling Bowden-Cable Divider

    Disassembling Bowden-cable divider S320050 • Remove fasteners of Bowden cables at entry to Bowden-cable divider. • Remove Bowden cable for starting-speed in- crease. • Remove retainer (1) for roller of Bowden-cable divider. • Remove Bowden cables. • Installation is the reverse of the removal proce- dure.
  • Page 202 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 203 Contents Page Installing rear swinging arm ......................21 33.2...

  • Page 204: Technical Data

    Technical Data R 1150 GS 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 (0.0027 ... 0.0063) Taper roller bearing preload mm (in) 0.05 ... 0.1 (0.0020 ... 0.0039)
  • Page 205 33.4...

  • Page 206: Removing, Disassembling, Reassembling And Installing Rear Wheel Drive

    Disengage reaction link from rear wheel drive. Remove needle roller bearing with counter-sup- • Remove floating bearing/fixed bearing stud port 22/1, BMW No. 00 8 572, and internal puller bolts. 21/4, BMW No. 00 8 573, with ring support. •...

  • Page 207: Removing Input Bevel Pinion

    33 1 700 S330030 Removing input bevel pinion • 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 208: 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 209: Removing Needle Roller Bearing For Input Bevel Pinion

    Heat the housing to 120 °C (248 °F). • Remove the outer ring of the needle roller bear- ing using internal puller, BMW No. 00 8 573, threaded extension, BMW No. 00 8 575, and counter-support, BMW No. 00 8 572.

  • Page 210: Installing Input Bevel Pinion

    33 1 720 33 1 700 S330060 Installing input bevel pinion • Clamp holder, BMW No. 33 1 510, in the vise in such a way that the input neck of the housing is • Clean threads in the housing. pointing forward.
  • Page 211 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 212: Removing And Disassembling Crown Wheel

    (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 213: 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 214: Shimming Input Bevel Pinion And Crown Wheel

    Shimming input bevel pinion and crown wheel • It is important 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 numbers (1).

  • Page 215: 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 216: Checking And Adjusting Backlash

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

  • Page 217: 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 218: Installing Rear Wheel Drive

    R21330021 Installing rear wheel drive • Load approx. 85 kg (187 lbs) onto motorcycle and tighten loose reaction link (3). • Tighten clamping strap (4) on gaiter. Note: Do not lay oil-filled rear-wheel drive on its side prior Caution: to installation, as this will cause oil to escape when When tightening threaded fasteners coated with the motorcycle is on the road (suction effect).

  • Page 219: Removing And Installing Spring Strut

    Removing and installing spring strut • If necessary, fill with oil. Quantity: Note: Initial filling/oil changes............approx. 0.25 l (0.44 Imp. pint/0.26 US quart) To remove the spring strut, support the rear axle. Oil grade: • Brand-name hypoid gear oil, SAE 90, API class GL 5 Remove the seat.

  • Page 220: Removing And Installing Rear Swinging Arm

    R21330020 Removing and installing rear 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. • Loosen floating bearing stud bolt.

  • Page 221: Removing And Installing Taper Roller Bearing

    To install the bearing, heat the swinging arm to 80 °C (176 °F). Checking universal joint for wear • Drive in bearing with drift, BMW No. 33 5 700. Removing and installing flexible gaiter KR330360 • Measure axial and radial play.

  • Page 222: Installing Rear Swinging Arm

    R21330020 Installing rear swinging arm Caution: • Slide swinging arm over drive shaft as far as pos- When tightening threaded fasteners coated with sible until rubber gaiter connects on housing Loctite 2701, always apply final torque without de- neck. lay. Allow at least 3 hours for the Loctite to cure. •...
  • Page 223 34 Brakes Contents Page Technical Data ..........................3 Removing and installing front brake caliper ..............4 Disassembling and assembling front brake caliper ..........5 Removing and installing filler adapter ..................6 Removing and installing rear brake caliper ..............7 Disassembling and assembling rear brake caliper ...........8 Removing and installing front brake disc ...............9...
  • Page 224 Contents Page Removing ABS relay socket ..................... 19 Installing the ABS relay base ....................20 Removing and installing brake line (with ABS) ............21 Removing and installing front brake line ................21 Removing and installing rear brake line ................22 34.2...

  • Page 225: Technical Data

    Technical Data R 1150 GS Brake fluid DOT 4 Minimum lining thickness, front mm (in) 1.0 (0.04) Minimum lining thickness, rear 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.

  • Page 226: Removing And Installing Front Brake Caliper

    Removing and installing front brake caliper RS340021 Caution: Do not allow brake fluid to come into contact with painted parts of the motorcycle as brake fluid de- stroys paint. • Drain the brake system. • Disconnect brake line (1). • Remove screws securing the brake caliper.

  • Page 227: Disassembling And Assembling Front Brake Caliper

    • Remove brake pads by pulling downwards. Using piston compressor (7), • Close the bleed screw. BMW No. 34 1 500, if necessary press the pis- tons fully back. • Install the brake pads. Tightening torque: Bleed screw in brake caliper ......14 Nm •...

  • Page 228: Removing And Installing Filler Adapter

    • Remove the brake pads. KL340250 • Secure brake pistons with resetting tool, BMW No. 34 1 500. • Inject compressed air through the connecting KL340230 bore (arrow) in the brake caliper to blow out trac- es of thread-locking compound that might have •...

  • Page 229: Removing And Installing Rear Brake Caliper

    S340010 Removing and installing rear brake Sensor gap:..0.45...0.55 mm (0.018 ... 0.022 in) caliper Tightening torque: Caution: Brake caliper to rear wheel drive ....40 Nm Do not allow brake fluid to come into contact with Brake line to brake caliper......18 Nm painted parts of the motorcycle as brake fluid de- Bleed screw in brake caliper ......

  • Page 230: Disassembling And Assembling Rear Brake Caliper

    R21340010 Disassembling and assembling rear Caution: brake caliper Keep the brake pistons parallel with their bores when installing. • Remove retaining washer (1). • • Drive the retaining pin (2) out towards the wheel Coat both brake caliper pistons with brake fluid side.

  • Page 231: Removing And Installing Front Brake Disc

    R21360010 Removing and installing front brake disc • Remove screws securing the brake caliper. • Remove front wheel. • Remove and install brake discs. • Degrease brake discs before installing. Note: Installed direction (arrow) of brake discs must be correct. Tightening torque: Brake disc to front wheel (clean thread + Loctite 243)......

  • Page 232: Removing And Installing Rear Brake Disc (Mounted On Rear-Wheel Hub)

    Removing and installing rear brake disc (mounted on rear-wheel hub) • Remove screws securing the brake caliper. • Remove rear wheel. GS340161 • Remove brake disc. • Installation is the reverse of the removal proce- dure. • Degrease the brake disc before installing. Caution: [ABS] Check sensor gap and adjust with shims if necessary.

  • Page 233: Removing And Installing Front Abs Sensor

    R21340080 Removing and installing front ABS sensor • Remove front wheel. • Remove fuel tank. • Disconnect plug (1) of sensor cable. • Remove sensor (2) with Torx T 25. • Installation is the reverse of the removal proce- dure. Caution: Route the sensor cable correctly.

  • Page 234: Abs Sensor Gap, Front: Adjusting

    Attach dial gauge holder (1), BMW No. 00 2 500, with dial gauge, BMW No. 00 2 510, and meas- Sensor gap:..0.45...0.55 mm (0.018 ... 0.022 in) uring shoe (2), BMW No. 34 2 510, to fork slider tube. •...

  • Page 235: Removing And Installing Rear Abs Sensor

    R21340020 Removing and installing rear ABS sensor • Before removing/installing, clean the sensor bore. • Using Torx T 25, slacken sensor (1). • Disconnect plug (2) of sensor cable. • Installation is the reverse of the removal proce- dure. • Coat O-rings with oil before installing.

  • Page 236: Adjusting Rear Abs Sensor Gap

    After adjusting, rotate the wheel and check that the and extension, BMW No. 34 2 520, with dial sensor is clear at all times. gauge, BMW No. 00 2 510, firmly to the sensor mount. • Zero the dial gauge.

  • Page 237: Removing And Installing Rear Brake Master Cylinder

    • Installation is the reverse of the removal proce- dure. • Tighten non-reusable hose clip (5) with pliers, BMW No. 13 1 500. Caution: Bleed the brake system carefully. Check/adjust piston rod play. Tightening torque: Master cylinder to footrest assembly ....9 Nm...

  • Page 238: Checking And Adjusting Play Of Piston Rod

    Checking and adjusting play of piston Removing and installing footbrake lever • Release the pin in the brake linkage. • Remove fasteners securing footbrake lever. • Remove footbrake lever with torsion spring. • Installation is the reverse of the removal proce- dure.

  • Page 239: Removing And Installing Abs Unit

    (to close the brake fluid feed bore). Caution: Work on the ABS unit must be performed by an au- Caution: thorised BMW workshop. Switch off ignition. Disconnect earth (ground) lead from battery. Insulate earth (ground) lead. Removing the ABS unit •...

  • Page 240: Installing The Abs Unit

    Installing the ABS unit Removing and installing ABS relay and relay socket • Install the ABS unit (6). • Connect the central plug (5). Removing ABS relay Caution: Make sure the cable is not at an angle, or its insula- tion may be damaged.

  • Page 241: Installing The Abs Relay

    Installing the ABS relay Removing ABS relay socket • Insert the ABS relay with the FAG logo facing the detent hook. Caution: • Tighten the screws at the relay socket. Switch off ignition. • Push the relay socket into the relay housing, at Disconnect earth (ground) lead from battery.

  • Page 242: Installing The Abs Relay Base

    Installing the ABS relay base Caution: • Bend up the contact interlock on the plug. • Insert the contact into the relay socket. When sliding the cover on, make sure that all cables are correctly located in their cable entries. Caution: The contact engages with an audible click and must be firmly located.

  • Page 243: Removing And Installing Brake Line (With Abs)

    R21340021 Removing and installing brake line (with ABS) Removing and installing front brake line 34.21...

  • Page 244: Removing And Installing Rear Brake Line

    R21340022 Removing and installing rear brake line • Fill and bleed the brake system Tightening torque: Brake line to handlebar fitting....... 18 Nm Caution: Brake line to front/rear brake caliper .... 18 Nm Do not allow brake fluid to come into contact with Brake hose to bracket........
  • Page 245 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/installing rear wheel ....................8 Removing rear wheel ........................8 Installing rear wheel ........................8 Static balancing of front wheel/rear wheel ..............9...
  • Page 246 36.2...
  • Page 247 Technical Data R 1150 GS Rim size Front 2.50 x 19 MT H2 Rear 4.00 x 17 MT H2 Max. radial/lateral runout Spoked wheel Front mm (in) 1.3 (0.05) Rear mm (in) 1.3 (0.05) Tyre size Spoked wheel Front 110/80 R 19 59 H Tubeless...
  • Page 248 36.4...

  • Page 249: Removing And Installing Front Wheel

    R21360011 Removing and installing front wheel Installing the front wheel • Fit the front wheel. Removing front wheel • Install the spacing bushing and speedometer • Remove brake calipers. drive. Note: Do not apply handbrake lever with brake calipers re- Caution: moved/front wheel removed.

  • Page 250: Removing And Installing Wheel Bearings

    00 8 574 31 4 800 RS360024 • 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. 31 4 800, be- tween the wheel hub at the right and the claws of the internal puller.
  • Page 251 Heat bearing seat to 80°C (176 °F). 00 5 500 36 5 511 RS360028 • Clamp a drift, BMW No. 36 5 511, into the vise 36 5 511 and place the wheel on it with the wide bearing (2) down. •...

  • Page 252: Removing/Installing Rear Wheel

    R21360040 Removing/installing rear wheel Caution: Use only wheel studs with length code 63. Removing rear wheel Do not oil or grease wheel studs! • Caution: Tighten the wheel studs. • Do not operate the brake pedal when the brake cal- Install brake caliper.

  • Page 253: Static Balancing Of Front Wheel/Rear Wheel

    • Lightly preload bearing with knurled nut (3). • At the rear wheel, attach mounting fixture (4), BMW No. 36 3 613, on the centering collar side with the wheel studs and shims, then install the balancing shaft. • Allow wheel to settle.

  • Page 254: Checking Front/Rear Wheel Rim For Runout

    • At the rear wheel, attach mounting fixture (5), BMW No. 36 3 613, on the centering collar side with the wheel studs and shims, then install the balancing shaft. •...

  • Page 255: Removing/Installing Spokes

    Removing/installing spokes Centering the wheel rim Max. permissible lateral/vertical runout........... 1.3 mm (0.05 in) Max. horizontal runout which can be eliminated by centering ....2.0 mm (0.08 in) Note: Vertical runout cannot be compensated for by centering the rim. Centering lateral runout GS360080 Caution: It is not permitted to replace more than one spoke.
  • Page 256 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 bottom section of mudguard ..........8 Removing and installing top section of mudguard ............9 Removing and installing windscreen ................
  • Page 257 46.2...
  • Page 258 Technical Data R 1150 GS Location of manufacturer’s type plate/frame number On frame, at right Length, overall mm (in) 2189 (86.2) Max. height without mirrors mm (in) 1366 (53.8) Width of handlebar with weights mm (in) 903 (35.6) Width across rear footrests mm (in) 734 (28.9)
  • Page 259 46.4...

  • Page 260: Overall View, Frame

    Overall view, frame 46.5...

  • Page 261: Removing And Installing Main (Centre) Stand

    Remove the sump guard. dure. 00 1 520 R21460140 R21110030 • Secure stand, BMW No. 00 1 520, to motorcycle with overlength bushes and screws, BMW No. 00 1 527. Note: When installing the springs, make sure that the thick Note:...

  • Page 262: Removing And Installing Side Stand

    Removing and installing side stand Tightening torque: Pivot mounts of main stand, M 8 (stud (3)) (clean thread + Loctite 243)......21 Nm Pivot mount of main (centre) stand M 8 (machine screw) ........... 21 Nm Carrier plate to engine block M 12 (machine screw) (clean thread + Loctite 2701)......

  • Page 263: Removing And Installing Front Mudguard

    R21460070 Removing and installing front mudguard Removing and installing bottom section of mudguard • Remove front wheel. • Remove holder (1) for speedometer drive. • Remove mudguard. • Installation is the reverse of the removal proce- dure. Tightening torque: Mudguard to slider tube ......... 4 Nm (clean thread + Loctite 2701) Mudguard to slider tube bridge ......

  • Page 264: Removing And Installing Top Section Of Mudguard

    R21460080 Removing and installing top section of mudguard Caution: Switch off ignition. Disconnect earth (ground) lead from battery. Insulate earth (ground) lead. • Remove the indicator lenses, disconnect plug and pull the cable through the indicator mount. • Remove the turn indicators. •...

  • Page 265: Removing And Installing Windscreen

    R21460090 Removing and installing windscreen 46.10...

  • Page 266: Removing And Installing Fairing Bracket

    R21460020 Removing and installing fairing • Remove fairing bracket (6). • Installation is the reverse of the removal proce- bracket dure. Caution: Tightening torque: Switch off ignition. Front mount to fairing bracket ......8 Nm Disconnect earth (ground) lead from battery. Fairing bracket to frame .......

  • Page 267: Removing And Installing Luggage Rack

    GS460240 Removing and installing luggage rack • Remove rear seat. • Remove the toolkit. • Remove the luggage rack. Note: The rear mudguard drops out of position; support it if necessary. • Installation is the reverse of the removal proce- dure.

  • Page 268: Removing And Installing Number-Plate Carrier

    GS460151 Removing and installing number- plate carrier Caution: Switch off ignition. Disconnect earth (ground) lead from battery. Insulate earth (ground) lead. • Remove rear seat. • Remove the toolkit box. • Remove the tail light. • Remove the turn indicators. •...

  • Page 269: Removing/Installing Rear Mudguard

    GS460251 Removing/installing rear mudguard Caution: Switch off ignition. Disconnect earth (ground) lead from battery. Insulate earth (ground) lead. • Remove the seat. • Remove the toolkit box. • Remove the tail light. • Remove the turn indicators. • Remove number plate bracket. •...

  • Page 270: Removing And Installing Rear Footrest Plate

    GS460181 Removing and installing rear footrest plate Tightening torque: Footrest plate to rear frame ......21 Nm 46.15...

  • Page 271: Removing And Installing Front Footrest Plate

    R21460040 Removing and installing front footrest plate Removing and installing right footrest plate • Remove brake pedal. • Remove brake master cylinder. • Remove the footrest plate. Tightening torque: Footbrake lever to footrest plate ...... 21 Nm Footrest plate with rear frame to gearbox (clean thread + Loctite 243)......

  • Page 272: Removing And Installing Left Footrest Plate

    R21460120 Removing and installing left footrest plate • Remove the shift lever. • Remove hydraulic spring-strut adjuster. • Remove the footrest plate. Tightening torque: Shift lever to footrest plate ......35 Nm Footrest plate with rear frame to gearbox (clean thread + Loctite 243)......42 Nm Footrest plate to gearbox ......

  • Page 273: Removing/Installing Frame

    R21460180 Removing/installing frame Note: The screw pin is a press fit in the angular-contact • Remove fuel tank. ball bearing: remove as a complete unit. • Release brake line from frame. • • Release cable from frame. Remove frame. • •...

  • Page 274: Removing And Installing Frame Tail Section

    R21460150 Removing and installing frame tail section Caution: Switch off ignition. Disconnect earth (ground) lead from battery. Insulate earth (ground) lead. • Remove the seat. • Remove fuel tank. • Remove luggage rack. • Remove wiring harness from rear of frame/only loosen central electrical equipment box.

  • Page 275: 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 276 • 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 277: Measuring The Leading Link

    ............See Group 31 31 5 640 R21460170 • 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 axial play. Note: Shaft (1) must slide into the leading link without re- sistance.
  • Page 278 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 ..................5 Removing and installing lock barrel...
  • Page 279 51.2...

  • Page 280: Removing And Installing Ignition Switch/Steering Lock

    • Install steering lock with non-removable socket Use a 4-5 mm (0.16-0.20 in) dia. drill bit to drill wrench insert, BMW No. 51 0 531. the full length of the lock barrel. • Repeat with a drill bit of larger diameter until the lock barrel can be removed.

  • Page 281: Removing And Installing Lock Barrel

    GS510040 Removing and installing lock 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 282: Removing And Installing Seat Lock

    Removing and installing seat lock Removing and installing helmet lock GS510080 R21510040 • Open the retainer. Removing and installing lock barrel • Remove the helmet lock. • Use a screwdriver to pry off the cap on the in- • Remove luggage rack. side.
  • Page 283 52 Seat Contents Page Disassembling/assembling seat ..................3 52.1...
  • Page 284 52.2...
  • Page 285 R21520010 Disassembling/assembling seat 52.3...
  • Page 286 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 [ABS] ..............................7 Wiring-harness routing/connection in central electrical equipment box ....8 Wiring-harness routing/central electrical equipment box/output...
  • Page 287 61.2...

  • Page 288: Technical Data

    Technical Data R 1150 GS Battery Option: 61.3...
  • Page 289 61.4...

  • Page 290: Removing And Installing Central Electrical Equipment Box

    RS610062 • Removing and installing central 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 once or twice so that the Motronic control unit Caution: can register the throttle-valve positions.

  • Page 291: 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 R21610010 R21610010 1. Instrument cluster, indicator damping, brake light ........... 4 A 2. Parking light, tail light ........4 A 1. Flasher unit 3.

  • Page 292: Wiring-Harness Routing, Frame [Abs]

    Wiring-harness routing, frame [ABS] Caution: 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 as Ω Run wiring without kinking and avoid risk of abra- sion.
  • Page 293 RS610090 Wiring-harness routing/connection in central electrical equipment box 61.8...
  • Page 294 RS610110 Wiring-harness routing/central electrical equipment box/output Note: The white mark (arrow) must be covered by the grommet. 61.9...

  • Page 295: Wiring-Harness Routing/Connection In Central Electrical Equipment Box

    Wiring-harness routing View from left R21619010 61.10...
  • Page 296 R21619011 61.11...
  • Page 297 R21619012 61.12...

  • Page 298: Wiring-Harness Routing/Central Electrical Equipment Box/Output

    Wiring-harness routing View from right S619020 61.13...
  • Page 299 R21619021 61.14...
  • Page 300 R21619022 61.15...
  • Page 301 R21619023 61.16...

  • Page 302: Removing And Installing Battery Holder

    Removing and installing battery holder RS610010 • Remove fuel tank. • Remove the battery. Caution: Disconnect the negative battery terminal first, then the positive terminal. Connect the positive battery terminal first, then the negative terminal. • Remove Motronic control unit. •...
  • Page 303 62 Instruments Contents Page Technical Data ..........................3 Removing and installing instrument panel ..............4 62.1...
  • Page 304 62.2...
  • Page 305 Technical Data R 1150 GS Instrument cluster Telltale lights, turn indicator/high-beam headlight A 14 V 3 W Instrument lighting/telltale lights A 12 V 1.7 W Speedometer drive Speedometer drive ratio I = 3.0 62.3...
  • Page 306 R21620010 Removing and installing instrument panel Caution: Switch off ignition. Disconnect earth (ground) lead from battery. Insulate earth (ground) lead. • Remove windscreen. • Remove top cover. • Remove fastener securing instrument cluster to front mount. • Pull the instrument cluster up until it is clear of R21620020 the front mount.
  • Page 307 63 Lights Contents Page Technical Data ..........................3 Removing and installing headlight ..................4 Removing and installing front indicators ................5 63.1...
  • Page 308 63.2...
  • Page 309 Technical Data R 1150 GS Headlight Twin halogen headlights Bulbs Low (dipped) beam headlight H1 halogen bulb 12 V/55 W High (main) beam headlight H1 halogen bulb 12 V/55 W Parking light 12 V/4 W Standard designation T 8/4 Brake light/rear light...
  • Page 310 R21630010 Removing and installing headlight Caution: Switch off ignition. Disconnect earth (ground) lead from battery. Insulate earth (ground) lead. • Remove windscreen. • Remove top cover. • Remove headlight glass (1). • Disconnect plug (2) from protective cap, high- beam headlight. •...
  • Page 311 Removing and installing front indicators Caution: Switch off ignition. Disconnect earth (ground) lead from battery. Insulate earth (ground) lead. • Remove the indicator lenses, disconnect plug fromreflector and pull the cable through the indi- cator mount. Caution: Do not touch inner surface of reflector or bulbs with bare hands.

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