BMW Motorrad R 1150 GS Maintenance Instruction

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Maintenance instruction (89 pages)

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Maintenance Instructions

R 1150 GS

R 1150 GS Adventure

BMW Motorrad

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Rider's Manual

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Page 1 Maintenance Instructions R 1150 GS R 1150 GS Adventure BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad On-board On-board On-board...
Page 2 Please note Warning: This symbol stands for precau- tions and measures which are essential in order to protect the rider or other persons from pos- sibly severe or fatal injury. Caution: Specific instructions and safety precautions intended to prevent damage to the motorcycle. Disre- garding them may render the war- ranty invalid.
Page 3 Important: and will gladly advise and assist BMW refuses to accept liability you. for damage or consequential damage due to repairs or serv- Best wishes, ice work carried out by other than BMW-authorised work- BMW Motorrad shops.
Page 4: Important Safety Information
Important safety information Note, however, that BMW is unable to accept liability for spare parts and accessories which it has not approved. BMW cannot assess every sin- gle product of outside origin in order to decide whether it can be used on or with a BMW vehi- cle without constituting a safety hazard.
Page 5: Maintenance Work
Maintenance work Maintenance work is divided up into Service, Inspection and Annual Service. BMW Inspection 1,000 km BMW Running-in Check after the first 1,000 km. BMW Service After the first 10,000 km and subsequently every 20,000 km (30,000 km, 50,000 km, 70,000 km…) BMW Inspection After the first 20,000 km and...
Page 6: Confirmation Of Maintenance Work
Confirmation of maintenance work BMW Pre-delivery BMW Service check 10,000 km Carried out in accordance with Carried out in accordance with manufacturer’s instructions manufacturer’s instructions Odometer reading Odometer reading Date, stamp, signature Date, stamp, signature BMW Inspection BMW Inspection 1,000 km 20,000 km Carried out in accordance with Carried out in accordance with...
Page 7 Confirmation of maintenance work BMW Service BMW Service 30,000 km 50,000 km Carried out in accordance with Carried out in accordance with manufacturer’s instructions manufacturer’s instructions Odometer reading Odometer reading Date, stamp, signature Date, stamp, signature BMW Inspection BMW Inspection 40,000 km 60,000 km Carried out in accordance with...
Page 8 Confirmation of maintenance work BMW Service BMW Service 70,000 km 90,000 km Carried out in accordance with Carried out in accordance with manufacturer’s instructions manufacturer’s instructions Odometer reading Odometer reading Date, stamp, signature Date, stamp, signature BMW Inspection BMW Inspection 80,000 km 100,000 km Carried out in accordance with...
Page 9 Confirmation of maintenance work BMW Service BMW Service 110,000 km 130,000 km Carried out in accordance with Carried out in accordance with manufacturer’s instructions manufacturer’s instructions Odometre reading Odometre reading Date, stamp, signature Date, stamp, signature BMW Inspection BMW Inspection 120,000 km 140,000 km Carried out in accordance with...
Page 10 Confirmation of maintenance work Annual Service Annual Service Carried out in accordance with Carried out in accordance with manufacturer’s instructions manufacturer’s instructions Brake fluid changed: Brake fluid changed: Clutch fluid changed: Clutch fluid changed: Date, stamp, signature Date, stamp, signature Annual Service Annual Service Carried out in accordance with...
Page 11 Confirmation of maintenance work Annual Service Annual Service Carried out in accordance with Carried out in accordance with manufacturer’s instructions manufacturer’s instructions Brake fluid changed: Brake fluid changed: Clutch fluid changed: Clutch fluid changed: Date, stamp, signature Date, stamp, signature Annual Service Annual Service Carried out in accordance with...
Page 12 Confirmations of service work Record of all work carried out in workshop Work details Odometer reading Date This list is intended as a record of maintenance, warranty and repair work, of the installation of accessories, and also to confirm that special campaign work has been carried out.
Page 13 Confirmations of service work Record of all work carried out in workshop Work details Odometer reading Date This list is intended as a record of maintenance, warranty and repair work, of the installation of accessories, and also to confirm that special campaign work has been carried out.
Page 14 Confirmations of service work Odometer replaced Odometer replaced Distance reading, Distance reading, not total distance covered! not total distance covered! odometer reading odometer reading Date, stamp, signature Date, stamp, signature Odometer replaced Odometer replaced Distance reading, Distance reading, not total distance covered! not total distance covered! odometer reading odometer reading...
Page 15: General Instructions
General instructions Your motorcycle is equipped with Digital Motor Electronic (MOTRONIC) engine manage- ment, and a high-power ignition system. If you intend to perform the maintenance and general care Warning: work described in the following When the engine is running or section yourself, you must pos- the ignition is switched on, do sess the necessary knowledge...
Page 16 General instructions Your authorised BMW motorcy- cle dealer possesses the nec- essary technical know-how and employs company-trained staff. They can guarantee that your motorcycle is always main- tained in a fault-free technical condition. Remember: the safety and reli- ability of your motorcycle are the most important considerations.
Page 17 Genuine BMW parts are identi- risk for the rider. cal with those fitted to your motorcycle as original equip- ment. Note: BMW Motorrad refuses to Tampering with the MOTRONIC accept any liability whatsoever control unit invalidates the war- for other-make spare parts and ranty.
Page 18: Troubleshooting Chart
Troubleshooting chart Malfunction: Engine does not start at all or is very difficult to start Possible cause Remedy Page Wrong ignition key Operate correctly Rider’s Manual position Kill switch on Operate correctly Rider’s Manual Side stand extended, Operate correctly Rider’s Manual gear selected Power supply inter- Blown fuse...
Page 19 Troubleshooting chart Note: Note: For more serious faults – and More detailed technical infor- those not detailed on pages mation is available in the follow- 13...59 – take your motorcycle ing publications: to a specialist workshop, – BMW Repair Manual preferably an authorised –...
Page 20: Removing The Front Wheel
Removing the front wheel Caution: When removing, avoid damage to • Place the motorcycle on its brake pipes, brake discs, brake centre stand, pads or the wheel rim (mask off – after making sure that the with tape if necessary). ground is level and firm Do not scratch the rim when forc- •...
Page 21 Removing the front wheel Warning: Make sure that the motorcy- cle is standing firmly and can- not topple forwards or to either side. • Remove securing screws 1 for the left and right brake calipers • Push the brake pads back a little by lightly rocking the Note: brake calipers...
Page 22 Removing the front wheel • Remove quick-release axle 1 • Remove speedometer drive 4 and spacer bush 5 • Roll the front wheel forwards and out Note: Caution: Mark the installed position on When setting down the front the tyre or ABS toothed ring wheel, avoid damage to the or note the direction-of-rotation brake discs and ABS sensor...
Page 23: Installing The Front Wheel
Installing the front wheel • Roll the front wheel in between the fork legs Caution: Avoid damage to brake lines, Caution: discs and pads when installing. To avoid damaging the speedom- Keep dirt and moisture away eter drive, make sure that lug A from the wheel bearings.
Page 24 Installing the front wheel • Clean the quick-release axle, 4, grease it, and insert it from the right, turning it slightly at the same time (while lifting the wheel) • Hand-tighten axle screw 2 • Hand-tighten axle clamp screws 3 on left and right •...
Page 25 Installing the front wheel • Carefully push brake calipers 2 over the brake discs at left and right Warning: • Install the brake calipers and Motorcycle not equipped with tighten screws 1 to the speci- BMW Integral ABS: when as- fied torque sembly work has been com- pleted, pull the brake lever...
Page 26: Removing The Rear Wheel
Removing the rear wheel Warning: Make sure that the motorcy- cle is standing firmly and can- not topple forwards or to either side. Warning: Screws of rear-wheel cover 1 are secured with Loctite. Prior to reinstallation, clean the screw threads and recoat Caution: with Loctite 243.
Page 27 Removing the rear wheel Caution: Do not scratch the wheel when forcing back the brake pads or removing the caliper (apply • Remove screws 2 securing masking tape if necessary). brake caliper 1 To prevent damage to the brake • Force back the brake pads by caliper and possible difficulty tilting the caliper carefully when assembling: never oper-...
Page 28 Removing the rear wheel • Motorcycle with BMW Integral : remove spacing washer 5 from wheel center- ing spigot Caution: • Remove the four wheel studs Protect the wheel hub contact 3 with taper rings 4 face against dust and dirt. •...
Page 29: Installing The Rear Wheel
Installing the rear wheel • Check that the wheel centering spigot and the contact faces on Caution: the wheel hub and spacing Use only wheel studs with the washer are free from grease same length code number. Do • Motorcycle with BMW Integral not oil or grease the wheel : Fit spacing washer 5 on studs.
Page 30 Installing the rear wheel • Carefully place brake caliper 1 over the brake disc • Install rear brake caliper screw 2 with washer Caution: • Install front brake-caliper Make sure that retaining screw 2 with retaining angle A angle A is in the correct posi- •...
Page 31 Installing the rear wheel Tightening torque: Preload torque Warning: Wheel studs ....72 Nm Motorcycle not equipped with Tightening torque BMW Integral ABS: when as- Wheel studs ....105 Nm sembly work has been com- Brake caliper screws ..40 Nm pleted, depress the brake pedal firmly several times to check that the rear brake is...
Page 32: Checking Brake Pads
Checking brake pads • Place the motorcycle on its centre stand, after making sure Front brake that the ground is level and firm • Visually inspect both brake pads and the brake caliper Caution: and make sure that they all Have the brake pads replaced bear the same colour mark 2 before the minimum permitted...
Page 33: Rear Brake
Checking brake pads • Make sure the ground is level Rear brake and firm and lift the motor- cycle onto its centre stand • Visually check brake pad Caution: thickness Have brake pads replaced be- Minimum pad thickness: fore the minimum permitted Make sure that the brake thickness is reached.
Page 34 Headlight beam setting Headlight beam setting for riding on left/right • Slacken clamp screw 3 • Make sure the ground is level • Press the headlight against and firm and lift the motor- the stop cycle onto its centre stand –...
Page 35: Headlight Guard
Headlight guard R 1150 GS Adventure Note: Headlight guard 1 is not f the bulb for the low-beam or approved for use on public high-beam headlight requires roads. replacement, pull headlight guard 1 forward and off the lamp housing. Optional accessories...
Page 36: Fog Lamps
Fog lamps R 1150 GS Adventure Cleaning lenses Caution: Warning: When removing and installing Risk of injury. The housing mesh guard 2, take care not to becomes hot if the fog lamps damage it on locating pin 1. are on for a lengthy period of time.
Page 37 Information on changing bulbs Caution: Your vehicle has a high-beam/ low-beam bulb, a parking light bulb, a brake-light bulb/rear- light bulb, and four bulbs for Your motorcycle is equipped the flashing turn indicators. with Digital Motor Electronic If any of these bulbs should fail, (MOTRONIC) engine manage- you may have problems in see- ment and a high-power ignition...
Page 38: Changing Bulbs
Changing bulbs Note: Motorcycle with BMW Integral only: The dimmed brake light takes over the function of the rear light should the rear light fail. A warning lamp lit in the cockpit indicates that this is the case. Rider’s Manual, Chapter 3). Tail light/brake light Do not touch the glass of new bulbs with your fingers.
Page 39 Changing bulbs • Make sure the ground is level and firm and lift the motorcy- cle onto its main stand • Remove securing screws 1 • Remove tail-light glass 2 • Press bulb 3 forwards and • Installation is the reverse of turn the bulb counter-clock- the removal procedure wise to the left to release...
Page 40 Changing bulbs Flashing turn indicator • Make sure the ground is level and firm and lift the motor- cycle onto its centre stand Caution: • Remove retaining screw 3 Switch off the ignition before • Take off turn indicator glass 1 changing a bulb.
Page 41 Changing bulbs Low beam Caution: • Turn the handlebars to the left Switch off the ignition before • Turn left cover 1 counter- changing a bulb. clockwise to disengage and swing it down • Release spring clips 2 from Note: retainer A at left and right and Do not touch the glass of new swing clips upwards...
Page 42 Changing bulbs • Make sure the ground is level and firm and lift the motor- cycle onto its centre stand • Turn the handlebars to the right High-beam headlight • Turn right cover 1 counter- clockwise to disengage and swing it down Caution: •...
Page 43 Changing bulbs Parking light • Make sure the ground is level Caution: and firm and lift the motor- Switch off the ignition before cycle onto its centre stand changing a bulb. • Pull bulb holder 1 down and out of the headlight housing •...
Page 44: Fog Light
Changing bulbs R 1150 GS Adventure Fog light Note: Warning: Do not touch the glass of new Risk of injury. The housing bulbs with your fingers. Use a becomes hot if the fog lights clean, dry cloth to hold the are on for a lengthy period of bulbs when inserting them.
Page 45 Changing bulbs • Disengage clip 1 by pushing it toward the bulb holder and out at the same time • Remove bulb 6 • Installation is the reverse of the removal procedure Note: When installing, make sure that Note: the grooves in the bulb are cor- Clean sealing rings 7 and check rectly positioned.
Page 46: Replacing Fuses
Replacing fuses Equipment connected to fuses 1 Instrument cluster, indicator damping, brake light, with- out BMW integral ABS...4 A 2 Parking light, tail light ..4 A 3 RID, power socket..15 A Caution: 4 Horn ......7.5 A Before changing a fuse, switch 5 Engine electronics, off the ignition.
Page 47 Replacing fuses Replacing fuses • Make sure the ground is level and firm and lift the motor- cycle onto its centre stand • Remove the seat • Disengage and remove the cover of the central electrical equipment box • Use the tweezers 11 supplied to pull the blown fuse out of its holder Note:...
Page 48: Air Filter
Air filter • Disconnect plug 2 of the air- filter temperature sensor Replacing air filter • Unscrew two securing element screws 3 in air-filter housing 4 • Place the motorcycle on its main stand • Remove the seat Note: • Remove diagnosis Securing screws 3 remain in connector 1 from its holder air-filter cover 5.
Page 49 Air filter • Raise air filter cover 5 at the rear and remove it from the air filter housing. • Remove old filter element 4 from the air filter housing Note: • Place the new filter element in When installing, position the air position inside the air filter filter cover as illustrated and en- housing...
Page 50: Battery Safety Instructions
Battery safety instructions Warning: Gel batteries are maintenance- Do not attempt to jump-start free. Compliance with the the motorcycle using the on- instructions below is important board socket in order to maximise battery life: – Risk of fire! • Push-start the motorcycle only when the engine is Caution: cold.
Page 51 Battery safety instructions – Batteries that are not in use must be stored in a cool place. Do not store a Motorcycle out of use for a discharged battery lengthy period – If the battery is in storage for • The battery has to be charged an extended period of time, prior to lay-up periods of recharge it at regular intervals...
Page 52: Removing And Installing Battery
Removing and installing battery Removing the battery Warning: Avoid damage to fuel tank, wiring and hoses during • Make sure the ground is level removal work. and firm and lift the motor- Before disconnecting the bat- cycle onto its centre stand tery, switch off the ignition.
Page 53 Removing and installing battery 9 10 • Remove retaining screw 3 for air intake pipe • Disconnect the battery • Release clips 4 from air filter negative cable 8 housing • Open protective cap 9 for the • Open air filter cover 5 battery positive pole •...
Page 54 Removing and installing battery Warning: Before connecting the bat- tery, switch off the ignition. To avoid short-circuits: • Connect the positive battery lead (+) 2 first • Close protective cap 1 for the positive battery pole – Never install the battery wit- Installing battery hout the protective cap Installation of the battery is the...
Page 55 Removing and installing battery Note: Disconnecting the battery de- letes all entries (e.g. faults, set- tings) stored in the Motronic control unit’s memory. Caution: Loss of settings can temporarily Always have the tightening tor- impair the operating character- ques checked by a specialist istics when the engine is re- workshop, started.
Page 56 Cleaning/care Caution: Avoid damage to rubber or plas- tic parts caused by aggressive or Note: penetrating cleansing agents or Regular cleaning, using the cor- solvents. rect methods, is an important Do not use a steam jet or high- factor in maintaining the value pressure cleaning equipment.
Page 57 Cleaning/care Washing the motorcycle • Do not use solvents or clean- Warning: ing products to wash the After cleaning or before start- instrument cluster, switches ing a journey, always test the and windscreen – do not brakes. scratch the windscreen •...
Page 58 Cleaning/care Removing road salt • Wash the motorcycle down Cleaning the windscreen immediately with cold water at the end of the journey Caution: Do not use detergent products. Note: Fuel or chemical solvents at- Do not use warm water – warm tack the windscreen material.
Page 59 Cleaning/care Note: More extensive damage should be attended to by a specialist Touching up paint damage workshop, preferably an author- ised BMW motorcycle dealer. Caution: Care of exhaust silencer Comply with the manufacturer’s • Changes in the appearance of working instructions and safety the exhaust system (these precautions.
Page 60 Laying up Laying up • Clean the motorcycle 55-57) • Remove the battery Note: 50-52) Before laying the vehicle up out • Spray the clutch lever pivots of use have the engine oil and and the main and side stand the oil filter element changed by pivots with a suitable lubri- a specialist workshop, prefera-...
Page 61: Restoring To Use
Restoring to use Restoring to use • Perform safety checks • If necessary, remove protec- (Rider's Manual 28-57) tive wax coating • Check the brakes • Clean the motorcycle ( (Rider's Manual 36-44) • Install a charged battery • Check/correct tyre pressures (Rider's Manual...
Page 62 Engine R 1150 GS / GS Adventure Type Air-cooled flat-twin (“Boxer”) with additional oil cooling in the exhaust valve areas and a single side- mounted, chain-driven camshaft on each side, operating 4 valves per cylinder by means of tappets and short pushrods;...
Page 63: Power Train
Power train R 1150 GS / GS Adventure Clutch Lightweight single-plate dry clutch mounted on crankshaft, with increased-leverage diaphragm spring and starter gear ring. Hydraulic operation. Clutch plate Ø 165 mm Manual gearbox 6-speed with claw shift and integral torsional vibration damper Gear ratios 1st gear = 3.864 / 4.465...
Page 64: Frame And Suspension
Frame and suspension R 1150 GS / GS Adventure Frame Three-part frame. A cast aluminium front frame connects the load-bear- ing engine and gearbox assembly to the tubular steel rear frame. A forged aluminium footrest plate increases the strength of the gear- box mount.
Page 65 Frame and suspension R 1150 GS / GS Adventure Wheel location Front Light-touch wheel guidance (Tele- lever) with central suspension strut. Rear Cast aluminium single swinging arm with additional torque reaction strut to compensate for shaft drive effects (Paralever); central suspen- sion strut.
Page 66 Frame and suspension R 1150 GS GS Adventure Front suspension Central spring strut with progres- sive-rate coil spring (with taper- wound ends) and twin-tube, gas- filled shock absorber. Five-position spring preload adjustment. Spring travel (bump) 122 mm 137 mm Spring travel (rebound)
Page 67 Frame and suspension R 1150 GS / GS Adventure Wheels and tyres BMW cross-spoke wheels, low aspect-ratio tyres Front wheel Angled rim shoulder and double tyre retaining hump Size and designation 2.50 x 19 MT H2 Tyre size and designation...
Page 68 Frame and suspension R 1150 GS / GS Adventure Tyre pressures (with tyres cold) Solo Front 2.20 bar Rear 2.50 bar Two-up Front 2.50 bar Rear 2.70 bar Two-up with luggage Front 2.50 bar Rear 2.90 bar Recommended minimum tyre tread depth...
Page 69: Fuel And Lubricants
Fuel and lubricants R 1150 GS / GS Adventure Engine oil Brand-name HD oil, API classification SF, SG or SH; CD or CE suffixes are permissible; alternatively, brand-name HD oil, CCMC classification G4 or G5; suffix PD2 is permissible. SAE 20...
Page 70: Fuels And Lubricants
Fuels and lubricants R 1150 GS / GS Adventure Gearbox oil Brand-name hypoid gear oil, API class GL 5 Capacity Gearbox approx. 1.0 l (to bottom edge of filler opening) Rear wheel drive approx. 0.25 l (to bottom edge of filler opening)
Page 71 Fuel and lubricants R 1150 GS / GS Adventure Bearings and other Brand-name anti-friction bearing lubrication points grease, usable temperature range –25 °C …+120 °C, drip point 190 °C, high corrosion protection, good resistance to water and oxidation; e.g. Shell Retinax EP2...
Page 72: Electrical System
Electrical system R 1150 GS / GS Adventure Battery Gel battery, 12 V 19 Ah maintenancefree Spark plugs Approved makes/types Primary spark plug NGK BKR 7 EKC Secondary spark plug Bosch YR6LDE or NGK DCPR 8 EKC Electrode gap 0.8 mm Wear limit 1.0 mm...
Page 73: Dimensions And Weights
Dimensions and weights R 1150 GS GS Adventure Overall length 2,190 mm 2,180 mm Width - across mirrors 945 mm 980 mm - across handlebars (with ends) 903 mm 903 mm - across rider’s footrests 602 mm 602 mm - across pillion passenger’s...
Page 74: Performance Data
Performance data R 1150 GS GS Adventure Top speed acc. to type approval test 196 km/h 192 km/h with massive-bar tyres 160 km/h 160 km/h Flexibility 4th gear, 80-120 km/h 3.44 s 3.44 s 5th gear, 80-120 km/h 4.37 s 4.37 s...
Page 75 A - E Accessories, genuine BMW Capacities parts, 15 engine, 67 Air filter engine oil, 67 replacing, 46 Capacity Annual Service, confirmation of gearbox, 68 maintenance work, 8 Castor, 63 Annual Service, instructions, 3 Cleaning/care general instructions, 54, 56 removing road salt, 56 Battery touching up paint damage, 57 charging, 48...
Page 76 F - P Flashing turn indicator, 38 Idle speed, 60 Flexibility, 72 Inspection (Running-in Check), Fog lamps, 34 Notes, 3 Frame, 62 Inspection 1000 km/600 miles, 3 Front wheel Installing brake caliper installing, 21, 22, 23 Rear wheel, 53 removing, 18 technical data, 65 Front wheel stand, 18 Laying up, 58...
Page 77 P - Z Power-weight ratio, 72 Tightening torque Pre-delivery check, 4 rear wheel, 29 Tightening torques front wheel, 23 Rear wheel front wheel brake installing, 27, 28, 29 caliper, 23, 29 removing, 24, 25, 26 Rear wheel, 53 technical data, 65 Top speed, 72 Rear wheel drive Torque, 60...
Page 78 Motorcycle data Model Frame No. Colour No. First registered on Registration No. Dealer data Person to contact for Service work Ms./Mr. Tel. No. Dealer’s address with telephone No. (company stamp)
Page 79 No claims will be enter- Errors and omissions excepted. tained as a result of such © 2004 BMW Motorrad discrepancies. Not to be reproduced either wholly Dimensions, weights, fuel con- or in part without written permis-...
Page 80 BMW recommends Castrol BMW Motorrad Printed information Order No.: 01 41 7 690 761 05.2004 The Ultimate 7th edition GB / RF Driving Machine...

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