BMW R 1150 GS Manuals

Manuals and User Guides for BMW R 1150 GS. We have 1 BMW R 1150 GS manual available for free PDF download: Repair Manual

BMW R 1150 GS Repair Manual

BMW R 1150 GS Repair Manual (311 pages)

Brand: BMW | Category: Motorcycle | Size: 53.42 MB
Table of contents
Table Of Contents10................................................................................................................................................................
Tightening Torques13................................................................................................................................................................
Table Of Operating Fluids20................................................................................................................................................................
Check The Shipping Crate For Damage22................................................................................................................................................................
Unpacking The Motorcycle22................................................................................................................................................................
In Case Of Damage In Germany22................................................................................................................................................................
In Case Of Damage In Importer Markets22................................................................................................................................................................
Inspecting Motorcycle For Damage23................................................................................................................................................................
Checking That Delivery Is Complete23................................................................................................................................................................
Installing Remaining Items On Motorcycle24................................................................................................................................................................
Installing Sump Guard25................................................................................................................................................................
Filling And Charging The Battery26................................................................................................................................................................
Disengaging And Raising The Fuel Tank26................................................................................................................................................................
Checking Engine Oil When Engine Is Cold, Topping Up If Necessary27................................................................................................................................................................
Checking Headlight Beam Angle, Adjusting If Necessary28................................................................................................................................................................
Checking Tyre Pressures28................................................................................................................................................................
Attaching Adhesive Label28................................................................................................................................................................
Final Inspection And Function Check29................................................................................................................................................................
Handing Over The Motorcycle29................................................................................................................................................................
Final Cleaning29................................................................................................................................................................
Key To Maintenance Intervals30................................................................................................................................................................
Changing Oil In Gearbox31................................................................................................................................................................
Replacing Fuel Filter32................................................................................................................................................................
Greasing The Battery Posts34................................................................................................................................................................
Checking Brake System For Correct Operation And Freedom From Leaks36................................................................................................................................................................
Rear Brake36................................................................................................................................................................
Repairing/replacing If Necessary36................................................................................................................................................................
Front Brake36................................................................................................................................................................
Checking Brake Disc Wear37................................................................................................................................................................
Checking Front Brake Pad Wear37................................................................................................................................................................
Checking Rear Brake Pad Wear37................................................................................................................................................................
Replacing Brake Pads, Front Brake38................................................................................................................................................................
Replacing Brake Pads, Rear Brake38................................................................................................................................................................
Final Inspection With Road Safety And Functional Check47................................................................................................................................................................
Removing Engine62................................................................................................................................................................
Removing Cylinder Head Cover67................................................................................................................................................................
Locking The Engine At Tdc68................................................................................................................................................................
Removing And Installing Chain Tensioner69................................................................................................................................................................
Remove Valve Gear Carrier70................................................................................................................................................................
Disassembling/assembling Valve Gear Carrier71................................................................................................................................................................
Removing Cylinder Head73................................................................................................................................................................
Disassembling, Checking, Repairing And Reassembling Cylinder Head74................................................................................................................................................................
Removing Cylinder78................................................................................................................................................................
Removing And Disassembling Piston78................................................................................................................................................................
Checking Pistons And Cylinders79................................................................................................................................................................
Assembling Pistons79................................................................................................................................................................
Removing And Installing Conrod80................................................................................................................................................................
Removing And Installing Alternator Mount Cover With Engine Installed81................................................................................................................................................................
Replacing Radial Shaft Seal In Alternator Mount Cover81................................................................................................................................................................
Removing Alternator Mount Cover81................................................................................................................................................................
Removing Auxiliary Shaft Drive82................................................................................................................................................................
Removing Oil Pump83................................................................................................................................................................
Removing Radial Shaft Seal From Crankshaft With Engine Installed84................................................................................................................................................................
Disassembling Crankcase85................................................................................................................................................................
Removing And Installing Oil Intake Strainers88................................................................................................................................................................
Removing Conrods88................................................................................................................................................................
Checking Conrods88................................................................................................................................................................
Replacing Oil Level Sight Glass88................................................................................................................................................................
Removing And Installing Oil Thermostat88................................................................................................................................................................
Measuring Crankshaft Bearing Play89................................................................................................................................................................
Measuring Big End Bearing Play91................................................................................................................................................................
Assembling Engine92................................................................................................................................................................
Installing Conrods92................................................................................................................................................................
Installing Crankshaft93................................................................................................................................................................
Installing Auxiliary Shaft/timing Chains93................................................................................................................................................................
Installing Timing Chain Tensioning And Slide Rails93................................................................................................................................................................
Assembling Engine Block94................................................................................................................................................................
Installing Radial Shaft Seals On Crankshaft97................................................................................................................................................................
Installing Clutch Housing98................................................................................................................................................................
Installing Oil Pump99................................................................................................................................................................
Installing Auxiliary Shaft Drive100................................................................................................................................................................
Installing Piston101................................................................................................................................................................
Installing Cylinder102................................................................................................................................................................
Installing Cylinder Head103................................................................................................................................................................
Adjusting Valve Clearances104................................................................................................................................................................
Installing Right Cylinder Head105................................................................................................................................................................
Installing Left Cylinder Head106................................................................................................................................................................
Installing Alternator110................................................................................................................................................................
Removing And Installing Coil And Ignition Lead116................................................................................................................................................................
Checking Ignition Coil Resistance116................................................................................................................................................................
Removing And Installing Alternator117................................................................................................................................................................
Disassembling/assembling Alternator118................................................................................................................................................................
Option 50 A119................................................................................................................................................................
Removing And Installing Starter Motor120................................................................................................................................................................
Disassembling/assembling Starter Motor121................................................................................................................................................................
Replacing Carbon Brushes121................................................................................................................................................................
Checking Starter Motor121................................................................................................................................................................
Checking Starter Relay121................................................................................................................................................................
Removing And Installing Magnetic Gate122................................................................................................................................................................
Timing The Ignition123................................................................................................................................................................
Fuel Preparation And Control124................................................................................................................................................................
Fuel Tank And Lines131................................................................................................................................................................
Removing And Installing Fuel Tank135................................................................................................................................................................
Removing And Installing Roll-over Valve136................................................................................................................................................................
Removing And Installing Fuel Filter, Fuel Pump And Fuel Level Sensor137................................................................................................................................................................
Removing And Installing Fuel Filter137................................................................................................................................................................
Removing And Installing Fuel Pump And Fuel Level Sensor137................................................................................................................................................................
Removing And Installing Fuel Distributor And Pressure Regulator138................................................................................................................................................................
Exhaust System139................................................................................................................................................................
Removing And Installing Exhaust System141................................................................................................................................................................
Removing And Installing Silencer And Front Silencer141................................................................................................................................................................
Removing And Installing Exhaust Manifolds142................................................................................................................................................................
Installing Clutch149................................................................................................................................................................
Replacing The Shaft Sealing Rings In The Gearbox Housing And Gearbox Cover160................................................................................................................................................................
Removing Gearbox Housing162................................................................................................................................................................
Removing Selector Drum163................................................................................................................................................................
Disassembling/assembling Selector Shaft163................................................................................................................................................................
Removing Gearbox Shafts164................................................................................................................................................................
Replacing Grooved Ball Bearings Of Intermediate Shaft164................................................................................................................................................................
Disassembling/assembling Input Shaft165................................................................................................................................................................
Checking Endplay169................................................................................................................................................................
Checking/adjusting Fully Assembled Length Of Gearbox Shafts And Selector170................................................................................................................................................................
Shimming Selector Shaft174................................................................................................................................................................
Assembling Gearbox175................................................................................................................................................................
Installing Input, Output And Intermediate Shafts175................................................................................................................................................................
Installing Selector Shaft176................................................................................................................................................................
Installing Selector Drum176................................................................................................................................................................
Installing Gearbox Housing177................................................................................................................................................................
Removing And Installing Telescopic Fork183................................................................................................................................................................
Removing And Installing Telescopic Fork Without Fork Bridge183................................................................................................................................................................
Removing And Installing Fork Bridge184................................................................................................................................................................
Removing And Installing Slider Tube Bridge186................................................................................................................................................................
Disassembling/assembling Telescopic Fork187................................................................................................................................................................
Disassembling Telescopic Fork187................................................................................................................................................................
Assembling Telescopic Fork187................................................................................................................................................................
Measuring Telescopic Fork188................................................................................................................................................................
Removing And Installing Leading Link189................................................................................................................................................................
Disassembling/assembling Leading Link189................................................................................................................................................................
Removing And Installing Front Spring Strut189................................................................................................................................................................
Removing And Installing Left Handlebar Fitting194................................................................................................................................................................
Removing And Installing Right Handlebar Fitting195................................................................................................................................................................
Removing And Installing Brake Piston In Handlebar Fitting196................................................................................................................................................................
Removing And Installing Clutch Piston In Handlebar Fitting197................................................................................................................................................................
Checking And Adjusting Operating Clearance At Front Brake/clutch Levers198................................................................................................................................................................
Removing And Installing Handlebar199................................................................................................................................................................
Bowden Cable For Throttle Actuation And Starting-speed Increase200................................................................................................................................................................
Disassembling Bowden-cable Divider201................................................................................................................................................................
Removing, Disassembling, Reassembling And Installing Rear206................................................................................................................................................................
Removing And Installing Taper Roller Bearing In Rear Wheel Drive206................................................................................................................................................................
Wheel Drive206................................................................................................................................................................
Removing Rear Wheel Drive206................................................................................................................................................................
Removing Input Bevel Pinion207................................................................................................................................................................
Disassembling Input Bevel Pinion208................................................................................................................................................................
Assembling Input Bevel Pinion209................................................................................................................................................................
Installing Input Bevel Pinion210................................................................................................................................................................
Removing And Disassembling Crown Wheel212................................................................................................................................................................
Assembling And Installing Crown Wheel213................................................................................................................................................................
Shimming Input Bevel Pinion And Crown Wheel214................................................................................................................................................................
Checking Tooth Contact Pattern215................................................................................................................................................................
Checking And Adjusting Backlash216................................................................................................................................................................
Shimming Housing Cover217................................................................................................................................................................
Installing Housing Cover217................................................................................................................................................................
Installing Sliding Element217................................................................................................................................................................
Installing Rear Wheel Drive218................................................................................................................................................................
Removing And Installing Spring Strut219................................................................................................................................................................
Removing And Installing Rear Swinging Arm220................................................................................................................................................................
Removing Rear Swinging Arm220................................................................................................................................................................
Removing And Installing Taper Roller Bearing221................................................................................................................................................................
Removing Drive Shaft221................................................................................................................................................................
Removing And Installing Flexible Gaiter221................................................................................................................................................................
Installing Rear Swinging Arm222................................................................................................................................................................
Removing And Installing Front Brake Caliper226................................................................................................................................................................
Disassembling And Assembling Front Brake Caliper227................................................................................................................................................................
Removing And Installing Filler Adapter228................................................................................................................................................................
Removing And Installing Rear Brake Caliper229................................................................................................................................................................
Disassembling And Assembling Rear Brake Caliper230................................................................................................................................................................
Removing And Installing Front Brake Disc231................................................................................................................................................................
Removing And Installing Rear Brake Disc (mounted On Rear-wheel Hub)232................................................................................................................................................................
Removing And Installing Front Abs Sensor233................................................................................................................................................................
Abs Sensor Gap, Front: Adjusting234................................................................................................................................................................
Marking Sensor Ring234................................................................................................................................................................
Removing And Installing Rear Abs Sensor235................................................................................................................................................................
Adjusting Rear Abs Sensor Gap236................................................................................................................................................................
Marking Sensor Wheel236................................................................................................................................................................
Removing And Installing Rear Brake Master Cylinder237................................................................................................................................................................
Checking And Adjusting Play Of Piston Rod238................................................................................................................................................................
Removing And Installing Footbrake Lever238................................................................................................................................................................
Removing And Installing Abs Unit239................................................................................................................................................................
Removing The Abs Unit239................................................................................................................................................................
Installing The Abs Unit240................................................................................................................................................................
Removing And Installing Abs Relay And Relay Socket240................................................................................................................................................................
Removing Abs Relay240................................................................................................................................................................
Installing The Abs Relay241................................................................................................................................................................
Removing And Installing Front Wheel249................................................................................................................................................................
Installing The Front Wheel249................................................................................................................................................................
Removing Front Wheel249................................................................................................................................................................
Removing And Installing Wheel Bearings250................................................................................................................................................................
Removing/installing Rear Wheel252................................................................................................................................................................
Removing Rear Wheel252................................................................................................................................................................
Installing Rear Wheel252................................................................................................................................................................
Static Balancing Of Front Wheel/rear Wheel253................................................................................................................................................................
Checking Front/rear Wheel Rim For Runout254................................................................................................................................................................
Removing/installing Spokes255................................................................................................................................................................
Centering The Wheel Rim255................................................................................................................................................................
Centering Lateral Runout255................................................................................................................................................................
Removing And Installing Main (centre) Stand261................................................................................................................................................................
Removing And Installing Side Stand262................................................................................................................................................................
Removing And Installing Front Mudguard263................................................................................................................................................................
Removing And Installing Bottom Section Of Mudguard263................................................................................................................................................................
Removing And Installing Top Section Of Mudguard264................................................................................................................................................................
Removing And Installing Windscreen265................................................................................................................................................................
Removing And Installing Fairing Bracket266................................................................................................................................................................
Removing And Installing Luggage Rack267................................................................................................................................................................
Removing/installing Rear Mudguard269................................................................................................................................................................
Removing And Installing Rear Footrest Plate270................................................................................................................................................................
Removing And Installing Front Footrest Plate271................................................................................................................................................................
Removing And Installing Right Footrest Plate271................................................................................................................................................................
Removing And Installing Left Footrest Plate272................................................................................................................................................................
Removing/installing Frame273................................................................................................................................................................
Removing And Installing Frame Tail Section274................................................................................................................................................................
Checking Running Gear275................................................................................................................................................................
Measuring Wheel Track Offset275................................................................................................................................................................
Measuring The Leading Link277................................................................................................................................................................

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