BMW R 1150 GS - Service Manual - Manuel Reparation - Manual de Taller

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BMW R 1150 GS - SERVICE MANUAL


- Multilanguage (English, Español, Deutsch, Français, Italiano, Nederlands and Português) Repair Manual, to motorcycles BMW R 1150 GS.


CONTENTS:

INTRODUCTION
MAINTENANCE SCHEDULE
PRE-DELIVERY CHECK
SERVICE DATA
GENERAL TABLE OF CONTENTS
00 MAINTENANCE AND GENERAL INSTRUCTIONS
Tightening torques
Table of operating fluids
Pre-delivery check
General view of crated motorcycle
Check the shipping crate for damage
In case of damage in Germany
In case of damage in importer markets
Unpacking the motorcycle
Inspecting motorcycle for damage
Checking that delivery is complete
Installing remaining items on motorcycle
Install the windscreen
Installing sump guard
Filling and charging the battery
Disengaging and raising the fuel tank
Filling and charging the battery
Checking engine oil when engine is cold, topping up if necessary
Checking headlight beam angle, adjusting if necessary
Checking tightness of rear wheel studs
Checking tyre pressures
Attaching adhesive label
Final inspection and function check
Final cleaning
Handing over the motorcycle
Maintenance
Key to maintenance intervals
Reading out MoDiTeC fault memory
Changing engine oil, replacing oil filter element
Changing oil in gearbox
Changing the oil in the rear wheel drive
Replacing fuel filter
Checking battery fluid level and topping up if necessary; cleaning and greasing the battery posts
Replacing intake air filter element
Replacing Poly-V belt
Checking brake system for correct operation and freedom from leaks; repairing/replacing if necessary
Checking brake fluid level
Front brake
Rear brake
Checking brake pads and discs for wear/replacing
Checking front brake pad wear
Checking rear brake pad wear
Checking brake disc wear
Replacing brake pads, front brake
Replacing brake pads, rear brake
Changing brake fluid and bleeding brake system
Bleeding front brake circuit/changing brake fluid
Bleeding rear brake circuit/changing brake fluid
Checking clutch operating fluid level
Changing the clutch fluid
Checking tightness of rear wheel studs
Checking rear wheel bearing play by tilting wheel
Checking swinging arm bearings, adjusting if necessary
Greasing the side stand pivot
Checking function of side stand contact switch
Checking/replacing spark plugs
Tightening cylinder heads
Checking/adjusting valve clearances
Checking freedom of throttle cable, checking for chaffing and kinks, replacing if necessary Check...
Final inspection with road safety and functional check
11 ENGINE
Cutaway drawing of engine
Lubricating-oil circuit
Cooling-oil circuit
Removing engine
Disassembling engine
Removing cylinder head cover
Locking the engine at TDC
Removing and installing chain tensioner
Remove valve gear carrier
Disassembling/assembling valve gear carrier
Removing cylinder head
Disassembling, checking, repairing and reassembling cylinder head
Removing cylinder
Removing and disassembling piston
Checking pistons and cylinders
Assembling pistons
Removing and installing conrod
Removing and installing alternator mount cover with engine installed
Removing alternator mount cover
Replacing radial shaft seal in alternator mount cover
Removing auxiliary shaft drive
Removing oil pump
Removing radial shaft seal from crankshaft with engine installed
Disassembling crankcase
Removing crankshaft, auxiliary shaft and timing chain tensioning and slide rails
Removing and installing oil intake strainers
Replacing oil level sight glass
Removing and installing oil thermostat
Removing conrods
Checking conrods
Measuring crankshaft bearing play
Measuring big end bearing play
Assembling engine
Installing conrods
Installing crankshaft
Installing timing chain tensioning and slide rails
Installing auxiliary shaft/timing chains
Assembling engine block
Installing radial shaft seals on crankshaft
Installing clutch housing
Installing oil pump
Installing auxiliary shaft drive
Installing piston
Installing cylinder
Installing cylinder head
Adjusting valve clearances
Installing right cylinder head
Installing left cylinder head
Installing alternator mount cover
Installing magnetic gate/belt pulley
Installing alternator
Installing engine
12 ENGINE ELECTRICS
Removing and installing coil and ignition lead
Checking ignition coil resistance
Removing and installing alternator
Disassembling/assembling alternator
Checking alternator
Checking armature for short to ground (earth)
Disassembling/assembling alternator (Option 50 A)
Checking alternator
Checking armature for short to ground (earth)
Removing and installing starter motor
Disassembling/assembling starter motor
Replacing carbon brushes
Checking starter motor
Checking starter relay
Removing and installing magnetic gate
Timing the ignition
13 FUEL PREPARATION AND CONTROL
Removing and installing air filter housing
Removing and installing trottle- valve stub pipe
Removing and installing throttle- valve potentiometer
Removing and installing Motronic control unit
16 FUEL TANK AND LINES
Removing and installing fuel tank
Removing and installing roll-over valve
Removing and installing fuel filter, fuel pump and fuel level sensor
Removing and installing fuel filter
Removing and installing fuel pump and fuel level sensor
Removing and installing fuel distributor and pressure regulator
18 EXHAUST SYSTEM
Removing and installing exhaust system
Removing and installing silencer and front silencer
Removing and installing exhaust manifolds
21 CLUTCH
Removing and installing clutch
Removing clutch
Installing clutch
Removing and installing clutch hydraulic line
Removing and installing clutch slave cylinder
Filling/bleeding clutch line
23 TRANSMISSION
Gearbox - sectional drawing
Removing and installing gear-shift lever
Removing/installing gearbox
Replacing the shaft sealing rings in the gearbox housing and gearbox cover
Disassembling gearbox
Removing gearbox housing
Removing selector drum
Disassembling/assembling selector shaft
Removing gearbox shafts
Replacing grooved ball bearings of intermediate shaft
Disassembling/assembling input shaft
Disassembling/reassembling output shaft
Checking endplay
Checking/adjusting fully assembled length of gearbox shafts and selector drum
Shimming selector shaft
Assembling gearbox
Installing input, output and intermediate shafts
Installing selector shaft
Installing selector drum
Installing gearbox housing
31 FRONT FORKS
Removing and installing telescopic fork
Removing and installing telescopic fork without fork bridge
Removing and installing fork bridge
Removing and installing slider tube bridge
Checking friction at ball joint/angular- contact ball bearing
Disassembling/assembling telescopic fork
Disassembling telescopic fork
Assembling telescopic fork
Measuring telescopic fork
Removing and installing leading link
Disassembling/assembling leading link
Removing and installing front spring strut
32 STEERING
Removing and installing left handlebar fitting
Removing and installing right handlebar fitting
Removing and installing brake piston in handlebar fitting
Removing and installing clutch piston in handlebar fitting
Checking and adjusting operating clearance at front brake/clutch levers
Removing and installing handlebar
Removing and installing Bowden- cable divider, Bowden cable for throttle actuation and starting...
Disassembling Bowden-cable divider
33 REAR WHEEL DRIVE
Removing, disassembling, reassembling and installing rear wheel drive
Removing rear wheel drive
Removing and installing taper roller bearing in rear wheel drive
Removing input bevel pinion
Disassembling input bevel pinion
Assembling input bevel pinion
Installing input bevel pinion
Removing and disassembling crown wheel
Assembling and installing crown wheel
Shimming input bevel pinion and crown wheel
Checking tooth contact pattern
Checking and adjusting backlash
Shimming housing cover
Installing housing cover
Installing sliding element
Installing rear wheel drive
Removing and installing spring strut
Removing and installing rear swinging arm
Removing rear swinging arm
Removing and installing taper roller bearing
Removing and installing flexible gaiter
Removing drive shaft
Installing drive shaft
Installing rear swinging arm
34 BRAKES
Removing and installing front brake caliper
Disassembling and assembling front brake caliper
Removing and installing filler adapter
Removing and installing rear brake caliper
Disassembling and assembling rear brake caliper
Removing and installing front brake disc
Removing and installing rear brake disc (mounted on rear-wheel hub)
Removing and installing front ABS sensor
ABS sensor gap, front: adjusting
Marking sensor ring
Checking and adjusting sensor gap
Removing and installing rear ABS sensor
Adjusting rear ABS sensor gap
Marking sensor wheel
Checking and adjusting sensor gap
Removing and installing rear brake master cylinder
Checking and adjusting play of piston rod
Removing and installing footbrake lever
Removing and installing ABS unit
Removing the ABS unit
Installing the ABS unit
Removing and installing ABS relay and relay socket
Removing ABS relay
Installing the ABS relay
Removing ABS relay socket
Installing the ABS relay base
Removing and installing brake line (with ABS)
Removing and installing front brake line
Removing and installing rear brake line
36 WHEELS AND TYRES
Removing and installing front wheel
Removing front wheel
Installing the front wheel
Removing and installing wheel bearings
Removing/installing rear wheel
Removing rear wheel
Installing rear wheel
Static balancing of front wheel/rear wheel
Checking front/rear wheel rim for runout
Removing/installing spokes
Centering the wheel rim
Centering lateral runout
46 FRAME
Overall view, frame
Removing and installing main (centre) stand
Removing and installing side stand
Removing and installing front mudguard
Removing and installing bottom section of mudguard
Removing and installing top section of mudguard
Removing and installing windscreen
Removing and installing fairing bracket
Removing and installing luggage rack
Removing and installing number- plate carrier
Removing/installing rear mudguard
Removing and installing rear footrest plate
Removing and installing front footrest plate
Removing and installing right footrest plate
Removing and installing left footrest plate
Removing/installing frame
Removing and installing frame tail section
Checking running gear
Measuring wheel track offset
Measuring the leading link
51 EQUIPMENT
Removing and installing ignition switch/steering lock
Removing and installing ignition/light switch
Removing and installing lock barrel
Removing and installing lock barrel for fuel tank filler cap
Removing and installing seat lock
Removing and installing lock barrel
Removing and installing helmet lock
52 SEAT
Disassembling/assembling seat
61 GENERAL ELECTRICAL EQUIPMENT
Removing and installing central electrical equipment box
Disassembling/assembling central electrical equipment box
Relay positions/fuse assignments (central electrical equipment box)
Wiring-harness routing, frame [ABS]
Wiring-harness routing/connection in central electrical equipment box
Wiring-harness routing/central electrical equipment box/output
Wiring-harness routing View from left
Wiring-harness routing View from right
Removing and installing battery holder
62 INSTRUMENTS
Removing and installing instrument panel
63 LIGHTS
Removing and installing headlight
Removing and installing front indicators