BMW R 1150 RT - Service Manual - Manual de Taller - Werkstatthandbuch

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BMW R 1150 RT - SERVICE MANUAL

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


CONTENTS:
    
REPAIR MANUAL
INTRODUCTION
How to use this manual
Key to symbols
Contents
Activities
MAINTENANCE SCHEDULE
PRE-DELIVERY CHECK
SERVICE DATA
CONTENTS
00 TIGHTENING TORQUES, TABLE OF OPERATING FLUIDS
Tightening torques
Table of operating fluids
00 PRE-DELIVERY CHECK
General view of crated motorcycle
Checking the crated motorcycle 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
Assembling the motorcycle
Installing the front wheel
Installing front mudguard
Assembling case
Installing cover for windscreen adjuster and installing windscreen
Installing mirrors
Filling and charging the battery
Integral ABS: Performing bleed test with BMW MoDiTeC
Checking engine oil level when cold, adding oil if necessary
Checking tyre pressures
Checking tightness of rear wheel studs
Checking headlight beam angle, adjusting if necessary
Final inspection and function check
Final cleaning
Handing over the motorcycle
00 MAINTENANCE
Maintenance interval codes
Reading the BMW MoDiTeC fault code memory
Integral ABS: Performing bleed test with BMW MoDiTeC
Changing engine oil, replacing oil filter element
Changing oil in gearbox
or at the latest every 2 years
Changing the oil in the rear wheel drive
every 40,000 km (24,000 miles) or at the latest every 2 years
Replacing fuel filter
In normal operating conditions every 40,000 km (24,000 miles); if fuel quality is poor every 20,0...
Checking battery fluid level and topping up if necessary; cleaning and greasing the battery posts
Replacing intake air filter element
in very dirty and dusty operating conditions, replace every 10,000 km (6,000 miles) or even more ...
Checking brake fluid level
Front brake
Rear brake
Checking brake system for correct operation and freedom from leaks; repairing/replacing if necessary
Checking brake pads and discs for wear/replacing
Checking brake pads for wear
Brake pads, front brake
Brake pads, rear brake
Checking brake disc wear
Replacing brake pads
Brake pads, front brake
Brake pads, rear brake
Changing/bleeding brake fluid in wheel circuit
Change brake fluid in wheel circuit once a year
Bleeding/changing brake fluid in front wheel circuit
Instructions for filling front wheel circuit reservoir
Bleeding/changing brake fluid in rear wheel circuit
Instructions for filling rear wheel circuit reservoir
Changing/bleeding brake fluid in control circuit
Change brake fluid in control circuit every 2 years
Bleeding/changing brake fluid in front control circuit
Bleeding/changing brake fluid in rear control circuit
Checking clutch operating fluid level
Changing the clutch fluid
every 2 years at the latest
Checking tightness of rear wheel studs
Checking rear wheel bearing play by tilting wheel
Checking swinging arm bearings, adjusting if necessary
Checking function of side stand contact switch
Greasing the side stand pivot
Tensioning poly-V belt
Retension new poly-V belt once after 10,000 km (6,000 miles)
Replacing poly-V belt
Replace poly-V belt every 60,000 km (37,000 miles)
Poly-V belt tensioning procedure
Checking/replacing spark plugs
(Inspection II) check/(Inspection III) replace
Tightening cylinder heads
Checking/adjusting valve clearances
Checking freedom of throttle cable, checking for chafing and kinks, replacing if necessary Checki...
Final inspection with road safety and functional check
Road safety check
Roadworthiness check
11 MOTOR
Technical Data
Cutaway drawing of engine
Lubricating-oil circuit
Cooling-oil circuit
Removing and installing engine
Removing engine
Installing auxiliary frame (raising frame unit clear of engine)
Removing auxiliary frame (lowering frame unit onto engine)
Disassembling and reassembling engine
Disassembling engine
Removing cylinder head cover
Locking the engine at TDC
Firing TDC
Removing and installing chain tensioner
Work instructions, timing-chain tensioner
Removing and installing valve gear carrier
Disassembling and assembling valve gear carrier
Removing cylinder head
Disassembling, checking, repairing and reassembling cylinder head
Removing and installing valves
Removing valve stem seals
Checking valves for wear
Remachining valve seat
Checking and repairing cylinder head
Checking valve guide for wear
Replacing valve guides
Installing valve and valve stem seal
Removing cylinder
Removing and disassembling piston assembly
Checking pistons and cylinders
Assembling pistons
Removing and installing conrods
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 on 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 main bearing play
Measuring radial bearing play
Installing main bearing
Measuring axial 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 the crankshaft-end radial shaft seal
Installing the clutch-end radial shaft seal
Installing clutch housing
Installing oil pump
Installing auxiliary shaft drive
Installing piston
Installing cylinder
Installing cylinder head
Adjusting valve clearances
Installing cylinder head, right
Adjustment specification
Installing left cylinder head
Adjustment specification
Installing alternator mount cover
Installing magnetic gate/belt pulley
Timing the ignition
Installing alternator
Poly-V belt adjusting procedure
Installing engine
12 ENGINE ELECTRICS
Technical Data
Removing and installing coil and ignition lead
Checking ignition coil resistance
Removing and installing alternator
Poly-V belt adjusting procedure
Disassembling and assembling alternator
Checking alternator
Checking armature for short to ground (earth)
Removing and installing starter motor
Disassembling and 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
Technical Data
Removing and installing air filter housing
Removing and installing throttle-valve stub pipe
Removing and installing throttle-valve potentiometer
Removing and installing Motronic control unit
16 FUEL TANK AND LINES
Technical Data
Removing and installing fuel tank
Removing and installing roll- over valve
Removing and installing fuel- pump unit
Fuel filter removal and installation
Removing and installing fuel pump
Checking fuel pump pressure
Removing and installing fuel distributor and pressure regulator
Removing and installing immersed level sensor
18 EXHAUST SYSTEM
Technical Data
Removing and installing exhaust system
Removing and installing silencer and oxygen sensor
Removing and installing exhaust manifold
21 CLUTCH
Technical Data
Removing and installing clutch
Removing clutch
Removing clutch from vehicle
Removing clutch from engine
Installing clutch
Installing clutch in engine
Installing clutch in vehicle
Removing and installing clutch hydraulic line
Removing and installing clutch slave cylinder
Filling and bleeding clutch line
23 GEARBOX
Technical Data
Gearbox - sectional drawing
Removing and installing gear-shift lever
Removing and installing gearbox
Replacing shaft sealing rings in gearbox housing and gearbox cover
Replacing input shaft sealing ring at input end
Replacing output shaft sealing ring
Replacing input shaft sealing ring at output end
Replacing shaft sealing ring for selector drum
Replacing sealing ring for gearshift shaft
Disassembling gearbox
Removing gearbox housing
Removing selector drum
Disassembling and assembling selector shaft
Removing gearbox shafts
Replacing grooved ball bearings of intermediate shaft
Disassembling and assembling input shaft
Disassembling input shaft
Assembling input shaft/checking and adjusting end float of spring cluster
Disassembling and assembling output shaft
Disassembling output shaft
Assembling output shaft
Checking endplay
Checking and adjusting fully assembled length of gearbox shafts and selector drum
Checking and adjusting fully assembled length of intermediate shaft
Checking and adjusting fully assembled length of output shaft
Checking and adjusting fully assembled length of input shaft
Checking and adjusting fully assembled length of 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
Technical Data
Removing and installing telescopic fork
Removing and installing telescopic fork without fork bridge
Removing and installing fork bridge
Removing and installing pot-type joints
Removing and installing angular-contact ball bearing
Removing and installing slider tube bridge
Removing and installing ball joint in slider tube bridge
Checking friction at ball joint/ angular-contact ball bearing
Assembly instructions for telescopic fork
Disassembling and assembling telescopic fork
Disassembling telescopic fork
Assembling telescopic fork
Measuring telescopic fork
Examining slider tube bridge and fork bridge
Checking runout of fixed tube
Checking runout of slider tube
Removing and installing leading link
Disassembling and assembling leading link
Measuring the leading link
Removing and installing front suspension strut
32 STEERING
Technical Data
Removing and installing handlebar grip unit
Removing and installing left handlebar grip unit
Removing and installing left multi- function switch
Removing and installing clutch switch
Removing and installing clutch piston in handlebar fitting
Adjusting blow-by clearance at handlebar fitting for clutch
Removing and installing right handlebar grip unit
Removing and installing right multi- function switch
Removing and installing front-brake switch for brake light
Removing and installing brake piston in handlebar fitting
Adjusting blow-by clearance at handlebar fitting for brake
Removing and installing handlebars
Removing and installing left handlebar
Removing and installing right handlebar
Removing and installing Bowden-cable divider, Bowden cable for throttle actuation and starting-sp...
Disassembling Bowden-cable divider
33 REAR WHEEL DRIVE
Technical Data
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
Removing needle roller bearing for input bevel pinion
Installing needle roller bearing for 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 splined element
Installing rear-wheel drive unit
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
Checking universal joint for wear
Installing drive shaft
Installing rear swinging arm
34 BRAKES
Technical Data
Removing and installing front brake caliper
Disassembling and assembling front brake caliper
Removing and installing rear brake caliper
Disassembling and assembling rear brake caliper
Disassembling rear brake caliper
Assembling rear brake caliper
Removing and installing front brake discs
Removing and installing rear brake disc
Removing and installing Integral ABS sensor
Removing and installing front Integral ABS sensor
Removing and installing rear Integral ABS sensor
Removing and installing footbrake lever
Removing and installing rear brake master cylinder
Checking and adjusting blow-by clearance of piston rod
Checking blow-by clearance of piston rod
Adjusting blow-by clearance at piston rod
Checking and adjusting setting of rear brake light switch
Checking setting of brake light switch, rear
Adjusting brake light switch, rear
Removing and installing piston in brake-lever fitting
Removing and installing Integral ABS pressure modulator
Removing Integral ABS pressure modulator
Installing Integral ABS pressure modulator
Draining the Integral ABS brake system  
Drain both wheel circuits
Draining front wheel circuit
Draining rear wheel circuit
Draining control circuits
Draining front control circuit
Draining rear control circuit
Filling and bleeding Integral ABS system
Filling and bleeding control circuits
Filling the front control circuit
Bleeding front control circuit
Filling the rear control circuit
Bleeding the rear control circuit
Filling and bleeding wheel circuits
Filling and bleeding front wheel circuit
Instructions for filling front wheel circuit reservoir
Filling and bleeding rear wheel circuit
Instructions for filling rear wheel circuit reservoir
Integral ABS Reading fault memory with BMW MoDiTeC
Integral ABS Performing bleed test with BMW MoDiTeC
Integral ABS Removing and installing bleed lines, wheel circuit reservoirs
Integral ABS: Removing and installing brake lines
Installed position of front brake line
Installed position of rear brake line
36 WHEELS AND TYRES
Technical Data
Removing and installing front wheel
Removing front wheel
Installing front wheel
Removing and installing wheel bearings
Removing wheel bearings
Installing wheel bearings
Removing and installing rear wheel
Removing rear wheel
Installing rear wheel
Static balancing of front wheel/rear wheel
Checking front/rear wheel rim for runout
46 FRAME
Technical Data
Exploded view of fairing sections and trim panels
Removing and installing windscreen adjuster
Removing and installing inner trim of fairing
Removing and installing fairing
Removing and installing fairing side section
Removing and installing tank trim
Removing and installing upper section of fairing
Removing and installing rear trim panels
Removing and installing front mudguard
Removing and installing the rear section
Removing and installing number-plate carrier
Removing and installing luggage rack/case holder
Removing and installing footrest plates
Removing and installing left footrest plate
Removing and installing right footrest plate
Removing and installing fairing bracket
Removing and installing frame
Removing and installing frame front section
Removing and installing frame rear section
Removing and installing main (centre) stand
Removing and installing side stand
Measuring wheel track offset
Measurement record, wheel track offset
Key to measurement result:
Front wheel
Rear wheel
Example
51 EQUIPMENT
Removing and installing ignition switch/steering lock
Removing and installing ignition/light switch
Removing and installing lock barrel
Drilling out lock barrel
Removing and installing lock barrel for fuel tank filler cap
Drilling out lock barrel
Removing and installing seat lock
Removing and installing seat lock
Removing and installing cover of radio compartment/stowage compartment
52 SEAT
Disassembling and assembling seat
61 GENERAL ELECTRICAL EQUIPMENT
Technical Data
Removing and installing central electrical equipment box
Disassembling and assembling central electrical equipment box
Relay positions/fuse assignments (central electrical equipment box)
Relay positions
Fuse assignments
Wiring-harness routing, frame
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
Wiring harness Front
Removing and installing battery carrier
62 INSTRUMENTS
Technical Data
Removing and installing instrument cluster
Disassembling and assembling instrument cluster
63 LIGHTS
Technical Data
Removing and installing headlight
Adjusting headlight
Removing and installing Bowden cable for headlight beam throw adjustment
Removing Bowden cable
Installing and adjusting Bowden cable
Removing and installing rear light cluster