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BMW R 1100 S, Repair Manual

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BMW R 1100 S Repair Manual Download Page 183

31.5

Removing and installing telescopic 
fork

Removing and installing telescopic 
fork without fork bridge

•

Remove front wheel.

•

Remove mudguard.

•

[ABS] 

Remove sensor.

•

Remove brake line retainer.

•

Place a support beneath the telescopic fork.

•

Heat leading link mount at front to max. 120 °C 
(248 °F) and unscrew.

•

Remove fasteners (cable ties) securing Bowden 
cable for starting-speed increase and brake line.

•

Remove fastener securing fixed tube in upper 
fork bridge while holding the hexagon of the fixed 
tube and then pull the telescopic fork down to 
remove.

R21310020

31 5 603

31 5 601

R21310070

Summary of Contents for R 1100 S

Page 1: ...Repair Manual BMW Motorrad After Sales R 1150 GS...

Page 2: ...2 All rights reserved Not to be reprinted translated or duplicated either wholly or in part without prior written permission Errors and omissions excepted subject to technical amendment Printed in Ge...

Page 3: ...rmed Removal Disas sembly Repair Assembly Installation The entire contents are divided into individual chapters corresponding to the Construction Groups 11 10 Chap Page number within chapter Work to b...

Page 4: ...ake air filter element every 10 000 km 6 000 miles or even more often if necessary Renew Poly V belt renew Poly V belt every 60 000 km 36 000 miles do not adjust 60 000 36 000 Check brake fluid level...

Page 5: ...when cold add oil if necessary Check headlight beam angle adjust if necessary Check security of rear wheel studs comply with correct tightening torque Check tyre pressures Fill fuel tank Final inspec...

Page 6: ...mm in mm in Idle speed 1100 50 min 1 Throttle cable setting for cold start increased idle speed for throttle twistgrip cable for divider cable zero play app 0 5 0 02 zero play mm in free travel Brake...

Page 7: ...instructions 11 Engine 12 Engine electrics 13 Fuel preparation and control 16 Fuel tank and lines 18 Exhaust system 21 Clutch 23 Transmission 31 Front forks 32 Steering 33 Rear wheel drive Next Gener...

Page 8: ...Group Section 34 Brakes 36 Wheels and tyres 46 Frame 51 Equipment 52 Seat 61 General electrical equipment 62 Instruments 63 Lights Back Next Group Section...

Page 9: ...00 1 Contents Page 00 Tightening torques 5 Table of operating fluids 12 00 Maintenance and general instructions Tightening torques and table of consumables Pre delivery check Maintenance...

Page 10: ...emaining items on motorcycle 16 Install the windscreen 16 Installing sump guard 17 Filling and charging the battery 18 Disengaging and raising the fuel tank 18 Filling and charging the battery 18 Chec...

Page 11: ...y fluid level and topping up if necessary cleaning and greasing the battery posts 26 Inspections III and IV Replacing intake air filter element 26 Inspection III In very dirty and dusty operating cond...

Page 12: ...swinging arm bearings adjusting if necessary 35 Inspections I and III Greasing the side stand pivot 36 Inspections I II and III Checking function of side stand contact switch 36 Inspections I II III...

Page 13: ...n one nut 2 Tighten nut to initial torque 20 3 Tighten nut to wrench angle 180 4 Slacken and retighten M 10 screw 40 Timing gear carrier to cylinder head 9 Bearing cap on rocker shaft 18 Locknut valve...

Page 14: ...crankcase 9 Cylinders Tightening sequence 1 M 8 screw 20 2 M 6 screw 9 3 Chain guide rail pivot screw 18 Timing chain Chain tensioner 32 Connecting rod Big end cap Closing torque 20 Wrench angle 80 Cr...

Page 15: ...to tank 6 18 Exhaust system Manifold to cylinder head 21 Clamp for manifold 45 apply Optimoly TA to clamp seat Front silencer to manifold 45 apply Optimoly TA to clamp seat Front silencer to main sta...

Page 16: ...om oil and grease Slider tube bridge to slider tube 25 clean thread Loctite 243 Threaded stud to frame 130 clean thread Loctite 243 Ball joint to fork slider bridge 230 apply light coat of Never Seeze...

Page 17: ...rcycle and tighten loose reaction link Spring strut to rear frame 50 Spring strut to rear swinging arm 58 clean thread Loctite 243 Hydraulic spring preload adjuster to footrest plate 22 34 Brakes Brak...

Page 18: ...ning 72 Final tightening 105 Sensor ring to front rear wheel 4 hand tight clean threads Loctite 2701 Spoke nipple 3 5 2 Grub screw 1 1 46 Frame Frame to engine 82 Struts to frame 58 Struts to engine 5...

Page 19: ...Mudguard at bottom to slider tube 4 clean thread Loctite 2701 Mudguard at bottom to slider tube bridge 5 clean thread Loctite 2701 51 Equipment Mirrors 10 Ignition steering lock to fork bridge 20 mic...

Page 20: ...ant 81 22 9 407 301 50 ml tube Loctite 577 Thread locking compounds 07 58 2 328 736 5 g tube Curil K 2 Heat conductive sealant 81 22 9 400 243 250 g can Adhesives and retaining agents Loctite 648 Join...

Page 21: ...00 13 Pre delivery check General view of crated motorcycle...

Page 22: ...supplier e g freight company without delay Unpacking the motorcycle Lever off the cover Take out the separate pack of items Documentation Windscreen Sump guard with fasteners Force off cross struts w...

Page 23: ...2 33220 Rectify the fault If parts are needed order them through the usual channel Costs are to be processed by the warranty claim system stage 4 Defect codes Parts missing 10 01 00 00 00 Parts damage...

Page 24: ...00 16 Installing remaining items on motorcycle Install the windscreen Carefully tighten the securing screws by hand R21000070...

Page 25: ...ll the spacer bushing at the front left XTightening torque Bushing to engine block 20 Nm Install the front rubber mounts with the long thread down Install the rear rubber mounts Install the inner plat...

Page 26: ...y does not achieve full charge capacity from being filled so it has to be charged with a battery charger L Note Follow the instructions for use supplied with the bat tery charger Charge current amps 1...

Page 27: ...tries e g faults settings stored in the Motronic control unit s memory Loss of settings can temporarily impair the operat ing characteristics when the engine is restarted XTightening torque Fuel tank...

Page 28: ...throw Turn screw clockwise shorter throw Setting for headlight beam angle adjuster 15 cm 5 9 in over a distance of 10 m 32 8 ft Checking tightness of rear wheel studs XTightening torque Rear wheel st...

Page 29: ...ld damage seals the hydraulic system or electrical components Handing over the motorcycle This is the ideal opportunity to familiarise the cus tomer with the motorcycle in order to ensure the customer...

Page 30: ...ating temperature Remove screw plug Remove oil drain plug and drain off oil Reinstall the oil drain plug with a new sealing ring Use oil filter wrench BMW No 11 4 650 to re move the oil filter Coat se...

Page 31: ...arbox Brand name hypoid gear oil SAE 90 API class GL 5 Changing the oil in the rear wheel drive Inspections I III and IV Every 40 000 km 24 000 miles or at the latest every 2 years Change the gearbox...

Page 32: ...00 miles Remove the seat Remove right trim panel Disengage fuel tank eCaution Fuel is flammable and a hazard to health Observe relevant safety regulations Seal the fuel feed and return lines with hose...

Page 33: ...ect direction of flow through fuel filter Secure non reusable hose clips with pliers BMW No 13 1 500 eCaution Make sure O ring 2 is in perfect condition X Tightening torque Fuel pump unit 6 Nm e Cauti...

Page 34: ...h dis tilled water Grease the battery posts Acid proof battery post grease e g Bosch Ft 40 V1 Replacing intake air filter element Inspection III In very dirty and dusty operating conditions replace ev...

Page 35: ...oly V belt adjusting procedure Poly V belt installation procedure Place the Poly V belt in position tension it and turn the engine over once then relieve belt ten sion Poly V belt tensioning procedure...

Page 36: ...e MIN mark this indicates some other fault Front brake Place the motorcycle on its centre stand Turn the handlebars to the right Check that the front wheel is on the ground Required level with new bra...

Page 37: ...ear brake pad wear Make sure that the brake disc is not visible through the bore in the inner brake pad If necessary check measure thickness of brake pads eCaution Brake pad thickness must not fall be...

Page 38: ...h resetting tool BMW No 34 1 500 X Tightening torque Brake caliper to fork slider tube 40 Nm Replacing brake pads rear brake Remove brake caliper Remove keeper arrow from retaining pin Drive the retai...

Page 39: ...g tool and insert spacer BMW No 34 1 520 in its place Use resetting tool BMW No 34 1 500 to force the pistons of the left hand brake caliper fully back and allow the resetting tool to remain in positi...

Page 40: ...ht Check that the front wheel is on the ground Required level with new brake pads Initial fill quantity make sure that no bubbles are visible in the sight glass Handlebar centred Check that the front...

Page 41: ...e pistons fully back Connect the brake bleeding device and open the bleed screw Draw off brake fluid until it emerges clear and free from air bubbles eCaution While bleeding the system do not allow th...

Page 42: ...lling and bleeding device with vacuum extraction of brake flu id at the bleed line If other devices are used comply with their manu facturers instructions Motorcycle standing upright Release clamps se...

Page 43: ...ar in the correct position punch marks aligned Recheck the fluid level X Tightening torque Grub screw in filler adapter 10 Nm Handlebar to fork bridge 21 Nm Consumables Brake fluid DOT 4 Checking tigh...

Page 44: ...ect a gear Start the engine without releasing the clutch le ver Extend the side stand L Note The side stand switch is in correct working order if the engine stops when the side stand is extended Check...

Page 45: ...ial torque 20 Nm 1 3 Tighten nut to specified wrench angle 180 2 Slacken and retighten M 10 screw 40 Nm Checking adjusting valve clearances Inspections I II and III Check valve clearance with feeler g...

Page 46: ...Play of throttle cable approx 2 mm 0 08 in Connect hose of BMW Synchro to vacuum adapter and connect cables to BMW MoDiTeC Adjust idle speed by turning the air bypass screws while checking that the ca...

Page 47: ...ct by turning the adjusting screws of the throttle valve Bowden cable L Note Make sure that when the throttle grip is released both throttle valves return to their fully closed posi tions Tighten the...

Page 48: ...ove valve gear carrier 23 Disassembling assembling valve gear carrier 24 Removing cylinder head 26 Disassembling checking repairing and reassembling cylinder head 27 Removing and installing valves 27...

Page 49: ...stat 41 Removing conrods 41 Checking conrods 41 Measuring crankshaft bearing play 42 Measuring radial bearing play 42 Installing main bearings 43 Measuring axial bearing play 43 Measuring big end bear...

Page 50: ...11 3...

Page 51: ...11 4...

Page 52: ...heoretical volume in circulation at 6 000 rpm Lubricating oil Cooling oil l Imp gal US gal l Imp gal US gal 30 6 6 7 9 33 7 3 8 7 Oil filter Full flow type Pressure differential needed to open bypass...

Page 53: ...head edge thickness Inlet mm in 1 00 0 2 0 04 0 008 Wear limit mm in 0 5 0 02 Exhaust mm in 0 9 0 2 0 003 0 008 Wear limit mm in 0 5 0 02 Max runout of valve head at valve seat Inlet exhaust mm in 0 0...

Page 54: ...n 39 0 1 54 Rocker Bore mm in 16 016 16 034 0 6306 0 6312 Rocker shaft dia mm in 15 973 15 984 0 6289 0 6293 Radial clearance mm in 0 032 0 061 0 0016 0 0024 Wear limit mm in 0 1 0 004 Axial play min...

Page 55: ...59 965 59 999 2 3608 2 3621 mm in Yellow 59 979 60 013 2 3614 2 3628 Main bearing journal dia mm in Green 59 939 59 948 2 3598 2 3602 mm in Yellow 59 949 59 958 2 3602 2 3606 Radial clearance mm in 0...

Page 56: ...lel of conrod bores at distance of 150 mm 5 90 in mm in 0 02 0 00079 Weight classes Class 0 2 spots white grammes oz 520 0 525 9 18 356 18 565 1 2 spots blue grammes oz 526 0 531 9 18 568 18 776 2 3 s...

Page 57: ...oduction locating point towards exhaust side see Installing piston Piston rings 1st groove Piston ring asymmetric convex oval Height mm in 1 170 1 190 0 0461 0 0469 Wear limit mm in 1 1 0 04 Ring gap...

Page 58: ...ia mm in 21 995 22 000 0 8664 0 8662 Wear limit mm in 21 960 0 8646 Bore in piston mm in 22 005 22 011 0 8664 0 8666 Radial clearance in piston mm in 0 005 0 016 0 0002 0 0006 Wear limit mm in 0 070 0...

Page 59: ...11 12 Cutaway drawing of engine...

Page 60: ...11 13 Lubricating oil circuit...

Page 61: ...11 14 Cooling oil circuit...

Page 62: ...negative terminal first then positive ter minal Disconnect the air temperature sensor plug Disconnect the diagnostic plug Remove air filter cover Remove the intake air pipe Disconnect plug from Hall...

Page 63: ...ont silencer Remove starter motor cover and disconnect ca ble to power socket Disconnect cables from starter motor Remove the starter motor Disconnect cable from oil pressure switch Disconnect plug 1...

Page 64: ...flat of the fuel tank anchorage install the threaded bushings 4 at the connecting struts frame and tighten Remove front fasteners for rear frame 5 on left and right Install adapter 6 in link rear fra...

Page 65: ...ading link insert it from the left and tighten Remove the fastener securing the front spring strut at the bottom Press leading link down at front or pull tail sec tion down eCaution If necessary mask...

Page 66: ...ing engine Secure engine mount BMW No 11 0 630 to the engine block Transfer engine to assembly frame Drain engine oil Remove the oil filter using oil filter wrench BMW No 11 4 650 11 0 630 RS110010 11...

Page 67: ...11 20 Removing cylinder head cover Remove spark plugs with the spark plug wrench BMW No 12 3 510 Remove cylinder head cover eCaution Catch escaping oil 12 3 510 RS110020...

Page 68: ...is visible and 2 The inlet and exhaust valves of the cylinder in question are closed Install locking device BMW No 11 5 640 to lock clutch housing L Note The engine can be locked at TDC by inserting l...

Page 69: ...g chain tensioner Removing Remove timing chain tensioner then remove camshaft sprocket from camshaft Installing First install camshaft sprocket then timing chain tensioner eCaution Failure to observe...

Page 70: ...moved after loosening it must be held firmly and prevented from falling into the engine block e g with a cable strap Remove valve gear carrier Secure rockers with a rubber band 2 L Note If no work is...

Page 71: ...Remove bearing cap Insert a suitable pin into the bore arrow of the rocker shaft and turn the shaft back and forth to remove it from its bearing Remove pushrods eCaution Do not mix up the rocker shaf...

Page 72: ...r camshaft bearing cap Rocker shaft recess must be aligned with the bores L Note Locate pushrods in ball cups of rockers and hold the rockers together with a rubber band to secure the pushrods in posi...

Page 73: ...11 26 Removing cylinder head RS110110 M6 x 30 M6 x 30 M6 x 30 M10 x 70...

Page 74: ...ompressor BMW No 11 5 690 onto cylinder head Compress the valve springs Gently tap valve head to release collets from spring retainer Remove valve collets Relieve tension on valve springs Remove top a...

Page 75: ...st always be main tained if valve seat is machined a see Technical Data Checking and repairing cylinder head Remove combustion residues from combustion chamber Check sealing face for damage distortion...

Page 76: ...the bore if bore is damaged or not to correct dimensions Determine actual diameter of valve guide using micrometer Ream bore with 12 7 H7 mm 12 700 12 718 mm 0 5000 0 5007 in reamer Repair method 2 t...

Page 77: ...in dia drift BMW No 11 5 602 eCaution Remove the shrink fit tube Install lower spring retainer valve spring and up per spring retainer Compress the valve springs with the valve spring compressor BMW N...

Page 78: ...hat the piston does not strike the engine block Removing and disassembling piston Remove both retaining rings from piston pin Press out piston pin by hand Remove piston Carefully remove piston rings w...

Page 79: ...al Data Install piston rings in cylinder Measure ring gap using feeler gauge a See Technical Data Assembling pistons Carefully fit piston rings to piston in the following sequence using piston ring pl...

Page 80: ...talled positions on the conrods Install conrods eCaution Oil the bearings Screw in the big end bolts by hand and tighten with commercially available angle of rotation in dicator or tightening angle in...

Page 81: ...ing device BMW No 11 5 640 to lock clutch housing Remove pulley 1 Remove magnetic gate 2 L Note It is not necessary to remove magnetic gate 2 when removing the alternator mount cover as a unit Remove...

Page 82: ...1 and swing the pipe forwards Remove chain tensioner 2 Remove chain tensioning rail 3 Remove chain guide rail 4 Install locking device BMW No 11 5 640 to lock clutch housing Remove chain sprocket ret...

Page 83: ...oil pump cover 1 Remove complete oil pump 2 together with cooling oil pipe 3 and disassemble eCaution Check installed positions of parts which have al ready been run together RS110410 M6 x 45 M6 x 50...

Page 84: ...ke care not to damage the sealing faces of crank case and crankshaft L Note The radial shaft seals can be removed when the crankcase is disassembled Using awl BMW No 00 8 583 carefully punch a hole in...

Page 85: ...11 38 Disassembling crankcase Turn engine on to its side Remove screws on right side RS110261 M10 x 100 M10 x 100 M8 x 80 M8 x 80 M8 x 35 M8 x 35...

Page 86: ...ve screws on left side Remove upper section of crankcase RS110260 M6 x 50 M6 x 50 M6 x 50 M6 x 50 M6 x 25 M6 x 25 M10 x 100 M10 x 100 M6 x 50 M6 x 50 M6 x 50 M6 x 35 M6 x 35 M6 x 35 M6 x 35 M6 x 35 M6...

Page 87: ...11 40 Removing crankshaft auxiliary shaft and timing chain tensioning and slide rails S110050...

Page 88: ...t BMW No 00 5 550 Removing and installing oil thermostat Remove screws securing oil cooler line to fairing bracket Disconnect oil cooler line from crankcase Remove support plate 1 control element 2 an...

Page 89: ...asured values on record sheet a See Technical Data eCaution The crankshaft can only be reground in grinding stage 0 after this it must be rehardened and fin ished Grinding stages are identified by a p...

Page 90: ...rection Enter measured values on record sheet and cal culate main bearing play a See Technical Data Measuring axial bearing play Place crankshaft in crankcase Insert tensioner rail slide rail pivot pi...

Page 91: ...and assemble conrods Using tightening angle indicator BMW No 11 2 500 tighten the big end bolts X Tightening torque Big end bolts oiled Closing torque 20 Nm Tightening angle 80 Measure big end bearin...

Page 92: ...and tighten with tightening angle indicator BMW No 11 2 500 eCaution Oil the bearings Do not mix up conrods or bearing shells Always use new big end bolts Use a felt tipped pen or similar to mark the...

Page 93: ...rt pivot screw 1 into chain tensioner rail us ing a new seal X Tightening torque Chain guide rail pivot pin 18 Nm Installing auxiliary shaft timing chains When installing the auxiliary shaft make sure...

Page 94: ...Bond 1209 Secure the timing chain with rubber band 1 to the timing chain tensioner and slide rail RS110920 M10 x 100 M10 x 100 M6 x 50 M6 x 50 M6 x 50 M6 x 50 M6 x 50 M6 x 50 M6 x 50 M6 x 50 M6 x 25...

Page 95: ...case sections together X Tightening torque tightening sequence 1 M 10 screw oiled Initial torque 25 Nm Wrench angle 90 2 M 8 screw oiled 22 Nm 3 M 6 screw 9 Nm RS110391 M10 x 100 M10 x 100 M8 x 80 M8...

Page 96: ...11 49 11 5 702 00 5 500 11 5 661 11 5 662 11 5 701 11 5 703 11 5 702 11 5 703 11 5 703 11 5 703 11 5 703 11 5 662 00 5 500 00 5 500 11 5 661 11 5 661...

Page 97: ...ount sleeve complete with radial shaft seal on crankshaft 4 Use drift BMW No 11 5 701 together with sleeve 5 to drive the radial shaft seal onto the crankshaft Remove sleeve 6 Installing the clutch en...

Page 98: ...r Install clutch housing with mark 1 aligned with crankshaft mark 2 Install locking device BMW No 11 5 640 to lock clutch housing Insert all screws by hand and tighten X Tightening torque Clutch housi...

Page 99: ...2 eCaution O ring 3 must be in perfect condition Install Woodruff key 4 outer rotor 5 and inner rotor 6 in cooling oil pump Secure housing cover 7 to oil pump eCaution Note different lengths of screw...

Page 100: ...ue M 6 screw 10 Nm Install drive shaft chain with chainwheel 2 X Tightening torque Securing screw in chainwheel 70 Nm Install and secure chain guide rail 3 Install and secure chain tensioner rail 4 In...

Page 101: ...ke sure that retaining rings are properly seated on piston pin Oil the friction faces Always use pistons of the same weight class in any one engine Markings or a See Technical Data eCaution Always ins...

Page 102: ...2 900 Install the cylinder and at the same time pass the timing chain and the tensioner and guide rails through the timing case cavity Tighten cylinder securing screws Fit new seals to pivot pins for...

Page 103: ...ghten cylinder head nuts in diagonally opposite sequence 1 Slacken one nut 2 Tighten nut to initial torque 20 Nm 3 Tighten nut to wrench angle 180 4 Slacken and retighten M 10 screw 40 Nm Fit camshaft...

Page 104: ...Correct valve clearance with adjusting screw and tighten locknut Valve clearances with engine cold max 35 C 95 F Inlet 0 15 mm 0 0056 in Exhaust 0 30 mm 0 0118 in X Tightening torque Locknut 8 Nm Rech...

Page 105: ...C by inserting pin BMW No 11 2 650 through holes in clutch housing and engine block L Note With engine installed set engine to TDC with dial gauge holder BMW No 00 2 650 and dial gauge BMW No 00 2 510...

Page 106: ...C by inserting pin BMW No 11 2 650 through holes in clutch housing and engine block L Note With engine installed set engine to TDC with dial gauge holder BMW No 00 2 650 and dial gauge BMW No 00 2 510...

Page 107: ...Rocker end float min 0 05 mm 0 002 in max 0 40 mm 0 016 in Install cylinder head cover eCaution Make sure that gaskets are correctly seated Gas kets and sealing faces must be free from oil and grease...

Page 108: ...lling magnetic gate belt pulley Install Hall effect trigger plate 1 Install locking device BMW No 11 5 640 to lock clutch housing Secure rotor 2 of Hall effect gate to the Po ly V belt pulley 3 with f...

Page 109: ...n Using TDC locating pin BMW No 11 2 650 lock the clutch housing Connect BMW MoDiTeC with adapter cable to Hall effect gate plate Set the timing following the tester instructions Remove the TDC locati...

Page 110: ...justing screw 2 by hand do not use tools Tighten adjusting screw 2 with a torque wrench and keep preload applied Tighten upper retain ing nut 3 then remove torque wrench from ad justing screw X Tighte...

Page 111: ...seal X Tightening torque Oil filter sealing face lightly oiled 11 Nm Oil drain plug 32 Nm Install spark plugs with spark plug socket wrench BMW No 12 3 510 X Tightening torque Spark plug 20 Nm Instal...

Page 112: ...Checking alternator 7 Checking armature for short to ground earth 7 Disassembling assembling alternator Option 50 A 8 Checking alternator 8 Checking armature for short to ground earth 8 Removing and...

Page 113: ...12 2...

Page 114: ...4 000 rpm A 40 option 50 Nominal current at engine speed 1 000 rpm A 10 option 18 Max operating speed rpm 18 000 option 20 000 Spark plug NGK BKR 7 EKC Electrode gap mm in 0 8 0 03 Wear limit mm in 1...

Page 115: ...12 4...

Page 116: ...ion coil Disconnect plug Disconnect ignition lead Remove spark plug cover 4 Pull off spark plug cap with special puller BMW No 12 3 520 Remove ignition leads Installation is the reverse of the removal...

Page 117: ...ine fully open the throttle once or twice so that the Motronic control unit can register the throttle valve positions L Note Disconnecting the battery deletes all entries e g faults settings stored in...

Page 118: ...t 2 and remove sleeve 3 Remove the cover Remove voltage regulator 4 Installation is the reverse of the removal proce dure L Note The belt pulley cannot be removed Checking alternator Test with BMW MoD...

Page 119: ...nd remove the cover Remove voltage regulator 3 Remove the Poly V belt pulley Installation is the reverse of the removal proce dure X Tightening torque Belt pulley to alternator 50 Nm Checking alternat...

Page 120: ...re Switch on the ignition Without starting the engine fully open the throttle once or twice so that the Motronic control unit can register the throttle valve positions L Note Disconnecting the battery...

Page 121: ...ft Installation is the reverse of the removal proce dure Coat the Bendix gear and pull in ring with grease Lubricant Bosch PZ 2 V 3 silicone grease or equivalent Replacing carbon brushes Disconnect le...

Page 122: ...tallation Remove magnetic gate 4 Installation is the reverse of the removal proce dure Affix rotor 5 of Hall effect gate with adhesive to the Poly V belt pulley 3 Adhesive Loctite instant adhesive or...

Page 123: ...the ignition Using TDC locating pin BMW No 11 2 650 lock the clutch housing Connect BMW MoDiTeC with adapter cable to Hall effect gate plate Set the timing following the tester instructions 11 2 650...

Page 124: ...ta 3 Removing and installing air filter housing 5 Removing and installing trottle valve stub pipe 6 Removing and installing throttle valve potentiometer 7 Removing and installing Motronic control unit...

Page 125: ...13 2...

Page 126: ...nical Data R 1150 GS Fuel grade Super premium unleaded 95 octane RON Mixture preparation Motronic MA 2 4 Throttle stub pipe intl dia mm in 45 1 771 Throttle angle in rest position 5 Air filter Round p...

Page 127: ...13 4...

Page 128: ...13 5 Removing and installing air filter housing a Preparatory work See Group 23 removal of transmission RS130090...

Page 129: ...d injector Remove fuel injector if necessary Press in the spring catch at the injector plug and pull off the plug Remove locking device 4 from the injector Slacken hose clamps Push intake neck into ai...

Page 130: ...Motronic control unit Remove fuel tank eCaution Switch off ignition disconnect earth ground lead from battery and insulate it Disconnect plug from Hall sensor Remove Motronic control unit Remove conn...

Page 131: ...ll over valve 6 Removing and installing fuel filter fuel pump and fuel level sensor 7 Removing and installing fuel filter 7 Removing and installing fuel pump and fuel level sensor 7 Checking fuel pump...

Page 132: ...16 2...

Page 133: ...l Imp gal US gal 22 4 8 5 81 Including reserve of l Imp gal US gal approx 4 0 88 1 06 Fuel pump Type Turbine wheel pump Make VDO type HPI 3 0 Operating voltage V 7 15V Fuel pressure bar psi 3 0 2 42 6...

Page 134: ...16 4...

Page 135: ...nk Seal the fuel feed and return lines with hose clips BMW No 13 3 010 and disconnect Disconnect breather and overflow hoses Disconnect the plug of the fuel pump Remove fuel tank Installation is the r...

Page 136: ...ve the fuel filler cap Remove the reducer unit with roll over valve 1 and disconnect the hoses Remove the roll over valve Installation is the reverse of the removal proce dure Secure non reusable hose...

Page 137: ...uel level sensor Disconnect the electrical connections at the fuel pump 5 Release the hose clip at the fuel pump Remove fuel pump Installation is the reverse of the removal proce dure Secure non reusa...

Page 138: ...uel distributor and pressure regulator Remove air filter box a See Group 23 removing transmission Remove the fuel distributor with pressure regula tor from the holder Installation is the reverse of th...

Page 139: ...stalling exhaust system 3 Removing and installing silencer and front silencer 3 Removing silencer end cap and silencer guard 3 Installing silencer end cap and silencer guard 3 Removing and installing...

Page 140: ...18 2...

Page 141: ...No 11 7 020 Removing silencer end cap and silencer guard Remove end cap Remove fasteners securing silencer bracket Remove silencer guard from silencer Installing silencer end cap and silencer guard Pu...

Page 142: ...ust manifold Remove exhaust manifold Installation is the reverse of the removal proce dure eCaution After a trial run read out Motronic fault memory Note position of wiring for oxygen sensor X Tighten...

Page 143: ...tch 5 Removing clutch from vehicle 5 Removing clutch from engine 7 Installing clutch 7 Installing clutch in engine 7 Installing clutch in vehicle 7 Removing and installing clutch hydraulic line 8 Remo...

Page 144: ...21 2...

Page 145: ...g Actuation Hydraulic with master and slave cylinders Master cylinder piston dia mm in 13 0 51 Slave cylinder piston dia mm in 24 0 94 Clutch fluid DOT 4 brake fluid Clutch plate dia mm in 165 6 50 We...

Page 146: ...21 4...

Page 147: ...s Remove holders of injection valves Remove injection valves from throttle stub pipes Loosen the fasteners securing the right and left footrest plates Remove top screws on left and right L Note When i...

Page 148: ...ove the gearbox Always use oiled guide pins BMW No 23 1 820 when removing or installing the gearbox Remove the rear wheel rear wheel drive and swinging arm together with the gearbox eCaution Take care...

Page 149: ...nstall clutch eCaution Make sure that colour marks on the clutch housing thrust plate and housing cover are offset 120 Secure the clutch with the retaining screws Center the clutch plate with centerin...

Page 150: ...te When installing fit new sealing rings X Tightening torque Clutch line to handlebar fitting 14 Nm Removing and installing clutch slave cylinder Remove the seat Remove rear brake caliper Remove rear...

Page 151: ...tening sequence Connecting pipe gearbox 1 to gearbox and left footrest plate clean thread Loctite 243 42 Nm 2 clamp block connecting tube to gearbox 9 Nm 3 to gearbox and right footrest plate clean th...

Page 152: ...sembling selector shaft 12 Removing gearbox shafts 13 Replacing grooved ball bearings of intermediate shaft 13 Disassembling assembling input shaft 14 Disassembling input shaft 14 Assembling input sha...

Page 153: ...23 2 Contents Page Assembling gearbox 23 Installing input output and intermediate shafts 24 Installing selector shaft 25 Installing selector drum 25 Installing gearbox housing 26...

Page 154: ...ear round Brand name SAE 90 hypoid gear oil API Class GL 5 Capacity l Imp pint US quart approx 1 0 1 76 1 06 to lower edge of filler screw Endplay of spring segment at input shaft mm in 0 4 0 6 0 0157...

Page 155: ...23 4...

Page 156: ...23 5 Gearbox sectional drawing R21239010...

Page 157: ...23 6...

Page 158: ...nostic plug Remove air filter cover Remove the air filter Remove the intake air pipe Unfasten air filter box at front and rear Disconnect plug of oxygen sensor and remove cable Disconnect hose clamps...

Page 159: ...he fixed bearing stud of the rear wheel drive in the swinging arm Remove floating bearing fixed bearing stud bolts Remove rear wheel drive from universal shaft Slacken the floating bearing stud of the...

Page 160: ...t end Carefully lever out the shaft sealing ring with a screwdriver Drive the new sealing ring in with the sealing lips facing inwards using slip over sleeve BMW No 23 4 712 and drift BMW No 23 4 711...

Page 161: ...r Install the new sealing ring with the sealing lips facing inwards using guide BMW No 23 4 722 and impact driver BMW No 23 4 723 Replacing shaft sealing ring for selector drum Carefully lever out the...

Page 162: ...efully drive back centering pins 4 from the cover side or casing side as applicable Remove screws 5 securing cover to housing Set the gearbox down on its cover eCaution Avoid damage to the housing cov...

Page 163: ...he same time Remove thrust washers 2 and spacing washer 11 Release the locking lever 6 Remove the selector shaft 7 with spacing washer Remove selector forks 3 Selector fork 8 remains in the intermedia...

Page 164: ...lar Replacing grooved ball bearings of intermediate shaft eCaution If the grooved ball bearings are replaced the fully assembled length must be re adjusted Pull off the grooved ball bearings with a un...

Page 165: ...h spacing washer 8 Note the thickness of spacing washer 8 Remove retaining ring 7 Compress spring cluster 4 and remove keepers 6 Remove spacer 5 spring cluster 4 anti rattle disc 3 thrust block 2 and...

Page 166: ...cing upwards on anti rattle disc 3 Install spacer 5 Compress spring cluster 4 and insert the keep ers 6 in the ring groove Install retaining ring 7 with the shoulder facing over keepers 6 Check axial...

Page 167: ...eel 7 Remove circlip 8 backup washer 9 shift gear wheel for 3rd gear 10 and needle roller bearing 11 Remove backup washer 12 4th gear shift wheel 13 needle roller bearing 14 and backup washer 15 Remov...

Page 168: ...washer 12 and needle roller 11 Install shift wheel for 3rd gear 10 with pockets facing away from the 4th gear shift wheel 13 Install backup washer 9 and circlip 8 After installing the 3rd and 4th shi...

Page 169: ...d ball bearing 1 Check 2nd gear endplay Checking endplay Secure dial gauge BMW No 00 2 510 to dial gauge stand Position dial gauge stylus on edge of the gear wheel and check endplay eCaution Excessive...

Page 170: ...n the intermediate shaft Place the grooved ball bearing on the reference washer Insert intermediate shaft in measuring stand Using the dial gauge measure the deviation from zero of dimension B at the...

Page 171: ...output shaft Place the grooved ball bearing on the reference washer Insert the output shaft into the measuring stand Using the dial gauge measure the deviation from zero of dimension B at the inner b...

Page 172: ...eference washer Insert input shaft with adapter disc BMW No 23 4 767 in measuring stand Using the dial gauge measure deviation from zero of dimension B at the inner bearing race Deviation from zero is...

Page 173: ...ace spacing washer and both thrust washers on the selector drum Using slide gauge determine fully assembled length A If necessary adjust fully assembled length A with a shim washer arrow Fully assembl...

Page 174: ...ance A from shouldered bushing to cover mating face Measure distance B from shouldered bushing to housing mating face Measure distance C from the shoulder on the selector shaft to the back of the slee...

Page 175: ...the position illustrated Push assembly sleeve BMW No 23 4 712 on to the input shaft splines L Note This is necessary only if the shaft sealing ring is in stalled Heat the bearing points in the cover...

Page 176: ...t washer on selector drum 6 and secure with a small amount of grease Swing locking lever 8 toward the input shaft and install the selector drum Swing locking lever 8 towards selector drum 6 pull back...

Page 177: ...d sets within 30 minutes with in this time place the housing in position and screw it down Apply Loctite 574 sealing compound to the mat ing face of the cover Place assembly sleeve BMW No 23 4 732 on...

Page 178: ...all the oil drain plug with a new sealing ring Install oil check and oil filler plug 6 with new sealing ring Install shift lever in correct position L Note The shift lever is in the correct position w...

Page 179: ...dge 8 Removing and installing ball joint in slider tube bridge 8 Checking friction at ball joint angular contact ball bearing 8 Disassembling assembling telescopic fork 9 Disassembling telescopic fork...

Page 180: ...31 2...

Page 181: ...le 42 Total suspension travel mm in 190 7 48 Fixed tube surface Hard chrome plated Extl dia of fixed fork tubes mm in 35 0 1 38 Maximum permissible runout of fixed fork tube mm in 0 4 0 016 Telescopic...

Page 182: ...31 4...

Page 183: ...ace a support beneath the telescopic fork Heat leading link mount at front to max 120 C 248 F and unscrew Remove fasteners cable ties securing Bowden cable for starting speed increase and brake line R...

Page 184: ...ach the handlebar to a crane and release the fastener securing the handlebar to the fork bridge Remove fasteners cable ties securing Bowden cable for starting speed increase and brake line Remove fast...

Page 185: ...ng angular contact ball bearing Remove retaining ring 1 Heat fork bridge to approx 100 C 212 F Remove angular contact ball bearing if neces sary striking lightly with a plastic faced hammer Press out...

Page 186: ...oving and installing ball joint in slider tube bridge Mount the slider tube bridge in retaining fixture BMW No 31 5 670 Use w f 46 socket BMW No 31 5 630 to re lease and tighten ball joint X Tightenin...

Page 187: ...acity per fixed tube 0 47 l 0 82 Imp pint 0 49 US quart Oil grade in telescopic fork BMW telescopic fork oil L Note No oil changes required during services unit is maintenance free Install fixed tube...

Page 188: ...r face irregularities eCaution Replace slider tube bridge fork bridge if deformed Checking runout of fixed tube Place both ends of fixed tube in V blocks Rotate fixed tube slowly and check with dial g...

Page 189: ...the reverse of the removal proce dure Apply a light coating of grease to the shaft before installing Tighten the ball joint in the leading link using socket BMW No 31 5 601 and Allen key BMW No 31 5 6...

Page 190: ...handlebar fitting 7 Removing and installing clutch piston in handlebar fitting 8 Checking and adjusting operating clearance at front brake clutch levers 9 Front brake 9 Clutch 9 Removing and installi...

Page 191: ...32 2...

Page 192: ...32 3 32 Technical Data R 1150 GS Steering lock angle 2 x 42 Steering head tube dia mm in 22 0 866 Width of handlebar with weights mm in 903 35 551...

Page 193: ...32 4...

Page 194: ...uring multi function switch eCaution Do not allow brake fluid to come into contact with painted parts of the motorcycle as brake fluid de stroys paint Drain the clutch operating system Disconnect clut...

Page 195: ...ch 7 eCaution Do not allow brake fluid to come into contact with painted parts of the motorcycle as brake fluid de stroys paint Drain the brake system Disconnect brake line from handlebar fitting Loos...

Page 196: ...o installation coat the piston and the boots 6 with brake fluid eCaution Sealing lips of the boots 6 toward the pressure chamber Prior to installation carefully press back the brake piston using an Al...

Page 197: ...of the removal proce dure pay particular attention to the following Prior to installation coat the piston and the boots 6 with brake fluid eCaution Sealing lips of the boots 6 toward the pressure cham...

Page 198: ...hread locking compound screw can be released and tightened a number of times Clutch Remove the lower section of the clutch lever fit ting Remove the handlebar weight Remove the grip Heated grips Relea...

Page 199: ...ebar Installation is the reverse of the removal proce dure eCaution Make sure that all lines and cables are correctly routed Align the punch mark on the handlebar with the gap between the clamp blocks...

Page 200: ...cable cover from fitting for throttle actuation Disengage Bowden cable B Disengage throttle cables from right and left throttle flap stubs Remove cable ties securing Bowden cables Disconnect engine br...

Page 201: ...cable divider Remove Bowden cable for starting speed in crease Remove retainer 1 for roller of Bowden cable divider Remove Bowden cables Installation is the reverse of the removal proce dure eCaution...

Page 202: ...pinion 9 Removing and disassembling crown wheel 11 Assembling and installing crown wheel 12 Shimming input bevel pinion and crown wheel 13 Checking tooth contact pattern 14 Checking and adjusting bac...

Page 203: ...33 2 Contents Page Installing rear swinging arm 21...

Page 204: ...art up to lower edge of thread in filler neck approx 0 25 0 4402 0 2642 Drive shaft Layout Two piece shaft with universal joints at each end central sliding joint and integral torsional vibration damp...

Page 205: ...33 4...

Page 206: ...xed bearing stud bolt 5 Disengage reaction link from rear wheel drive Remove floating bearing fixed bearing stud bolts L Note Note inner races of needle bearings Remove rear wheel drive from universal...

Page 207: ...ew threaded bushings 2 down on to the rear wheel drive and secure them with the wheel studs Heat hex nut 3 at the input bevel pinion to 100 C 212 F and unscrew with w f 36 socket wrench insert and red...

Page 208: ...drops out Remove the input bevel pinion and the spacer Disassembling input bevel pinion Remove outer bearing race 1 Clamp input bevel pinion 2 into vise with protec tive jaws splines facing upwards U...

Page 209: ...r bearing seat to 100 C 212 F Press in needle roller bearing using drift or the in put bevel pinion Assembling input bevel pinion Clean the threads of the input bevel pinion Heat the inner race 1 to 1...

Page 210: ...rior to installation in refrig erator freezer or similar or use cooling spray Install spacer 2 Install input bevel pinion 1 from above Clamp holder BMW No 33 1 510 in the vise in such a way that the i...

Page 211: ...o 33 1 700 Install thrust ring 6 L Note Make sure that the lip of the shaft seal is seated cor rectly on the thrust ring Tighten hex nut 7 with w f 36 socket wrench in sert and reduction adapter BMW N...

Page 212: ...vise with protective jaws Insert thrust block arrow BMW No 00 7 511 Use puller BMW No 33 1 830 to pull off the grooved ball bearing Insert thrust block BMW No 11 0 561 Using puller BMW No 00 7 500 pu...

Page 213: ...e g taper roller bearing check tooth backlash and adjust if necessary Place original spacer 1 or spacer measuring 2 25 mm 0 0886 in in thickness on crown wheel for provisional backlash L Note Install...

Page 214: ...K 77 50 mm 0 20 mm 77 70 mm 3 0512 in 0 0079 in 3 059 in Measure housing dimension G If G deviates from the housing basic dimension of 75 50 mm 2 972 in the two places after the decimal point are stat...

Page 215: ...th marking ink Install measuring fixture BMW No 33 2 600 centre crown wheel and use the balls of your hands to press it into the housing and turn it back and forth a few times If the correct shim is i...

Page 216: ...nd fro to check tooth backlash L Note Check tooth backlash at three points 120 degrees apart turn the bevel pinion with the crown wheel Compensate for excessive backlash by inserting a thinner shim wa...

Page 217: ...y a light coat of grease to the selected shim washer and install it Preload 0 05 0 1 mm 0 0020 0 0039 in Installing housing cover Lightly oil the lip and outer edge of the sealing ring Using drift BMW...

Page 218: ...stud bolt 1 with Loctite eCaution Make sure that the inner race never presses against the ends of the needles Install floating bearing stud bolt 2 with Loctite Tighten fixed bearing stud bolt Tighten...

Page 219: ...5 0 55 mm 0 018 0 022 in Install rear wheel cover X Tightening torque Rear wheel cover to rear wheel drive M 5 clean thread Loctite 638 5 Nm Removing and installing spring strut L Note To remove the s...

Page 220: ...heel drive unit Remove rear spring strut Swinging arm bearing studs are secured with Loctite heat to max 120 C 248 F to release Loosen floating bearing stud bolt Loosen fixed bearing stud bolt Remove...

Page 221: ...winging arm When installing coat inner and outer sealing lips arrows with Staburags NBU 30 PTM eCaution Drive shaft clearance when suspension is com pressed gap of retaining ring must be in the hori z...

Page 222: ...strut eCaution The universal joints for universal shaft and rear wheel drive must be installed in the same position e Caution When tightening threaded fasteners coated with Loctite 2701 always apply...

Page 223: ...alling front ABS sensor 11 ABS sensor gap front adjusting 12 Marking sensor ring 12 Checking and adjusting sensor gap 12 Removing and installing rear ABS sensor 13 Adjusting rear ABS sensor gap 14 Mar...

Page 224: ...ntents Page Removing ABS relay socket 19 Installing the ABS relay base 20 Removing and installing brake line with ABS 21 Removing and installing front brake line 21 Removing and installing rear brake...

Page 225: ...Brake pad surface area cm2 sq in 100 15 5 Piston dia in brake caliper mm in 32 34 1 26 1 34 Piston diameter in handlebar lever cylinder mm in 16 0 6 Sensor gap front mm in 0 45 0 55 0 018 0 022 Brake...

Page 226: ...the brake pads and pistons arrows eCaution Do not damage brake pads Carefully remove the brake caliper Installation is the reverse of the removal procedure Force back the brake pads and pistons Fill a...

Page 227: ...ngers between the pistons risk of injury Carefully press out brake pistons 2 using a compressed air gun at the brake line connection Remove the two sealing rings 3 4 from the left and right brake cyli...

Page 228: ...o detach the remains of the adhesive and blow out with a low pressure jet of air Secure brake pistons with resetting tool BMW No 34 1 500 Inject compressed air through the connecting bore arrow in the...

Page 229: ...g the brake caliper Installation is the reverse of the removal proce dure Force back the brake pads and pistons Fill and bleed the brake system eCaution Replace the sealing rings 2 in the brake line D...

Page 230: ...isk of injury Remove sealing rings 4 from left and right bores Inspect the brake caliper piston for hairline cracks score marks and other damage Coat the new sealing rings with brake fluid and insert...

Page 231: ...e discs before installing L Note Installed direction arrow of brake discs must be correct X Tightening torque Brake disc to front wheel clean thread Loctite 243 24 Nm eCaution Check and if necessary a...

Page 232: ...r wheel Remove brake disc Installation is the reverse of the removal proce dure Degrease the brake disc before installing eCaution ABS Check sensor gap and adjust with shims if necessary Sensor gap 0...

Page 233: ...g 1 of sensor cable Remove sensor 2 with Torx T 25 Installation is the reverse of the removal proce dure eCaution Route the sensor cable correctly Check sensor gap and adjust if necessary with shim 3...

Page 234: ...replaced brake disc etc and a used and therefore marked sensor ring is installed the sensor ring must be measured and marked again Remove the old mark Retighten clamp screw of left fork tube Check ad...

Page 235: ...r 1 Disconnect plug 2 of sensor cable Installation is the reverse of the removal proce dure Coat O rings with oil before installing eCaution Route the sensor cable correctly Check sensor gap and adjus...

Page 236: ...delibly mark the point where the sensor is farthest away from the sensor ring eCaution If parts are replaced rear wheel etc and a used and therefore marked sensor ring is installed the sensor ring mus...

Page 237: ...rain the brake system Disconnect brake line 1 and hose 2 Release and remove pin 3 Remove brake master cylinder 4 Installation is the reverse of the removal proce dure Tighten non reusable hose clip 5...

Page 238: ...o obtain play Carefully back off piston rod to take up play and tighten locknut Tighten locknut and recheck play Apply coloured sealing lacquer to the locknut Removing and installing footbrake lever R...

Page 239: ...ted against dirt penetration seal or cover ends of lines and ports Hold the front brake lever against the handlebar grip with a rubber band to close the brake fluid feed bore eCaution Switch off ignit...

Page 240: ...at all cables are correctly located in their cable entries Scrap the old cover Screw ABS brake lines 1 to ABS unit Fill and bleed the brake system Install the fuel tank X Tightening torque ABS unit to...

Page 241: ...lways use new self locking nuts Install a new cover 1 eCaution When sliding the cover on make sure that all cables are correctly located in their cable entries Scrap the old cover Removing ABS relay s...

Page 242: ...e red engine cable us ing the Torx screw Use the second Torx screw to secure the flat plug to the relay Press the contact interlock into the relay socket at the side Push the relay socket into the rel...

Page 243: ...34 21 Removing and installing brake line with ABS Removing and installing front brake line R21340021...

Page 244: ...line to master cylinder in such a way that it cannot kink or chaff when the handlebar is turned Fill and bleed the brake system X Tightening torque Brake line to handlebar fitting 18 Nm Brake line to...

Page 245: ...wheel 5 Removing and installing wheel bearings 6 Removing installing rear wheel 8 Removing rear wheel 8 Installing rear wheel 8 Static balancing of front wheel rear wheel 9 Checking front rear wheel r...

Page 246: ...36 2...

Page 247: ...wheel Front mm in 1 3 0 05 Rear mm in 1 3 0 05 Tyre size Spoked wheel Front 110 80 R 19 59 H Tubeless Rear 150 70 R 17 69 H Tubeless Tyre pressures cold Solo Front bar psi 2 2 31 9 Rear bar psi 2 5 36...

Page 248: ...36 4...

Page 249: ...ing and speedometer drive eCaution Locate the reaction peg arrow on the speedometer drive in front of the fork slider tube Apply a light coating of Molykote paste to the quick release axle and install...

Page 250: ...een the wheel hub at the right and the claws of the internal puller Heat bearing seat to 100 C 212 F Pull out the wheel bearing with counter support 22 1 BMW No 00 8 572 and internal puller 21 3 BMW N...

Page 251: ...tube 1 Bearing seat temperature 80 C 176 F Insert narrow bearing 3 with drift BMW No 36 5 512 and handle BMW No 00 5 500 Install retaining ring and driver Drive in shaft sealing ring with drift BMW N...

Page 252: ...wheel eCaution Contact faces on rear wheel drive and hub must be clean and free of grease Hold rear wheel in position at rear wheel drive and high tighten the wheel studs with taper rings e Caution U...

Page 253: ...ar wheel attach mounting fixture 4 BMW No 36 3 613 on the centering collar side with the wheel studs and shims then install the balancing shaft Allow wheel to settle Clean the attachment points for th...

Page 254: ...ering collar side with the wheel studs and shims then install the balancing shaft Clamp locating discs 6 BMW No 36 3 615 to the balancing shaft at left and right in such a way that the shaft cannot wa...

Page 255: ...opposite the largest deviation Remove grub screw from relevant spoke nipple before tightening Working forwards and backwards from the point opposite the maximum and minimum value points take up slack...

Page 256: ...oving and installing fairing bracket 11 Removing and installing luggage rack 12 Removing and installing number plate carrier 13 Removing installing rear mudguard 14 Removing and installing rear footre...

Page 257: ...46 2...

Page 258: ...3 1 33 9 Wheelbase in normal load position mm in 1509 59 4 Ground clearance in normal load position mm in 200 7 9 Caster angle in normal load position mm in 115 4 5 Steering head angle in normal load...

Page 259: ...46 4...

Page 260: ...46 5 Overall view frame...

Page 261: ...nnect tension springs Remove machine screws 1 in bearing bushings 2 Remove right and left bearing bushings 2 Disconnect the plug from the side stand switch Remove the main centre stand Remove right an...

Page 262: ...achine screw 21 Nm Removing and installing side stand Place the motorcycle on its main centre stand Disconnect tension springs Disconnect plug 1 from the side stand switch and remove the switch Remove...

Page 263: ...mudguard Remove front wheel Remove holder 1 for speedometer drive Remove mudguard Installation is the reverse of the removal proce dure X Tightening torque Mudguard to slider tube 4 Nm clean thread L...

Page 264: ...gnition Disconnect earth ground lead from battery Insulate earth ground lead Remove the indicator lenses disconnect plug and pull the cable through the indicator mount Remove the turn indicators Remov...

Page 265: ...46 10 Removing and installing windscreen R21460090...

Page 266: ...eadlight 2 Release instrument cluster 3 and pull it up until it is clear of the front mount L Note Carefully pull thrust pad 5 on bracket of instrument carrier out of the front mount 4 Release left or...

Page 267: ...installing luggage rack Remove rear seat Remove the toolkit Remove the luggage rack L Note The rear mudguard drops out of position support it if necessary Installation is the reverse of the removal p...

Page 268: ...Disconnect earth ground lead from battery Insulate earth ground lead Remove rear seat Remove the toolkit box Remove the tail light Remove the turn indicators Remove the number plate carrier Remove num...

Page 269: ...d lead from battery Insulate earth ground lead Remove the seat Remove the toolkit box Remove the tail light Remove the turn indicators Remove number plate bracket Remove mudguard Release the wiring ha...

Page 270: ...46 15 Removing and installing rear footrest plate X Tightening torque Footrest plate to rear frame 21 Nm GS460181...

Page 271: ...right footrest plate Remove brake pedal Remove brake master cylinder Remove the footrest plate X Tightening torque Footbrake lever to footrest plate 21 Nm Footrest plate with rear frame to gearbox cl...

Page 272: ...draulic spring strut adjuster Remove the footrest plate X Tightening torque Shift lever to footrest plate 35 Nm Footrest plate with rear frame to gearbox clean thread Loctite 243 42 Nm Footrest plate...

Page 273: ...ry mask off the leading link to prevent it from being scratched Hand tighten the ball joint at the front of the lead ing link Remove fasteners securing strut 2 to frame and slacken fasteners securing...

Page 274: ...nd de tach the cable Disconnect the idle switch plug and detach the cable Disconnect the diagnostic plug and detach the cable Remove holder of brake line Remove brake fluid reservoir from its holder R...

Page 275: ...he supports in on the other side Adjust support 1 so that the measuring plane is as close as possible to the wheel centreline The gauge must slide freely up to the motorcycle Position the measuring st...

Page 276: ...sult Negative sign wheel track offset to left Positive sign wheel track offset to right EXAMPLE Formula S Fixed value A length of measuring stops A 50 0 mm 1 97 in Half of rear wheel rim width 66 3 mm...

Page 277: ...de into the leading link without re sistance Check runout of shaft 1 Insert test mandrel 2 all the way into the bore L Note Check the leading link for signs of the paint flaking Interpreting result of...

Page 278: ...gnition light switch 3 Removing and installing lock barrel 3 Drilling out lock barrel 3 Removing and installing lock barrel for fuel tank filler cap 4 Drilling out lock barrel 4 Removing and installin...

Page 279: ...51 2...

Page 280: ...sulated 20 Nm Removing and installing ignition light switch Remove screw 1 Remove the ignition light switch Installation is the reverse of the removal proce dure Removing and installing lock barrel Ke...

Page 281: ...press down on retainer 2 Pull out lock barrel with key Lubricate the new lock barrel with Shell Retinax A Install lock barrel with key at a right angle to di rection of travel Installation is the reve...

Page 282: ...ax A Press lock barrel in until keeper engages Installation is the reverse of the removal proce dure Removing and installing helmet lock Open the retainer Remove the helmet lock Use a screwdriver to p...

Page 283: ...52 1 Contents Page 52 Disassembling assembling seat 3 52 Seat...

Page 284: ...52 2...

Page 285: ...52 3 52 Disassembling assembling seat R21520010...

Page 286: ...nts central electrical equipment box 6 Fuse assignments 6 Wiring harness routing frame ABS 7 Wiring harness routing connection in central electrical equipment box 8 Wiring harness routing central elec...

Page 287: ...61 2...

Page 288: ...61 3 61 Technical Data R 1150 GS Battery A h A h 14 Option 19...

Page 289: ...61 4...

Page 290: ...ith fuse box Installation is the reverse of the removal procedure After installation shorten the middle rubber lug of the anti spray fastener arrow to 10 mm 0 3937 in Switch on the ignition Without st...

Page 291: ...Relief relay 6 Horn relay 7 Fuel pump relay 8 Motronic relay 9 ABS warning relay Fuse assignments No 1 on left looking forwards 1 Instrument cluster indicator damping brake light 4 A 2 Parking light...

Page 292: ...ing and avoid risk of abra sion Note the number and position of the cable ties Apply a thin coating of contact grease e g CENTOPLEX 3 CU to the central earth ground point which must be cleaned to brig...

Page 293: ...61 8 Wiring harness routing connection in central electrical equipment box RS610090...

Page 294: ...61 9 Wiring harness routing central electrical equipment box output L Note The white mark arrow must be covered by the grommet RS610110...

Page 295: ...61 10 Wiring harness routing View from left 2 1 R21619010...

Page 296: ...61 11 R21619011 1...

Page 297: ...61 12 R21619012 2...

Page 298: ...61 13 Wiring harness routing View from right 1 2 3 S619020...

Page 299: ...61 14 R21619021 1...

Page 300: ...61 15 R21619022 2...

Page 301: ...61 16 R21619023 3...

Page 302: ...fitting Disconnect cable from left throttle valve Remove Bowden cable divider from holder Pull the battery holder to the left to remove Installation is the reverse of the removal proce dure Switch on...

Page 303: ...62 1 Contents Page 62 Technical Data 3 Removing and installing instrument panel 4 62 Instruments...

Page 304: ...62 2...

Page 305: ...62 Technical Data R 1150 GS Instrument cluster Telltale lights turn indicator high beam headlight A 14 V 3 W Instrument lighting telltale lights A 12 V 1 7 W Speedometer drive Speedometer drive ratio...

Page 306: ...t mount Pull the instrument cluster up until it is clear of the front mount L Note Carefully pull thrust pad 1 on bracket 4 of instru ment carrier out of the front mount Remove bracket 4 of instrument...

Page 307: ...63 1 Contents Page 63 Technical Data 3 Removing and installing headlight 4 Removing and installing front indicators 5 63 Lights...

Page 308: ...63 2...

Page 309: ...w dipped beam headlight H1 halogen bulb 12 V 55 W High main beam headlight H1 halogen bulb 12 V 55 W Parking light 12 V 4 W Standard designation T 8 4 Brake light rear light 12 V 21 5 W Standard desig...

Page 310: ...onnect plug 3 from protective cap low beam headlight Pull bulb holder 4 of the parking light out of the headlight housing Remove fastener 5 securing the headlight hold er L Note Carefully pry the ball...

Page 311: ...d from battery Insulate earth ground lead Remove the indicator lenses disconnect plug fromreflector and pull the cable through the indi cator mount eCaution Do not touch inner surface of reflector or...

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