BMW R1150 Service Manual
Maintenance BMW Integral ABS
R 1150 RT
BMW Motorrad
After Sales
Published by: © BMW Motorrad
After Sales
UX-VS-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.
Produced in Germany 01/01
BMW Motorrad
Maintenance schedule
R 1100 S EVO / R 1150 R / R 1150 RT
Customer Registration No.
Order No. Mechanic’s signature
Read the fault code memory with the BMW MoDiTeC
[Integral ABS] perform bleed test with BMW MoDiTeC
Change oil while at regular operating temperature and replace the oil filter element
If the motorcycle is ridden only for short distances or outside temperatures are below 0 °C: at the
latest every 3,000 km (1,800 miles)*
)
BMW Inspection
at 1,000 km
(600 miles)
BMW Service
10,000 km
(6,000 miles)
BMW Inspection
every 20,000 km
(12,000 miles)
BMW
Annual Service
Change oil in gearbox while at operating temperature
every 2 years*
Change oil in rear wheel drive while at operating temperature
if necessary, clean inductive sensor on rear wheel
every 40,000 km (24,000 miles) or at the latest every 2 years*
Replace fuel filter *
Normally every 40,000 km (24,000 miles), if fuel is of poor quality every 20,000 km (12,000 miles)
Check the battery fluid level, if necessary top up with distilled water
Clean and grease battery poles if necessary
Replace intake air filter element
In very dirty and dusty operating conditions, replace every 10,000 km (6,000 miles) or even more
frequently if necessary *
Replace Poly-V belt *
Replace the Poly-V belt every 60,000 km (36,000 miles); do not adjust it 60,000
Check brake fluid level at front and rear
Check operation of brake system and freedom from leaks; repair/replace items if necessary*
Examine brake pads and discs for wear, replace as necessary*
[Without ABS] change brake fluid every twelve months
[Integral ABS] change bake fluid in wheel circuit every 12 months
[Integral ABS] change brake fluid in control circuit every 2 years*
[Integral ABS] perform bleed test with BMW MoDiTeC
Check clutch fluid level
)
at the latest
)
)
)
)
)
)
)
40,000
40,000
every
2years
every
2years
every
2years
Change the clutch fluid*
every 2 years at the latest
Check tightness of rear wheel studs
Check rear wheel bearing play by tilting wheel
Check swinging arm bearings (freedom from play), adjust if necessary *
Grease the side stand pivot
Check function of side stand contact switch
Check condition of spark plugs
Replace spark plugs
Tighten cylinder head nuts
Check/adjust valve clearances
Check that the throttle cable moves freely and is free of kinks and chaffing, replace if necessary *
Check throttle-cable play
check synchronisation, repair leaks if necessary *
Final inspection with road safety and functional check:
– Condition of tyres and wheels, tyre pressures
– Lights and signalling equipment, telltale and warning lights, instruments,
– clutch, gearshift mechanism, hand brake and foot brake, steering,
– if necessary, test drive
)
*
Charged as an additional item
Order No. 01 71 0 029 614 UX-VS-2, 12.2000 Printed in Germany
)
every
2years
)
)
)
BMW Motorrad
Pre-delivery check
R 1100 S EVO / R 1150 R / R 1150 RT
Customer Registration No.
Order No. Mechanic’s signature
Check the shipping crate for damage
Motorcycle:
– unpack
– install remaining items
– inspect for damage
– check that delivery is complete: Toolkit
On-board literature
Ignition keys
Scope of optional extras
Fill and charge the battery (mark with charging date)
Check engine oil level when cold and correct if necessary.
BMW
Pre-delivery check
Check headlight setting and adjust if necessary.
Check tightness of rear wheel studs
(note correct tightening torque)
Check tyre pressures
Fill up with fuel
[Integral ABS] perform bleed test with BMW MoDiTeC
Final inspection as functional check:
– Clutch, gear shift
– Handbrake and foot brake
– Lights and signalling equipment, telltale and warning lights, instruments,
– Check operation of optional extras
– If necessary, test drive
Confirm pre-delivery check in “Service and Technical Booklet”.
Final cleaning
Motorcycle handed over on:
Order No. 01 71 0 029 614 UX-VS-2, 12.2000 Printed in Germany
BMW Motorrad
Service data
R 1150 RT
Oil capacities
Engine (with filter)
(without filter)
Item Desired value Unit of measure-
ment/specification
3.75 (6.6)
3.50 (6.15)
litres (Imp. pints)
litres (Imp. pints)
Engine oil grade: brand-name HD oil
for four-stroke spark-ignition engines,
API classes SE, SF, SG; combination
[SI 11 048 90]
with CC or CD specification
Transmission Initial filling
Oil changes
Rear wheel drive Initial filling/oil change
approx. 1.0 (1.76)
approx. 0.8 (1.41)
of oil to bottom edge of
filler neck
approx. 0.25 (0.44)
of oil to bottom edge of
filler neck
litres (Imp. pints)
litres (Imp. pints)
Brand-name hypoid gear oil, SAE
class GL 5 SAE 90
litres (Imp. pints)
Brand-name hypoid gear oil, SAE
class GL 5 SAE 90
Valve clearances
measured cold (max. 35 °C/95 °F)
Inlet: 0.15 (0.006)
Exhaust: 0.30 (0.012)
mm (in)
mm (in)
Ignition timing
static setting
adjust at TDC
Spark plugs
Electrode gap
Wear limit
Idle speed
0.8 (0.0315)
1.0 (0.039)
±50
1,100
mm (in)
mm (in)
rpm
Throttle cable setting
for cold-start (increased idle) speed
for throttle (twistgrip) cable
for divider cable
Brakes
Colour of identification mark on brake calipers/brake pads, front
Minimum front pad thickness
Minimum rear pad thickness
Minimum front disc thickness
Minimum rear disc thickness
Tyre pressures
depending on load
zero play
approx. 0.5 (0.02)
zero play
white
1.0 (0.039)
1.0 (0.039) (wear mark)
4.5 (0.177)
4.5 (0.177)
front: 2.2 – 2.5
(31.9 – 36.26)
rear: 2.5 – 2.9
mm (in) free travel
DOT 4 brake fluid
mm (in)
mm (in)
mm (in)
mm (in)
bar (psi)
bar (psi)
(36.26 – 42.06)
Tightening torques:
Oil filter
Engine oil drain plug
Gearbox oil filler plug
Gearbox oil drain plug
11
32
30
30
Nm
Nm
Nm
Nm
Rear wheel drive oil filler/drain plug 23 Nm
Fuel tank to rear frame
Fuel pump assembly to tank
Poly-V belt preload
Alternator to cover mount
Brake caliper fasteners, front
Brake caliper fasteners, rear
22
5
8
20
30
40
Nm
Nm
Nm
Nm
Nm
Nm
Rear wheel studs 105 Nm
Tightening cylinder heads
Nut
M 10 screw
unscrew/20
180
unscrew/40
Nm
° tightening angle
Nm
Locknut, valve adjusting screw 8 Nm
Cylinder head cover 8 Nm
Spark plugs NGK BKR 7 EKC 25 Nm
Order No. 01 71 0 029 621 UX-VS-2, 11.00 Printed in Germany
00
00 Tightening torque
Table of operating fluids
Contents Page
Tightening torque .........................................................................................................................3
11 Engine ...........................................................................................................................................3
12 Engine electrics ........................................................................................................................5
13 Fuel preparation and control ...............................................................................................5
16 Fuel tank and lines ...................................................................................................................5
18 Exhaust system .........................................................................................................................5
21 Clutch ............................................................................................................................................6
23 Transmission ..............................................................................................................................6
31 Front forks ...................................................................................................................................7
32 Steering ........................................................................................................................................7
33 Rear wheel drive .......................................................................................................................8
34 Brakes ...........................................................................................................................................9
36 Wheels and tyres ......................................................................................................................9
46 Frame ..........................................................................................................................................10
51 Equipment .................................................................................................................................11
61 General electrical equipment ............................................................................................11
Table of operating fluids .........................................................................................................12
00.1
00.2
00
Tightening torque
Model R 1150 RT
Connection
11 Engine
Cylinder head
Tightening sequence:
1 Tighten cylinder head nuts (oiled) in
diagonally opposite sequence
1.1 Tighten all nuts to closing torque Nm 20
1.2 Tighten all nuts to correct wrench
angle
1.3 Tighten all nuts to correct wrench
angle
2 M 10 screw Nm 40
3M6 screw Nm 9
After 1,000 km (600 miles), tighten cylinder
head nuts in diagonally opposite sequence:
1 Slacken one nut
2 Tighten nut to initial torque Nm 20
3 Tighten nut to wrench angle ° 180
4 Slacken and retighten M 10 screw Nm 40
Timing gear carrier to cylinder head Nm
Bearing cap on rocker shaft Nm 18
Locknut, valve adjusting screw Nm 8
Cylinder head cover to cylinder head Nm 8
Camshaft end cover to cylinder head Nm
° 90
° 90
9
9
Air intake connection to cylinder head Nm 9
Camshaft
Chain sprocket to camshaft Nm 65
Camshaft bearing cap Nm 15
Alternator mount cover
M 6 screw Nm 9
M 8 screw Nm 20
Auxiliary shaft
Chain sprocket to crankshaft Nm 10
Chainwheel to auxiliary shaft Nm 70
Chain tensioner housing to engine block Nm 9
00.3
Model R 1150 RT
Connection
11 Engine
Oil filter
Oil filter Nm 11
Oil drain plug Nm 32
Oil pump
Mesh filter basket to engine block Nm 10
Oil pump cover Nm 9
Pressure relief valve Nm 42
Oil pressure switch Nm 30
Oil cooler
Cooling oil line to engine block Nm 10
Cooling oil line banjo screw with oil vent
valve
Oil cooler to bracket Nm 9
Oil cooler return line to engine block Nm 35
Oil cooler connection to crankcase Nm 9
Cylinders
Tightening sequence:
1 M 8 screw Nm 20
2 M 6 screw Nm 9
3 Chain guide rail pivot screw Nm 18
Timing chain
Chain tensioner Nm 32
Connecting rod
Big end cap
Closing torque Nm 20
Wrench angle ° 80
Nm 25
Crankcase
Tightening sequence:
M 10 screw (oiled) to initial torque Nm 25
Wrench angle ° 90
M 8 screw Nm 22 (oiled)
M 6 screw Nm 9
00.4
Model R 1150 RT
Connection
12 Engine electrics
Starter motor to engine Nm 20
Positive lead to starter motor Nm 10
Alternator to generator support cover Nm 20
Tensioning and retaining link to alternator Nm 21
Spacer to alternator Nm 21
Positive lead to alternator Nm 15
Belt pulley to alternator Nm 50
Belt pulley to crankshaft Nm 50
Poly-V belt preload Nm 8
NGK BKR 7 EKC spark plug Nm 25
Model R 1150 RT
Connection
13 Fuel preparation and control
Oil temperature sensor to crankcase Nm 25
Air temperature sensor to air-filter housing Nm 10
Model R 1150 RT
Connection
16 Fuel tank and lines
Fuel tank to rear frame Nm 22
Fuel pump assembly to tank Nm 5
Model R 1150 RT
Connection
18 Exhaust system
Manifold to cylinder head Nm 21
Clamp for manifold Nm 45
(apply Optimoly TA to clamp seat)
Silencer to footrest plate Nm 35
Oxygen sensor to silencer Nm 45
(apply Optimoly TA to thread)
00.5
Model R 1150 RT
Connection
21 Clutch
Clutch housing
Initial tightening torque Nm 40
(oil screw threads lightly)
+ additional wrench angle °
Housing cover to housing Nm 12
Clutch line to handlebar fitting Nm 14
Slave cylinder to gearbox Nm 9
Grub screw in filler adapter Nm 10
Model R 1150 RT
Connection
23 Transmission
Oil drain plug Nm 30
Oil filler plug Nm 30
Gearbox to engine block Nm 22
Shift lever to footrest plate Nm 35
Selector lever to selector shaft Nm 9
Housing cover to housing Nm 9
Frame tube to gearbox
32
1. to gearbox and left footrest plate Nm 42
(clean thread + Loctite 243)
2. terminal block, frame tube to trans-
mission
3. to gearbox and right footrest plate Nm 42
Nm 9
(clean thread + Loctite 243)
00.6
Model R 1150 RT
Connection
31 Front forks
Quick-release axle clamp screws Nm 22
Sliding tube bridge to slider tube Nm 25
(clean thread + Loctite 243)
Threaded connection, fork fixed tube to
fork bridge
Threaded stud to frame Nm 130
Ball joint to sliding tube bridge Nm 230
Leading link
Leading link to ball joint
Initial tightening Nm 80
Final tightening Nm 130
Leading link to engine
Right 73
Left-hand screw cap 42
Spring strut
Spring strut to front frame Nm 43
Spring strut to leading link Nm 50
Nm 45
(free from oil and grease)
(clean thread + Loctite 243)
(lightly grease threads with Optimoly TA)
(clean thread + Loctite 2701)
(lightly grease threads with Optimoly TA
Model R 1150 RT
Connection
32 Steering
Handlebars to fork bridge Nm 21
Handlebar weight to handlebars Nm 21
Pivot screw, handlebar lever Nm 11
(Tuflok-Blau thread-locking compound; screw
can be released and tightened a number of
times)
00.7
Model R 1150 RT
Connection
33 Rear wheel drive
Rear axle differential
Oil filler plug Nm 23
Oil drain plug Nm 23
Threaded ring Nm 160
(clean thread + Loctite 577)
Hexagon nut, input bevel gear Nm
Cover to rear-wheel drive housing Nm 35
Swinging arm
Reaction link to rear wheel drive / gearbox Nm 43
Fixed bearing stud bolt,
Swinging arm to right rear axle housing
Floating bearing stud bolt,
Swinging arm to left rear axle housing
1. initial torque Nm 9
2. slacken
3. final torque Nm 7
Lock nut, floating bearing stud bolt,
Swinging arm to left rear axle housing
Fixed bearing stud bolt,
Swinging arm to right of transmission
200
(clean thread + Loctite 2701)
(load approx. 85 kg (187 lbs) onto motorcycle
and tighten loose reaction link)
Nm 160
(clean thread + Loctite 2701)
(clean thread + Loctite 2701)
Nm 160
Nm 160
(clean thread + Loctite 2701)
Floating bearing stud bolt,
Swinging arm to left of transmission
1. initial torque Nm 9
2. slacken
3. final torque Nm 7
(clean thread + Loctite 2701)
Lock nut, floating bearing stud bolt,
Swinging arm to left of transmission
Spring strut
Spring strut to rear frame Nm 50
Spring strut to rear swinging arm Nm 58
Hydraulic spring adjustment on rear frame Nm 22
Nm 160
(clean thread + Loctite 243)
00.8
Model R 1150 RT
Connection
34 Brakes
Front brake
Brake caliper to EVO brake sliding tube Nm 30
Front brake caliper bleed screw Nm
Brake disc to front wheel Nm 21
Pivot screw, handlebar lever Nm 11
Rear brake
Brake caliper to rear wheel drive Nm 40
Rear brake caliper bleed screw Nm
Brake disc to rear wheel drive Nm 21
Master cylinder to footrest plate Nm 9
Brake pedal to footrest plate Nm
Footbrake-lever stop Nm
Brake lines
Brake lines/brake hose to brake components
7
(clean thread + Loctite 2701)
(Tuflok-Blau thread-locking compound; screw
can be released and tightened a number of
times)
5
(clean thread + Loctite 2701)
21
(clean thread + Loctite 2701)
9
18
Nm
Brake hose to brake lever fitting Nm 18
Filler adapter to brake line Nm
Bracket to front frame Nm 9
Retainer to rear frame Nm 9
BMW Integral ABS
ABS pressure modulator on retainer Nm
ABS pressure modulator on battery carrier Nm 10
Model R 1150 RT
Connection
36 Wheels and tyres
Quick-release axle clamp screws Nm 22
Quick-release axle threaded fastener Nm 30
Rear wheel to rear wheel drive
screw wheel bolts finger-tight in a crosswise pattern
18
(clean thread + Loctite 2701)
7
Nm 105
00.9
Model R 1150 RT
Connection
46 Frame
Frame
Frame to engine Nm 82
Struts to frame Nm 58
Strut to engine Nm 58
(clean thread + Loctite 2701)
Rear frame to left/right of engine Nm 42
(clean thread + Loctite 2701)
Rear frame with footrest plate to left/right
of transmission
Fairing bracket to frame Nm 20
Side stand
Mounting bracket to right of engine, M 12
screw
Pivot mount to engine, left
M 12 screw Nm 72
M 8 screw Nm 21
Pivot mount of main (centre) stand (stud
bolt)
Pivot mount of main (centre) stand (machine screw)
Side stand to pivot mount Nm 58
Footrest plate
Footrest plate to left/right transmission Nm 19
Nm 42
(clean thread + Loctite 2701)
Nm 72
(clean thread + Loctite 2701)
(clean thread + Loctite 2701)
(clean thread + Loctite 2701)
Nm 21
(clean thread + Loctite 243)
Nm 21
(clean thread + Loctite 2701)
Footrest plate to left of rear frame
M 10 screw Nm 36
M 8 screw Nm 19
Footrest plate to right of rear frame
M 10 screw Nm 36
M 8 screw Nm 19
Shift lever to footrest plate Nm 35
00.10
Model R 1150 RT
Connection
51 Equipment
Ignition/steering lock to fork bridge Nm 20
(micro-encapsulated)
Model R 1150 RT
Connection
61 General electrical equipment
Horn to holder Nm 8
(clean thread + Loctite 243)
Horn to fairing bracket Nm 10
Ground (earth) strap to engine block Nm 9
Battery carrier to rubber-metal element Nm 8
Strut to battery carrier Nm 10
00.11
Table of operating fluids
Item Use Order number Quantity
Lubricant
Staburags NBU 30 PTM High-performance lubricating paste 07 55 9 056 992 75 g tube
Optimoly MP 3 High-performance lubricating paste 07 55 9 062 476 100 g tube
Optimoly TA High-temperature assembly paste 18 21 9 062 599 100 g tube
Silicone grease 300, heavy Damping grease 07 58 9 058 193 10 g tube
Retinax EP2
Contact spray Contact spray 81 22 9 400 208 300 ml spray
Chain spray Drive chain
Sealants
3-Bond 1110 B Surface sealant 07 58 9 056 998 5 g tube
3-Bond 1209 Surface sealant 07 58 9 062 376 30 g tube
OMNI VISC 1002 Surface sealant 07 58 1 465 170 90 g tube
Loctite 574 Surface sealant 81 22 9 407 301 50 ml tube
Loctite 577 Thread locking compound 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 Joint adhesive (narrow gap) 07 58 9 067 732 5 g bottle
Loctite 638 Joint adhesive (wide gap) 07 58 9 056 030 10 ml bottle
Loctite 243 Thread retainer, medium-strength 07 58 9 056 031 10 ml bottle
Wheel, steering head and taper roller
bearing grease
83 22 9 407 845 100 g tube
72 60 2 316 676
72 60 2 316 667
50 ml spray
300 ml spray
Loctite 270 Thread retainer, strong 81 22 9 400 086 10 ml bottle
Loctite 2701 Thread retainer, strong 33 17 2 331 095 10 ml bottle
Loctite 454 Cyanacrylate adhesive (gel) 07 58 9 062 157 20 g tube
Cleaners
Brake cleaner Brake cleaner 83 11 9 407 848 600 ml spray
Metal Polish Polish for chrome-plated parts 82 14 9 400 890 100 g tube
Testing agents
Penetrant MR 68
Developer MR 70
Installation aids
BMW cooling spray Cooling spray 83 19 9 407 762 300 ml spray
Crack testing agent for aluminium
housings
Crack testing agent for aluminium
housings
83 19 9 407 855 500 ml spray
81 22 9 407 495 500 ml spray
00.12
00
00 Pre-delivery check
Contents Page
General view of crated motorcycle ...................................................................................15
Checking the crated motorcycle for damage .............................................................16
In case of damage in Germany ...............................................................................................16
In case of damage in importer markets ..............................................................................16
Unpacking the motorcycle ....................................................................................................16
Assembling the motorcycle ..................................................................................................17
Installing the front wheel ............................................................................................................17
Installing front mudguard ...........................................................................................................17
Filling and charging the battery ...............................................................................................18
Installing cover for windscreen adjuster and installing windscreen ........................20
Installing mirrors ............................................................................................................................20
Assembling case ...........................................................................................................................20
Inspecting motorcycle for damage ...................................................................................21
Checking that delivery is complete ..................................................................................21
Checking engine oil level when cold, adding oil if necessary ...........................21
Checking tightness of rear wheel studs ........................................................................21
Checking tyre pressures .........................................................................................................21
Checking headlight beam angle, adjusting if necessary ......................................22
[Integral ABS] Performing bleed test with BMW MoDiTeC ..................................23
Final inspection and function check ................................................................................23
Final cleaning ................................................................................................................................23
Handing over the motorcycle ...............................................................................................24
00.13
00.14
00
General view of crated motorcycle
W
M
B
M
B
W
R22009010
00.15
Checking the crated motorcycle for damage
When the motorcycle arrives, check the crated
•
motorcycle immediately for damage and, if necessary, examine the contents for consequential
damage.
In case of damage in Germany
Note the damage on the delivery slip.
•
Read the information sheet on damage in transit.
•
Notify the supplier without delay (e.g. freight
•
company or DB) and also
Bavaria Wirtschaftsagentur GmbH
Abteilung ZW - 12
80788 München
Tel. +49 89/14327-632
Fax. +49 89/14327-709
Unpacking the motorcycle
Lever off the cover.
•
Remove plastic covers.
•
Take out the separate pack of items:
•
– Front wheel
– Case lid
– Aerial
– Windscreen
– Covers
– Engine spoiler
– Cover for windscreen adjuster
– Front mudguard
– Mirrors
– Small parts/fasteners
– Documentation
Remove the set of keys from the left rear footrest.
•
Force off cross-struts with a suitable lever.
•
In case of damage in importer markets
Note the damage on the delivery slip.
•
Comply with specific national market proce-
•
dures.
In case of doubt, please submit enquiries to:
Bavaria Wirtschaftsagentur GmbH
Abteilung ZW - 12
D-80788 München
Tel. +49 89/14327-632
Fax. +49 89/14327-709
Notify the supplier (e.g. freight company) without
•
delay.
e Attention:
Do not knock the cross-struts out or the motorcycle
may be damaged.
Remove the end-walls.
•
Remove the side-walls.
•
e Attention:
Remove any nails projecting from the base of the
crate or lying on the base or on the floor.
Dispose of the packing materials in an environ-
•
mentally responsible manner as described in Circular 23/91 - Sales.
00.16
Assembling the motorcycle
Installing the front wheel
e Attention:
Degrease all brake discs.
Remove front straps.
•
R22000010
Using the straps, secure the front of the motor-
•
cycle to the assembly crane,
BMWNo.465640.
1
3
2
A
B
R22000020
Install the front wheel with spacer (1) and speed-
•
ometer drive (2).
e Attention:
Locate stop on slider tube (A) in recess in speedometer drive (B).
Tighten the retaining screw (3).
•
Install the front brake calipers.
•
Release the motorcycle from the assembly
•
crane, BMW No. 46 5 640.
Compress the front fork firmly several times.
•
Tighten the clamp screws.
•
e Attention:
Do not damage the brake lines, Bowden cables and
fairing panels.
Raise the front of the motorcycle.
•
e Attention:
Make sure that the motorcycle cannot topple sideways.
Remove rear straps.
•
Using the assembly crane, BMWNo.465640,
•
carefully push the motorcycle forward off the pallet.
Extend the main stand and lower the motorcycle
•
until it is resting firmly on the main stand and the
rear wheel.
d Warning:
Integral ABS When removing and installing the
brake calipers, carefully force back the pistons only
far enough to ensure that the wheel-circuit reservoir
does not overflow.
If fluid escapes, top up the level in the wheel-circuit
reservoir to “MAX” mark.
d Warning:
The brakes are not ready for use until the brake
pads have been bedded against the brake discs
with the ignition switched on.
X Tightening torque:
Bolt of quick-release axle ............................ 30 Nm
Clamping screws of quick-release axle ....... 22 Nm
Brake caliper to fork slider ........................... 30 Nm
Installing front mudguard
Remove screws securing the front brake cali-
•
pers.
L Note:
Do not apply handbrake lever or footbrake lever with
brake calipers removed/front wheel removed.
R22000030
00.17
4x
2x
Filling and charging the battery
Remove seat.
•
Remove left side fairing panel.
•
Remove the air filter cover.
•
Remove air intake pipe.
•
Disengage the rubber strap holding the battery.
•
4x
3x
4x
R22460020
d Warning:
Battery acid is highly caustic.
It must not contact the eyes, face hands, clothing or
the motorcycle’s paintwork.
Fill all the cells with pure battery acid of
•
density 1.28 to the upper mark.
Allow the battery to stand for approximately
•
30 minutes.
Disconnect the battery breather hose.
•
Pull the battery to the left to remove.
•
00.18
R22000040
The battery 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 battery charger.
Charge current (amps)
.........................10 % of rated battery capacity (Ah)
Charging time
............................................................. 5-10 hours
Battery charge can be measured by checking
•
the density of the battery acid.
Acid density
Battery full charged
............1.26-1.30 at a temperature of 20 °C (68 °F)
Shake the battery slightly to allow the gas bub-
•
bles to escape.
Wait until the battery acid has settled, check that
•
no more bubbles rise and if necessary, top up
the acid to the max. mark.
Reinstall the plugs.
•
Make a note of the charging date on the battery.
•
Switch on the ignition.
•
L Note:
After switching on the ignition, always wait for the
BMW Integral ABS to complete its self-diagnosis.
Do not operate the brake lever until self-diagnosis
has completed.
With the ignition switched on, bed in the brake
•
pads against the brake discs.
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 means that the entries in
the fault memory of the Motronic MA2.4 control unit
are deleted and the adaptation values are reset.
This can temporarily impair the operating characteristics when the engine is restarted.
R22000050
e Attention:
Connect the positive battery terminal first, then the
negative terminal.
Connect the positive cable, coat with acid-proof
•
grease and install the protective cap.
Install the battery.
•
Connect the negative cable and coat with acid-
•
proof grease.
Assembly is the reverse of the disassembly pro-
•
cedure.
Install the left side fairing panel.
•
Install the engine spoiler.
•
Install the covers.
•
00.19
Installing cover for windscreen adjuster and installing windscreen
R22000060
Install the cover for the windscreen adjuster.
•
Install windscreen with washers.
•
Install the aerial.
•
Installing mirrors
Assembling case
R22000070
Position the lid on the case for alignment. Open
•
the hinges of the lid and guide them into the base
with the guide hook.
From the inside, insert the pop rivets into the
•
base and the hinges.
– 2x long rivets in hinge at rear, as viewed in for-
ward direction of travel.
– 2x short rivets in hinge at front, as viewed in for-
ward direction of travel.
Engage riveting tool on rivets, hold the hinge at
•
the outside to keep it in position and secure all
four rivets.
Oil the seal in the bottom of the case, using the
•
sponge provided for the purpose.
RT460280
Connect the turn indicators.
•
Position the mirror at the 3 attachment points.
•
Engage by pressing at the front first, then the
•
rear.
e Attention:
Make sure that the seal is not squeezed out of
shape and that the lid closes without catching.
Carefully close the case.
•
Insert the lock cylinder into the case with the key
•
in the lock and turn the lock.
Affix the stickers.
•
00.20
Inspecting motorcycle for damage
Check for defects.
•
Use the “express handling service” to notify
•
BMW Motorrad,
UX-VS-1
Fax: + 49 89-382-33220
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 damaged 10 02 00 00 00
– Incorrect parts delivered 10 03 00 00 00
Checking that delivery is complete
– All optional extras
– Toolkit
– Documentation
Checking engine oil level when cold, adding oil if necessary
L Note:
The difference between the oil level indicated when
the engine is at operating temperature and the oil
level indicated when the engine is very cold due to
extremely low outdoor temperatures can be as
much as 10 mm (0.3937 in).
Checking tightness of rear wheel studs
X Tightening torque:
Securing screws for rear wheel .................. 105 Nm
Checking tyre pressures
Check/correct tyre pressures.
•
Tyre pressures:
one-up ............................... front 2.2 bar (31.90 psi)
........................................... rear 2.5 bar (36.26 psi)
two-up ............................... front 2.5 bar (36.26 psi)
........................................... rear 2.9 bar (42.06 psi)
two-up + luggage............... front 2.5 bar (36.26 psi)
........................................... rear 2.9 bar (42.06 psi)
R22000080
Check oil level with the motorcycle upright.
•
e Attention:
Never top up the engine-oil level past the “MAX”
mark.
Required level:............................................... MAX
BMW recommends Castrol
00.21
Checking headlight beam angle, adjusting if necessary
1
R22000090
Motorcycle on level surface.
•
Rider’s weight on motorcycle
•
(approx. 85 kg/187.4 lbs).
Turn knob (1) counter-clockwise as far as it will
•
go.
Check headlight beam throw.
•
2
R22000110
Turn screw (2) to adjust beam throw, if neces-
•
sary.
Direction of rotation, left.....................further/higher
Direction of rotation, right.................shorter/deeper
R22000100
Setting for headlight beam angle adjuster
... .-10 cm (-3.937 in) at a distance of 10 m (32.8 ft)
00.22
Integral ABS Performing bleed test
with BMW MoDiTeC
d Warning:
Self-diagnosis is not performed unless both brake
levers are in their fully released positions. Prior
to conclusion of the self-diagnosis, only RESIDUAL
BRAKING FUNCTION is available.
Perform BMW Integral ABS self-diagnosis:
Release the brake levers, if necessary.
•
Switch on the ignition.
•
With the ignition switched on, bed in the brake
•
pads against the brake discs.
ABS warning light.............................flashes at 4 Hz
General warning light ........................................ ON
– Self-diagnosis is in progress
ABS warning light.............................flashes at 1 Hz
General warning light ....................................... OFF
– Self-diagnosis successfully completed.
Perform bleed test with BMW MoDiTeC:
Remove front and rear seats.
•
Connect the BMW MoDiTeC to the diagnosis
•
connector.
d Warning:
When performing maintenance and repair work on
BMW Integral ABS, never pump quickly or vigorously.
Final inspection and function check
Clutch
•
Check gear shift action.
•
Handbrake and foot brake
•
Check lights and signalling equipment:
•
– Front and rear parking lights
– Instrument lighting
– Low and high headlight beams, headlight flasher
– Fog lamps
– Brake light (operate brake at front and rear)
– Turn signals left/right
– Hazard warning lights
– Horn
– Telltale and warning lights
– Instruments
Check operation of optional extras.
•
If necessary, take the motorcycle for a test ride.
•
Confirm pre-delivery check in Service and Tech-
•
nical Booklet.
See “Checking motorcycle for damage” if defects
•
are found.
Final cleaning
Clean the motorcycle.
•
L Note:
Do not use a steam or high-pressure water jet. The
high steam or water pressure could damage seals,
the hydraulic system or electrical components.
Perform bleed test.
•
Perform all requisite repair work.
•
Perform BMW Integral ABS pull-away test:
When a speed of 5 km/h (3 mph) is reached, the
•
ABS warning light must go out.
L Note:
The ABS warning light and the general warning light
must both be OFF after successful self-diagnosis
and the pull-away test.
00.23
Handing over the motorcycle
This is the ideal opportunity to familiarise the customer with the motorcycle in order to ensure the
customer’s satisfaction and safety.
The following points must be demonstrated and
•
explained to the customer:
– documentation and stowage space
– toolkit and stowage space
– suspension preload adjustment to suit total
weight
– checking brake fluid/clutch operating fluid
– provision for adjusting handlebars lever positions
– procedure for adjusting seat
– how to adjust the mirrors
– controls
– instruments and telltale lights
– optional equipment and accessories fitted
– features of BMWIntegralABS:
brake servo,
residual braking function,
pump noises,
self-diagnosis with pull-away test.
The user must be given the following information:
•
– running-in recommendations and inspection in-
tervals
– safety check
– features of BMWIntegralABS:
fully integral brake,
brake-fluid levels in the control circuits remain
constant despite brake-pad wear.
– the clutch fluid level rises gradually as the motor-
cycle is ridden (clutch lining wear)
– Always check the oil level when the engine is at
operating temperature, because the difference
between the oil level indicated when the engine
is at operating temperature and the oil level indicated when the engine is very cold due to extremely low outdoor temperatures can be as
much as 10 mm (0.3937 in). After switching off
the engine at operating temperature, wait at least
5 minutes for the oil to drain back into the sump.
Checking the oil level just after the engine has
been run or when it is not properly warm will falsify the reading.
00.24
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