Bmw R1150GS (2000) User Manual [ru]

Repair Manual

R 1150 GS

BMW Motorrad

After Sales

Publisher	© 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.

Printed in Germany 02/00

Order number 01 79 0 021 120

Introduction

This Repair Manual will help you to perform all the main maintenance and repair work correctly and efficiently. It should be consulted regularly by workshop personnel as an addition to the practical and theoretical knowledge obtained in Training School courses. It is a contribution towards achieving even higher Service quality.

A new issue of this repair manual will be published if amendments or additions (supplements) are needed. The latest issue date is shown in the header of the microfiche. Microfiches rendered invalid by the new issue should be destroyed without delay.

All information in both text and illustrations refers to motorcycles in standard condition or with genuine BMW accessories installed, and not to motorcycles which have been modified in any way to depart from the manufacturer’s specification.

●The Repair Manual is structured in the logical sequence of the work to be performed: Removal, Disassembly, 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 be performed during an Inspection is described in Group “00”. The various inspection routines are numbered I, II, III and IV. This numbering is repeated in the work descriptions which follow, so that work can take place without interruption.

●Use of the BMW special tools needed for certain tasks is described in the work instructions.

If the need arises, repair instructions are also issued in the form of Service Information. This information is of course incorporated into the next issue of the Repair Manual. We also recommend you to consult the detailed illustrations on the Parts microfiches as an additional source of information.

BMW Motorrad

After Sales

Published by:	BMW Motorrad
	Hufelandstr. 6
	D - 80937 München

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 Germany

BMW Motorrad

Maintenance schedule

R 1100 S / R 850/1200 C / R 1150 GS

InspectionBMW

km1000at

miles)(600

ServiceBMW 00010everykm miles)000(6

InspectionBMW 00020everykm miles)000(12

BMW ServiceAnnual

Customer

Licence plate No.

Order No.

Mechanic’s signature

Read the fault code memory with the MoDiTeC

Change oil while at regular operating temperature and renew the oil filter element

if motorcycle is used only for short journeys or at outside temperatures under 0°C (32 °F), every

3 months, but at least every 3 000 km (1 800 miles) *)

Change oil in gearbox while at operating temperature

every

at least every 2 years*)

2 years

Change oil in rear wheel drive while at regular operating temperature;

if necessary, clean inductive sensor on rear wheel

40 000

every

every 40 000 km (24 000 miles) or at least every 2 years *)

(24 000)

2 years

Renew fuel filter *)

40 000

normally every 40 000 km (24 000 miles), if fuel quality is poor every 20 000 km (12 000 miles)

(24 000)

Check battery acid level, if necessary add distilled water

Clean and grease the battery terminals, if necessary

Renew intake air filter element

in very dusty or dirty operating conditions, renew the intake air filter element every 10 000 km

(6 000 miles) or even more often if necessary *)

Renew Poly-V belt *)

60 000

renew Poly-V belt every 60 000 km (36 000 miles); do not adjust

(36 000)

Check brake fluid level at front and rear

Check operation of brake system and freedom from leaks; repair/replace items if nec. *)

Examine brake pads and discs for wear, renew if necessary *)

Change the brake fluid annually

Check clutch fluid level

Change the clutch fluid

every

at least every 2 years *)

2 years

Check tightness of rear wheel studs

Check rear wheel bearing play by tilting wheel

Check swinging arm bearings (zero play); adjust if necessary *)

Grease the side stand pivot

Check function of side stand contact switch

Check condition of spark plugs

Renew spark plugs

Check security of cylinder head nuts

Check/adjust valve clearances

Check throttle cable for free movement, abrasion and kinking; renew if necessary *)

Check cable play

Check synchronisation and eliminate leaks *)

Final inspection with road safety and functional check:

– Condition of tyres and wheels, rims and spokes if applicable, tyre pressures

– Lights and signalling equipment

– Telltale and warning lights

–

Clutch, gear shift

– Front and rear brakes, steering

–

Instruments

–

If necessary, test ride

*)

Charged as an additional item

UX-VS-2, 04.00

Printed in Germany

BMW Motorrad Pre-delivery check

R 1100 S / R 850/1200 C / R 1150 GS

	Customer	Licence plate No.
	Order No.	Mechanic’s signature

BMW

Pre-delivery check

Check the shipping crate for damage

Motorcycle:

–	unpack
–	install remaining items
–	inspect for damage
–	check that delivery is complete:	tools
		documentation
		keys
		correct optional extras

Fill and charge the battery (mark with charging date)

Check engine oil level 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 inspection as functional check:

–Clutch, gear shift

–Front and rear brakes

–Lights and signalling equipment, telltale and warning lights, instruments

–Check operation of optional extras, ABS

–If necessary, test ride

Confirm pre-delivery check in Service and Technical Booklet

Final cleaning

Motorcycle handed over on:

UX-VS-2, 04.00

Printed in Germany

BMW Motorrad

Service data

R 1150 GS

		Item		Desired value		Unit of measurement/
						specification
Oil capacities				3.75 (6.60)		litres (Imp. pints)
Engine	(with filter)
	(without filter)			3.50 (6.16)		litres (Imp. pints)
						[SI 11 048 90]
						Engine oil grade: brand-name HD oil for
						four-stroke spark-ignition engines, API
						classes SE, SF, SG; combination with CC
						or CD specification
Gearbox		Initial filling/oil changes		approx. 1.0 (1.76)		litres (Imp. pints)
				up to lower edge of
						Brand-name hypoid gear oil, SAE class
				filler hole		GL 5 SAE 90
Rear wheel drive		Initial filling/oil changes		approx. 0.25 (0.44)		litres (Imp. pints)
				oil level with bottom		Brand-name hypoid gear oil, SAE class
				of filler neck		GL 5 SAE 90
Valve clearances
Measured cold (max. 35 °C/95 °F)				Inlet: 0.15 (0.006)		mm (in)
				Exhaust: 0.30 (0.011)		mm (in)
Ignition timing				adjust at TDC
Static setting
Spark plugs				0.8 (0.03)		mm (in)
Electrode gap
Wear limit				1.0 (0.04)		mm (in)
Idle speed				1100± 50		min-1
Throttle cable setting				zero play
for cold-start (increased idle) speed						mm (in) free travel
for throttle (twistgrip) cable				app. 0.5 (0.02)
for divider cable				zero play
Brakes				1.0 (0.04)		DOT 4 brake fluid
Minimum front pad thickness						mm (in)
Minimum rear pad thickness				wear mark		mm (in)
Minimum front disc thickness				4.5 (0.18)
Minimum rear disc thickness				4.5 (0.18)		mm (in)
Tyre pressures				front: 2.2 – 2.5		bar (psi)
depending on load				(31.3 – 35.6)
				rear: 2.5 – 2.9		bar (psi)
				(35.6 – 41.2)
Tightening torques:				11		Nm
Oil filter
Engine oil drain plug				32		Nm
Gearbox oil filler plug				30		Nm
Gearbox oil drain plug				30		Nm
Rear wheel drive oil filler/drain plug				23		Nm
Fuel tank to rear frame				21		Nm
Fuel pump unit to tank				6		Nm
Poly-V belt preload				8		Nm
Alternator to alternator carrier cover				20		Nm
Brake calliper mounting, front/rear				40		Nm
Rear wheel studs				initial torque 72		Nm
				105		Nm
Tightening cylinder heads Nut				slacken/20		Nm
				180		° tightening angle
		M 10 screw		slacken/40		Nm
Locknut, valve adjusting screw				8		Nm
Cylinder head cover				8		Nm
Spark plugs				20		Nm

Order No. 01 71 0 008 851

UX-VS-2, 06.99

Printed in Germany

General table of contents

<< Back

Group / Section

Group / Section

00 Maintenance and general instructions

11Engine

12Engine electrics

13Fuel preparation and control

16Fuel tank and lines

18Exhaust system

21Clutch

23Transmission

31Front forks

32Steering

33Rear wheel drive

>> Next

>> Next

Group / Section

Group / Section

34 Brakes

36 Wheels and tyres

46 Frame

51Equipment

52Seat

61 General electrical equipment

62Instruments

63Lights

<< Back

00

00 Maintenance and general instructions

Tightening torques and table of consumables Pre-delivery check

Maintenance

Contents	Page
Tightening torques .......................................................................................................................	5
Table of operating fluids .........................................................................................................	12

00.1

Pre-delivery check

Contents - Pre-delivery check

Page

Pre-delivery check .....................................................................................................................	13
General view of crated motorcycle ...................................................................................	13
Check the shipping crate for damage ............................................................................	14
In case of damage in Germany ...............................................................................................	14
In case of damage in importer markets ..............................................................................	14
Unpacking the motorcycle ....................................................................................................	14
Inspecting motorcycle for damage ...................................................................................	15
Checking that delivery is complete ..................................................................................	15
Installing remaining 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
Checking engine oil when engine is cold, topping up if necessary ...............	19
Checking headlight beam angle, adjusting if necessary ......................................	20
Checking tightness of rear wheel studs ........................................................................	20
Checking tyre pressures ........................................................................................................	20
Attaching adhesive label ........................................................................................................	20
Final inspection and function check ................................................................................	21
Final cleaning ...............................................................................................................................	21
Handing over the motorcycle ...............................................................................................	21

00.2

........................................................................................28

....................................................................................................26

Maintenance
Contents - Maintenance	Page
Maintenance ..................................................................................................................................	22
Key to maintenance intervals ..............................................................................................	22
Reading out MoDiTeC fault memory ................................................................................	22
(Inspections I, II, III and IV)
Changing engine oil, replacing oil filter element ......................................................	22
(Inspections I, II, III and IV)
Changing oil in gearbox ..........................................................................................................	23
(Inspections III and IV)
or at the latest every 2 years
Changing the oil in the rear wheel drive ........................................................................	23
(Inspections I, III and IV)
Every 40,000 km (24,000 miles) or at the latest every 2 years
Replacing fuel filter ...................................................................................................................	24
(Inspection III)
In normal operating conditions every 40,000 km (24,000 miles); if fuel quality is poor every
20,000 km (12,000 miles)

Checking battery fluid level and topping up if necessary; cleaning and greasing the battery posts

(Inspections III and IV)

Replacing intake air filter element ....................................................................................	26
(Inspection III)
In very dirty and dusty operating conditions, replace every 10,000 km (6,000 miles) or even
more frequently if necessary
Replacing Poly-V belt ...............................................................................................................	27
(Inspection III)
(every 60,000 km/36,000 miles)

Checking brake system for correct operation and freedom from leaks; repairing/replacing if necessary

(Inspection III)

Checking brake fluid level .....................................................................................................	28
(Inspections II and III)
Front brake .......................................................................................................................................	28
Rear brake ........................................................................................................................................	28
Checking brake pads and discs for wear/replacing ...............................................	29
(Inspections II and III)
Checking front brake pad wear ..............................................................................................	29
Checking rear brake pad wear ................................................................................................	29
Checking brake disc wear ........................................................................................................	29
Replacing brake pads, front brake ........................................................................................	30
Replacing brake pads, rear brake .........................................................................................	30

00.3

Contents - Maintenance	Page
Changing brake fluid and bleeding brake system ....................................................	31
Change the brake fluid annually
(Inspection IV)
Bleeding front brake circuit/changing brake fluid ...........................................................	31
Additional information for [ABS]
Bleeding rear brake circuit/changing brake fluid ............................................................	33
Checking clutch operating fluid level ..............................................................................	34
(Inspections II and III)
Changing the clutch fluid .......................................................................................................	34
(Inspections IV)
at the latest every 2 years
Checking tightness of rear wheel studs ........................................................................	35
(Inspection I)
Checking rear wheel bearing play by tilting wheel ..................................................	35
(Inspection III)
Checking 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 and IV)
Checking/replacing spark plugs ........................................................................................	36
(Inspection II) check/(Inspection III) replace
Tightening cylinder heads .....................................................................................................	37
(Inspection I)
Checking/adjusting valve clearances .............................................................................	37
(Inspections I, II and III)
Checking freedom of throttle cable, checking for chaffing and kinks,
replacing if necessary
Checking throttle-cable play
Checking and adjusting idle speed and throttle-valve synchronisation	......38
(Inspections I, II and III)
Final inspection with road safety and functional check .......................................	39
(Inspections I, II, III and IV)
Road safety check
Roadworthiness check

00.4

00

Tightening torques

Model	R 1150 GS
Connection	Nm

11 Engine

Cylinder head
Tightening sequence:
1.	Tighten cylinder head nuts (oiled) in diagonally
	opposite sequence
	1.1 Tighten all nuts to closing torque		20
	1.2 Tighten all nuts to correct angle	90°
	1.3 Tighten all nuts to correct angle	90°
2.	M 10 screw		40
3.	M 6 screw		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		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 adjusting screw			8
Cylinder head cover to cylinder head			8
Camshaft end cover to cylinder head			9
Air intake connection to cylinder head			9
Camshaft
Chain sprocket to camshaft			65
Camshaft bearing cap			15
Alternator mount cover
M 6 screw			9
M 8 screw			20
Auxiliary shaft
Chain sprocket to crankshaft			10
Chainwheel to auxiliary shaft			70
Chain tensioner housing to engine block			9
Oil filter
Oil filter			11
Oil drain plug			32

00.5

		Model			R 1150 GS
		Connection			Nm
		11 Engine
		Oil pump
		Mesh filter basket to engine block			10
		Oil pump cover			9
		Pressure relief valve			42
		Oil pressure switch			30
		Oil cooler
		Cooling oil line to engine block			10
		Cooling oil line - banjo screw with oil vent valve			25
		Oil lines to oil cooler			25
		Oil cooler to bracket			9
		Oil cooler return line to engine block			35
		Oil cooler connection to 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°
		Crankcase
		Tightening sequence:
		M 10 screw (oiled)	Initial torque		25
			Wrench angle	90°
		M 8 screw (oiled)			22
		M 6 screw			9
		12 Engine electrics
		Starter motor to engine			20
		Starter cover to gearbox housing			7
		Positive lead to starter motor			10
		Alternator to alternator support cover			20
		Tensioning and retaining link to alternator			21

00.6

Model			R 1150 GS
Connection			Nm
12 Engine electrics
Spacer to alternator			21
Positive lead to alternator			15
Belt pulley to alternator
Standard alternator 560 W			Do not release
Special alternator 700 W			50
Belt pulley to crankshaft			50
Poly-V belt preload			8
Spark plug			20
13 Fuel preparation and control
Temperature sensor, oil, in crankcase			25
Temperature sensor, air, in air-filter housing			10
16 Fuel tank and lines
Fuel tank to rear frame			21
Fuel pump assembly 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-stand link			20
Silencer to rear frame at top			35
Oxygen sensor to silencer			45	(apply Optimoly TA to thread)
End cap to rear silencer			8 (threads greased)
Bracket to rear silencer			15	(threads greased)
21 Clutch
Clutch housing	Closing torque		40	(oil screw threads lightly)
	Wrench angle	32°
Housing cover to housing			12
Clutch line to handlebar fitting			14
Slave cylinder to gearbox			9
Grub screw in filler adapter			10

00.7

		Model			R 1150 GS
		Connection			Nm
		23 Transmission
		Oil drain plug			30
		Oil filler plug			30
		Gearbox to engine block			22
		Shift lever to footrest plate			35
		Selector lever to selector shaft			9
		Housing cover to housing			9
		Frame tube to gearbox
		1.	to gearbox and left footrest plate		42	(clean thread + Loctite 243)
		2.	clamp block, frame tube to gearbox		9
		3.	to gearbox and right footrest plate		42	(clean thread + Loctite 243)
		31 Front forks
		Quick-release axle clamp screws			22
		Fastener, fixed tube and fork bridge			45	(free from 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 to thread)
		Leading link to ball joint			130 (clean thread + Loctite 2701)
		Leading link to engine		right	73
		Screw cap to leading link		left	42	(apply light coat of Never Seeze to thread)
		Suspension strut to front frame			43
		Spring strut to leading link			50
		32 Steering
		Handlebar to fork bridge			21
		Handlebar weight to handlebar			21
		Pivot screw, handlebar lever			11	(Tuflok Blue thread-locking compound; screw
					can be released and tightened a number of times)

00.8

Model	R 1150 GS
Connection	Nm
33 Rear wheel drive
Oil filler plug	23
Oil drain plug	23
Threaded ring	160 (clean thread + Loctite 577)
Hexagon nut, input bevel gear	200 (clean thread + Loctite 2701)
Cover to rear-wheel drive housing	35
Fixed bearing stud, swinging arm to
gearbox/rear axle housing	160 (clean thread + Loctite 2701)
Floating bearing stud, swinging arm to
gearbox/rear axle housing	7	(clean thread + Loctite 2701)
Locknut of floating bearing stud bolt	160
Reaction link to rear wheel drive	43
	(load approx. 85 kg (187 lbs) onto motorcycle and
	tighten loose reaction link)
Reaction link to gearbox	40
	(load approx. 85 kg (187 lbs) onto motorcycle 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
Brake caliper to fork slider tube	40
Brake caliper to rear wheel drive	40
Brake disc to front wheel	24 (clean thread + Loctite 243)
Brake disc to rear wheel drive	21 (clean thread + Loctite 243)
Master cylinder to footrest assembly	9
Footbrake lever to footrest assembly	21
Footbrake-lever stop	9
Brake lines/brake hose to brake components	18
Brake hose to bracket	9
Brake hose to brake lever fitting	18
Hose bracket to helmet lock	9
Bracket to front frame	9
Bracket to rear frame	9	(clean thread + Loctite 2701)
Bracket to fork bridge	5	(clean thread + Loctite 2701)
ABS sensor	4	(handtight)

00.9

		Model	R 1150 GS
		Connection	Nm
		34 Brakes
		Front brake caliper bleed screw	14
		Rear brake caliper bleed screw	6
		Pressure modulator bleed screw	14
		Filler adapter in brake caliper	18 (clean thread + Loctite 243 or new filler adapter)
		Grub screw in filler adapter	10
		ABS unit to holder
		M 6 screw	8 (clean thread + Loctite 243)
		36 Wheels and tyres
		Quick-release axle clamp screws	22
		Quick-release axle threaded fastener	30
		Rear wheel to rear-wheel drive
		Hand-tighten wheel studs, then tighten in diagonally
		opposite sequence
		Initial tightening	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	58 (clean thread + Loctite 2701)
		Rear frame to gearbox/engine
		to gearbox and footrest plate	42	(clean thread + Loctite 243)
		to engine	42
		Carrier plate for main stand to engine, right
		M 12 screw	72 (clean thread + Loctite 2701)
		Pivot mount to engine, left
		M 12 screw	72 (clean thread + Loctite 2701)
		M 8 screw	21
		Pivot mount of main (centre) stand (stud bolt)	21	(clean thread + Loctite 243)
		Pivot mount of main (centre) stand (machine screw)	21
		Side stand to pivot mount	58	(clean thread + Loctite 2701)

00.10

Model		R 1150 GS
Connection		Nm
46 Frame
Footrest plate to gearbox/
Rear footrest plate to rear frame
M 8 screws		21
Fairing bracket to front frame		21
Front carrier to fairing bracket		8
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 (micro-encapsulated)
61 General electrical equipment
Horn to holder		10 (clean thread + Loctite 243)
Ground (earth) strap to engine block		9

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	Wheel, steering head and taper roller	83 22 9 407 845	100 g tube
			bearing grease
		Contact spray	Contact spray	81 22 9 400 208	300 ml spray
		Chain spray	Drive chain	72 60 2 316 676	50 ml spray
				72 60 2 316 667	300 ml spray
		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 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	Joint adhesive (low clearance)	07 58 9 067 732	5 g bottle
		Loctite 638	Joint adhesive (greater clearance)	07 58 9 056 030	10 ml bottle
		Loctite 243	Thread retainer, medium-strength	07 58 9 056 031	10 ml bottle
		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	Crack testing agent for aluminum	83 19 9 407 855	500 ml spray
			housings
		Developer MR 70	Crack testing agent for aluminum	81 22 9 407 495	500 ml spray
			housings
		Installation aids
		BMW cooling spray	Cooling spray	83 19 9 407 762	300 ml spray

00.12

Pre-delivery check

General view of crated motorcycle

00.13

Check the shipping crate for damage

•When the motorcycle arrives, check the packing material 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

D-80788 München Tel. [phone] Fax. [phone]

In case of damage in importer markets

•Note the damage on the delivery slip.

•Comply with specific national market procedures.

In case of doubt, please submit enquiries to: Bavaria Wirtschaftsagentur GmbH

Abteilung ZW - 12 D-80788 München

Tel. [phone] Fax. [phone]

•Notify the 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 with a suitable lever.

eCaution:

Do not knock the cross-struts out or the motorcycle may be damaged.

•Remove the end-walls.

•Remove the side-walls.

eCaution:

Remove any nails projecting from the base of the packing or lying on the base or on the floor.

•Loosen the front tensioning straps.

•Release the handlebar and resecure in correct position (punch marks aligned).

eCaution:

Do not push the motorcycle until the handlebar has been secured in the correct position.

X Tightening torque:
Handlebar to fork bridge ..............................	21 Nm

•Loosen the rear tensioning straps.

•Push the motorcycle forwards off the pallet.

•Remove the set of keys from the left rear footrest.

•Dispose of the packing materials in an environmentally responsible manner as described in Service Information 23/91 - Sales - .

00.14

Inspecting motorcycle for damage

•Check for defects.

•Use the “express handling service” to notify BMW Motorrad, UX-VS-1

Fax:

[phone]

•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

00.15

R21000070

Installing remaining items on motorcycle

Install the windscreen

• Carefully tighten the securing screws by hand.

00.16

Installing sump guard

• Install 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 plate with the outer guard.

R21000080

00.17

R21000100

Filling and charging the battery

Disengaging and raising the fuel tank

•Remove seat.

•Remove right side trim.

eCaution:

Fuel is flammable and a hazard to health. Observe relevant safety regulations.

•Remove the fastener securing the fuel tank at the rear right.

•Raise the rear of the fuel tank and prop it in this position on a wooden block or similar.

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 fully charged .......	1.26-1.30 at 20 °C (68 °F)

Filling and charging the battery

dWarning:

Battery acid is highly caustic.

Protect your eyes, face, hands, clothing and the paintwork.

•Disengage the rubber strap holding the battery.

•Disconnect the battery breather hose.

•Remove the battery.

•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.

•The battery does not achieve full charge capacity from being filled, so it has to be charged with a battery charger.

•Shake the battery slightly to allow the gas bubbles 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.

e Caution:

Connect the positive battery terminal first, then the negative terminal.

•Install the battery.

•Apply acid-proof grease to the battery terminal posts.

•Connect the battery breather line.

•Secure the fuel tank in position.

•Install the right side trim panel.

•Install the seat.

00.18

•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 deletes all entries (e.g. faults, settings) stored in the Motronic control unit’s memory.

Loss of settings can temporarily impair the operating characteristics when the engine is restarted.

XTightening torque:
Fuel tank to frame ........................................	21 Nm

Checking engine oil when engine is cold, topping up if necessary

MAX

MIN

S000040

• Check oil level with the motorcycle upright.

eCaution:

Never top up the engine-oil level past the “MAX” mark.

Required level:...............................................

MAX

00.19

Checking headlight beam angle, adjusting if necessary

R21000140

•Motorcycle on level surface.

•Rider’s weight on motorcycle

•(approx. 85 kg/176 lbs).

•Move swivel lever to horizontal position (basic setting).

•Turn the adjusting screws to correct the headlight beam throw.

Lateral adjustment:

........................ Adjusting screw on left of headlight

Vertical adjustment:

......................Adjusting screw on right of headlight

Turn screw anti-clockwise:	............... longer throw
Turn screw clockwise: .....................	shorter throw

S000080

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 studs .......................................	105 Nm

Checking tyre pressures

• Check/correct tyre pressures.

Tyre pressures:
Solo .....................................	front 2.2 bar (31.3 psi)
.............................................	rear 2.5 bar (35.6 psi)
Two-up ................................	front 2.5 bar (35.6 psi)
.............................................	rear 2.7 bar (38.4 psi)
Two-up + luggage ................	front 2.5 bar (35.6 psi)
.............................................	rear 2.9 bar (41.2 psi)

Attaching adhesive label

•Remove the adhesive label from the package and fix it in position at the bottom of the glass cover of the rev. counter.

00.20

Final inspection and function check Handing over the motorcycle

•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

– Brake light (operate brake at front and rear)

– Turn signals left/right

– Hazard warning flashers

– Horn

– Telltale and warning lights

– Instruments

•Where necessary, check function of optional extras:

–ABS: perform starting test. When a speed of 5 km/h (app. 3 mile/h) is reached, both

ABS warning lights must go out.

•If necessary, take the motorcycle for a test ride.

•Confirm pre-delivery check in Service and Technical 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.

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 handlebar lever positions

–how to adjust the mirrors

–controls

–instruments and telltale lights

–optional equipment and accessories fitted

–noise during the regular ABS self-diagnosis pro-

cedure

• The user must be given the following information:

–running-in recommendations and inspection intervals

–safety check

–the clutch fluid level rises gradually as the motorcycle is ridden (clutch lining wear)

–before checking the engine oil level, the engine must be switched off for at least 10 minutes and the motorcycle must be standing on a flat, level surface

00.21

Maintenance

Key to maintenance intervals

– BMW Inspection at 1,000 km (600 miles)

I

–BMW Service every 10,000 km (6,000 miles) II

–BMW Inspection, every 20,000 km

(12,000 miles)	III
– BMW Annual Service	IV

Reading out MoDiTeC fault memory

(Inspections I, II, III and IV)

•Remove the seat.

•Connect the BMW MoDiTeC to the diagnosis connector.

•Read out the fault memory.

•Perform all requisite repair work.

Changing engine oil, replacing oil filter element

(Inspections I, II, III and IV)

L Note:

If the motorcycle is ridden only for short distances or outside temperatures are below 0°C (32°F) change the oil and replace the oil filter element every

3 months, or not later than every 3,000 km

(1,800 miles).

• Change the oil at operating temperature.

MAX

MIN

S000040

• Remove screw plug.

11 4 650

C000030

•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 remove the oil filter.

•Coat sealing ring on new oil filter element with oil and install filter.

•Refill with oil to correct level.

•Install the screw plug.

eCaution:

Never top up the engine-oil level past the “MAX” mark.

X Tightening torque:
Oil filter.........................................................	11 Nm
Oil drain plug................................................	32 Nm

Engine oil quantities:

With oil filter change................................................

..................... 3.75 l (6.6 Imp. pints/3.96 US quarts)

Without oil filter change...........................................

..................... 3.50 l (6.2 Imp. pints/3.69 US quarts)

Quantity of oil between

MIN and MAX marks ...............................................

.......................0.50 l (0.88 Imp. pint/0.52 US quart)

Engine oil grade:

Brand-name HD oil for spark-ignition engines, API classifications SF, SG, SH; combination with CD or CE specification.

Brand-name HD oil of CCMC classification G4, G5; amendment PD2 is permissible.

00.22