BMW R1150 R User Manual
Maintenance BMW Integral ABS
R 1150 R
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 R
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
green
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 0 026 973 UX-VS-2, 07.00 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 .........................................................................................................................6
21 Clutch ............................................................................................................................................6
23 Transmission ..............................................................................................................................7
31 Front fork ......................................................................................................................................7
32 Steering ........................................................................................................................................8
33 Rear wheel drive .......................................................................................................................8
34 Brakes ...........................................................................................................................................9
36 Wheels and tyres ....................................................................................................................10
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 R
Connection
11 Engine
Cylinder head
Tightening sequence:
1 Tighten cylinder head nuts (oiled) in go-
nally opposite sequence
1.1 Tighten all nuts to closing torque Nm 20
1.2 Tighten all nuts to correct angle ° 90
1.3 Tighten all nuts to correct angle ° 90
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
Air intake connection to cylinder head Nm
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
9
9
9
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 R
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 lines to oil cooler Nm 25
Oil cooler to bracket Nm 8
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
Nm 25
Wrench angle ° 80
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 R
Connection
12 Engine electrics
Starter motor to engine Nm 20
Starter cover to gearbox housing Nm 7
Positive lead to starter motor Nm 10
Alternator to alternator 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
Spark plug NGK BKR 7 EKC Nm 25
Model R 1150 R
Connection
13 Fuel preparation and control
Temperature sensor, oil, in crankcase Nm 25
Temperature sensor, air, in air-filter housing Nm 10
Model R 1150 R
Connection
16 Fuel tank and lines
Fuel tank to rear frame Nm 22
Fuel pump assembly to tank Nm 5
00.5
Model R 1150 R
Connection
18 Exhaust system
Manifold to cylinder head Nm 21
Clamp for manifold Nm 45
(apply Optimoly TA to clamp seat)
Front silencer to manifold Nm 45
(apply Optimoly TA to clamp seat)
Silencer to main stand lugs Nm 20
Silencer to rear frame at top Nm 35
Oxygen sensor to silencer Nm 45
(apply Optimoly TA to thread)
End cap to rear silencer Nm 8
(threads greased)
Bracket to rear silencer Nm 15
(threads greased)
Model R 1150 R
Connection
21 Clutch
Clutch housing
Closing torque Nm 40
(oil screw threads lightly)
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
32
00.6
Model R 1150 R
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
1. to gearbox and left footrest plate Nm 42
(clean thread + Loctite 243)
2. clamp block, frame tube to gearbox Nm 9
3. to gearbox and right footrest plate Nm 42
(clean thread + Loctite 243)
Model R 1150 R
Connection
31 Front fork
Quick-release axle clamp screws Nm 22
Clamp, fork fixed tube to fork bridge Nm 45
(free from oil and grease)
Slider tube bridge to slider tube Nm 25
(clean thread + Loctite 243)
Threaded stud to frame Nm 130
(clean thread + Loctite 243)
Ball joint to sliding tube bridge Nm 230
(lightly grease threads with Optimoly TA)
Leading link to ball joint
Initial tightening Nm 80
Final tightening Nm 130
(clean thread + Loctite 2701)
Leading link to engine Nm 130
Spring strut to front frame Nm 43
Spring strut to leading link Nm 50
00.7
Model R 1150 R
Connection
32 Steering
Handlebars to fork bridge, tightening sequence:
1. Front fastener (as viewed in forward
direction of travel) until seated
2. Rear fastener (as viewed in forward
direction of travel)
Handlebar weight to handlebars Nm 21
Pivot screw, handlebar lever Nm 11
Model R 1150 R
Connection
33 Rear wheel drive
Oil filler plug Nm 23
Oil drain plug Nm 23
Threaded ring Nm 160
Hexagon nut, input bevel gear Nm
Nm 21
Nm 21
(Tuflok Blue thread-locking compound; screw
can be released and tightened a number of
times)
(clean thread + Loctite 577)
200
(clean thread + Loctite 2701)
Cover to rear-wheel drive housing Nm 35
Fixed bearing stud bolt, swinging arm to
gearbox
Floating bearing stud bolt, swinging arm to
gearbox
1. initial torque Nm 9
2. slacken
3. final torque Nm 7
Locknut, floating bearing stud bolt,
swinging arm to gearbox
Fixed bearing stud bolt,
swinging arm to rear axle housing
Floating bearing stud bolt,
swinging arm to rear axle housing
1. initial torque Nm 9
2. slacken
3. final torque Nm 7
Locknut, floating bearing stud bolt,
swinging arm to rear axle housing
Nm 160
Nm 160
Nm 160
(clean thread + Loctite 2701)
Nm 160
(clean thread + Loctite 2701)
00.8
Model R 1150 R
Connection
33 Rear wheel drive
Reaction link to rear wheel drive / gearbox Nm 43
(load approx. 85 kg (187 lbs) onto motorcycle
and tighten loose reaction link)
Spring strut to rear frame Nm 50
Spring strut to rear swinging arm Nm 58
(clean thread + Loctite 243)
Hydraulic spring preload adjuster to footrest plate
Model R 1150 R
Connection
34 Brakes
Brake caliper to fork slider tube, Evo
brakes
Brake caliper to rear wheel drive Nm 40
Brake disc to front wheel Nm 21
Brake disc to rear wheel drive Nm 21
Master cylinder to footrest assembly Nm 9
Footbrake lever to footrest assembly Nm
Footbrake-lever stop Nm
Ball socket to thrust rod Nm
Nm 22
Nm 30
(clean thread + Loctite 2701)
(clean thread + Loctite 2701)
21
(clean thread + Loctite 2701)
9
9
Brake lines/brake hose to brake components
Brake hose to bracket Nm
Brake hose to brake lever fitting Nm 18
Bracket to front frame Nm 9
Bracket to rear frame Nm 9
Front brake caliper bleed screw Nm
Rear brake caliper bleed screw Nm
Filler adapter to brake line Nm 18
ABS hydraulic unit to bracket Nm
ABS hydraulic unit to battery carrier Nm
18
Nm
9
(clean thread + Loctite 2701)
9
6
8
8
00.9
Model R 1150 R
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
Hand-tighten wheel studs and tighten in
diagonally opposite sequence
[Integral ABS] Note spacer
Model R 1150 R
Connection
46 Frame
Frame to engine Nm 82
Struts to frame Nm 58
Strut to engine Nm 58
Rear frame to gearbox/engine
to gearbox and footrest plate Nm 42
to engine Nm 42
Carrier plate for main stand to engine, right
M 12 screw Nm 72
Nm 105
(clean thread + Loctite 2701)
(clean thread + Loctite 2701)
(clean thread + Loctite 2701)
Pivot mount to engine, left
M 12 screw Nm 72
(clean thread + Loctite 2701)
M 8 screw Nm 21
Pivot mount of main (centre) stand (stud bolt) Nm 21
(clean thread + Loctite 243)
Pivot mount of main (centre) stand (machine screw)
Side stand to pivot mount Nm 58
Footrest plate to gearbox Nm 21
Rear footrest plate to rear frame Nm 21
Front mudguard to fork slider tube bridge Nm 6
Nm 21
(clean thread + Loctite 2701)
(Tuflok Blue thread-locking compound; screw
can be released and tightened a number of
times
alternatively: clean thread + Loctite 243)
00.10
Model R 1150 R
Connection
46 Frame
Front and rear sections of front mudguard
to slider tube
Headlight bracket to fork bridge Nm 20
Model R 1150 R
Connection
51 Equipment
Mirrors Nm 15
Ignition/steering lock to fork bridge Nm 20
Model R 1150 R
Connection
61 General electrical equipment
Horn to holder Nm 8
Nm 3
(Tuflok Blue thread-locking compound; screw
can be released and tightened a number of
times
alternatively: clean thread + Loctite 243)
(micro-encapsulated)
(clean thread + Loctite 243)
Ground (earth) strap to engine block Nm 9
Battery carrier to rubber-metal element Nm 8
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 shipping pallet for damage .....................................................................16
In case of damage in Germany ...............................................................................................16
In case of damage in importer markets ..............................................................................16
Unpacking the motorcycle ....................................................................................................16
Installing remaining items on motorcycle .....................................................................16
Mounting the Speedster fairing ..............................................................................................16
Inspecting motorcycle for damage ...................................................................................16
Checking that delivery is complete ..................................................................................16
Filling and charging the battery .........................................................................................17
Removing the fuel tank ...............................................................................................................17
Filling and charging the battery ...............................................................................................17
Checking engine oil when engine is cold, topping up if necessary ...............18
Checking headlight beam angle, adjusting if necessary ......................................19
Checking tightness of rear wheel studs ........................................................................19
Checking tyre pressures .........................................................................................................19
[Integral ABS] Performing bleed test with BMW MoDiTeC ..................................20
Final inspection and function check ................................................................................20
Final cleaning ................................................................................................................................20
Handing over the motorcycle ...............................................................................................21
00.13
00.14
00
General view of crated motorcycle
00.15
Checking the shipping pallet for damage
00 11
Installing remaining items on
motorcycle
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 supplier (e.g. freight company or DB) and
•
Bavaria Wirtschaftsagentur GmbH
Abteilung ZW - 12
80788 München
Tel. 089/14327-632
Fax 089/14327-709
without delay.
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.
Fit the rear-view mirror.
•
X Tightening torque:
Mirror on handlebar fitting............................ 10 Nm
71 63 099
ing
Carefully tighten the Speedster fairing securing
•
screws by hand.
Mounting the Speedster fair-
R28000010
Unpacking the motorcycle
00 11
Lever off the cover.
•
Take out the separate pack of items:
•
– Documentation
– Optional Speedster fairing, if applicable
– Optional seat cover, if applicable
Force off cross-struts with a suitable lever.
•
e Important:
Do not knock the cross-struts out or the motorcycle
may be damaged.
Remove the end-walls.
•
Remove the side-walls.
•
e Important:
Remove any nails projecting from the base of the
packing or lying on the base or on the floor.
Loosen the front tensioning straps.
•
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 environ-
•
mentally responsible manner as described in Circular 23/91 - Sales.
X Tightening torque:
Fairing on fairing bracket................................2 Nm
Inspecting motorcycle for dam-
00 11
age
Check for faults.
•
“Express handling service” to:
•
BMW Motorrad
UX-VS-1
Fax number +49 (0)89-382-33220
Rectify the fault.
•
If parts are needed, order them through the usual
•
channel.
Costs are to be processed through 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
00.16
MAX
MI N
MI N
R28000020
61 21 Filling and charging the battery 16 11 533 Removing the fuel tank
Remove front/rear seat.
•
Lever off the right-hand and left-hand front trim
•
sections from the tank.
Remove the right-hand and left-hand oil cooler
•
trims.
Remove the right-hand cable trim.
•
Remove oil cooler with air ducting and fold for-
•
wards.
e Important:
Fuel is flammable and a hazard to health. Observe
relevant safety regulations.
Remove fuel tank retaining screw.
•
Remove bleed line and overflow pipe.
•
Disconnect the fuel line quick-release coupling.
•
Disconnect the fuel pump plug connection.
•
L Note:
Place a cloth between the fork stabilizer and the fuel
tank to prevent paintwork damage to the front of the
fuel tank.
Filling and charging the battery
61 21
d Warning:
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 to the upper mark with pure bat-
•
tery acid of density 1.28.
Allow the battery to stand for approximately
•
30 minutes.
Remove the fuel tank upwards from the rear.
•
00.17
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 (A)
.........................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)
Checking engine oil when
00 00
engine is cold, topping up if necessary
MAX
MIN
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.
Refit the plugs.
•
Make a note of the charging date on the battery.
•
e Important:
Connect the positive battery terminal first, then the
negative terminal.
Fit the battery.
•
Apply acid-proof grease to the battery terminals.
•
Connect the battery breather line.
•
Fit the fuel tank.
•
Connect the fuel pump connector and the fuel
•
line quick-release couplings.
Connect bleed line and overflow pipe.
•
Fit oil cooler with air ducting.
•
Fit cable trim.
•
Fit oil cooler trim.
•
Secure the right-hand and left-hand front trim
•
sections to the tank.
Fit front/rear seat.
•
Switch on the ignition.
•
Without starting the engine, fully open the throttle
•
once or twice so that the Motronic control unit
can record the throttle-valve positions.
R28000030
Check oil level with the motorcycle upright.
•
e Important:
Never top up the engine-oil level past the “MAX”
mark.
Required level:............................................... MAX
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.
X Tightening torque:
Fuel tank to frame ........................................ 22 Nm
00.18
BMW recommends Castrol
63 10 500 Checking headlight beam
angle, adjusting if necessary
2
R28000070
Motorcycle must be on a level surface.
•
Motorcycle with driver (approximately 85 kg/
•
187 lbs).
Remove trim (1).
•
Remove headlight (2) retaining bolts.
•
Correct the headlight range by swivelling the
•
headlight.
Checking tightness of rear wheel studs
X Tightening torque:
Securing screws for rear wheel .................. 105 Nm
Checking tyre pressures
1
Check/correct tyre pressures.
•
Tyre pressures:
Solo ..................................... front 2.2 bar (31.3 psi)
............................................. rear 2.5 bar (35.6 psi)
With pillion passenger.......... front 2.5 bar (35.6 psi)
............................................. rear 2.7 bar (38.4 psi)
With pillion passenger and
luggage................................ front 2.5 bar (35.6 psi)
............................................. rear 2.9 bar (41.2 psi)
R28000080
Setting for headlight beam angle adjuster
.. .-25 cm (9.8425 in) at a distance of 10 m (32.8 ft)
00.19
[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
the conclusion of the self-diagnosis, only RESIDUAL BRAKE FUNCTION is available.
Performing BMW Integral ABS self-diagnosis:
Release the brake levers if necessary.
•
Switch on the ignition.
•
ABS warning light.............................flashes at 4 Hz
General warning lamp ........................is continuous
– Self-diagnosis is in progress
ABS warning light.............................flashes at 1 Hz
General warning lamp ...............................goes out
– Self-diagnosis successfully completed.
Performing a bleed test using the
BMW MoDiTeC:
Remove front/rear seat.
•
Connect the BMW MoDiTeC to the diagnostic
•
connector.
d Warning:
Avoid rapid and forceful pumping of the brakes
when performing maintenance and repair work on
the BMW Integral ABS.
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
– Brake light (operate brake at front and rear)
– Turn signals left/right
– Hazard warning flashers
– Horn
– Indicator and warning lights
– Instruments
Where necessary, check function of optional ex-
•
tras:
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.
00 11 459
Clean the motorcycle.
•
Final cleaning
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.
•
Performing BMW Integral ABS pull-away test:
The ABS warning light must go out when a
•
speed of 5 km/h (approx. 3 mph) is reached.
L Note:
The ABS warning light and the general warning light
must both be OFF after successful self-diagnosis
and the pull-away test.
00.20
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 handlebar lever positions
– how to adjust the mirrors
– controls
– instruments and indicator 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:
partially 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)
– 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
00.22
00
00 Maintenance
Contents Page
Key to maintenance intervals ..............................................................................................27
Reading the BMW MoDiTeC fault code memory .......................................................27
(Inspections I, II, III and IV)
[Integral ABS] Performing bleed test with BMW MoDiTeC ..................................27
(Inspections I, II, III and IV)
Changing engine oil, replacing oil filter element ......................................................28
(Inspections I, II, III and IV)
Changing the transmission oil .............................................................................................29
(Inspections III and IV)
or at least every 2 years
Changing the oil in the rear wheel drive ........................................................................29
(Inspections I, III and IV)
Every 40,000 km (24,000 miles) or at the latest every 2 years
Replacing fuel filter ...................................................................................................................30
(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 terminals
(Inspections III and IV)
............................................................................................32
Replacing intake air filter element ....................................................................................32
(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 ...............................................................................................................33
(Inspection III)
every 60,000 km (36,000 miles)
[Without Integral ABS] Checking brake fluid level ...................................................34
(Inspections II and III)
Front brake .......................................................................................................................................34
Rear brake ........................................................................................................................................34
[Integral ABS] Checking brake fluid level .....................................................................35
(Inspections II and III)
Front brake .......................................................................................................................................35
Rear brake ........................................................................................................................................35
00.23
Contents Page
Checking brake system for correct operation and freedom from leaks;
repairing/replacing if necessary ........................................................................................35
(Inspection III)
Checking brake pads and discs for wear/replacing ...............................................35
(Inspections II and III)
Checking front brake pad wear ...............................................................................................35
Checking rear brake pad wear ................................................................................................36
Checking brake disc wear .........................................................................................................36
Replacing brake pads, front brake ........................................................................................37
Replacing brake pads, rear brake ..........................................................................................38
[Without Integral ABS] Changing brake fluid and bleeding
the brake system ........................................................................................................................39
Change the brake fluid annually
(Inspection IV)
[Without Integral ABS]
Bleeding/changing brake fluid in front system .................................................................39
[Without Integral ABS]
Bleeding/changing brake fluid in rear system ..................................................................40
[Integral ABS] Changing/bleeding brake fluid in wheel circuit ........................42
Change brake fluid in wheel circuit once a year
(Inspection IV)
[Integral ABS]
Bleeding/changing brake fluid in front wheel circuit ......................................................42
[Integral ABS]
Bleeding/changing brake fluid in front wheel circuit ......................................................46
[Integral ABS] Changing/bleeding brake fluid in control circuit ......................50
Change brake fluid in control circuit every 2 years
(Inspection IV)
[Integral ABS]
Bleeding/changing brake fluid in front control circuit ...................................................50
[Integral ABS]
Bleeding/changing brake fluid in rear control circuit .....................................................52
Checking clutch operating fluid level ..............................................................................53
(Inspections II and III)
Changing the clutch fluid .......................................................................................................54
(Inspection IV)
at least every 2 years
Checking tightness of rear wheel studs ........................................................................55
(Inspection I)
00.24
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