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

InspectionBMW

km1,000at

miles)(600

ServiceBMW km10,000 miles)(6,000

InspectionBMW 20,000everykm miles)(12,000

BMW ServiceAnnual

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)*)

Change oil in gearbox while at operating temperature

every

every 2 years*) at the latest

2 years

Change oil in rear wheel drive while at operating temperature

every

if necessary, clean inductive sensor on rear wheel

40,000

every 40,000 km (24,000 miles) or at the latest every 2 years*)

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)

40,000

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*)

every

2 years

[Integral ABS] perform bleed test with BMW MoDiTeC

Check clutch fluid level

Change the clutch fluid*)

every

every 2 years at the latest

2 years

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

BMW Motorrad Pre-delivery check

R 1100 S EVO / R 1150 R / R 1150 RT

Customer

Registration No.

BMW

Pre-delivery check

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.

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

Item		Desired value		Unit of measure-
				ment/specification

Oil capacities
Engine	(with filter)
	(without filter)

Transmission Initial filling

Oil changes

Rear wheel drive Initial filling/oil change

3.75(6.6)

3.50(6.15)

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)

[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

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		Inlet: 0.15 (0.006)		mm (in)
measured cold (max. 35 °C/95 °F)
		Exhaust: 0.30 (0.012)		mm (in)
Ignition timing		adjust at TDC
static setting
Spark plugs
Electrode gap		0.8 (0.0315)		mm (in)
Wear limit		1.0 (0.039)		mm (in)
Idle speed		1,100 ±50		rpm
Throttle cable setting		zero play
for cold-start (increased idle) speed				mm (in) free travel
for throttle (twistgrip) cable		approx. 0.5 (0.02)
for divider cable		zero play
Brakes		green		DOT 4 brake fluid
Colour of identification mark on brake calipers/brake pads, front
Minimum front pad thickness		1.0 (0.039)		mm (in)
Minimum rear pad thickness		1.0 (0.039) (wear mark)		mm (in)
Minimum front disc thickness		4.5 (0.177)		mm (in)
Minimum rear disc thickness		4.5 (0.177)		mm (in)
Tyre pressures		front: 2.2 – 2.5		bar (psi)
depending on load		(31.9 – 36.26)
		rear: 2.5 – 2.9		bar (psi)
		(36.26 – 42.06)
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		22		Nm
Fuel pump assembly to tank		5		Nm
Poly-V belt preload		8		Nm
Alternator to cover mount		20		Nm
Brake caliper fasteners, front		30		Nm
Brake caliper fasteners, rear		40		Nm
Rear wheel studs		105		Nm
Tightening cylinder heads		unscrew/20		Nm
Nut
		180		° tightening angle
M 10 screw		unscrew/40		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
3	M 6 screw	Nm	9
After 1,000 km (600 miles), tighten cylinder
head nuts in diagonally opposite se-
quence:
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	9
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	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 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		Nm	25
		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
			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	°	32
		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

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 se-
		quence:
		1. Front fastener (as viewed in forward	Nm	21
		direction of travel) until seated
		2. Rear fastener (as viewed in forward	Nm	21
		direction of travel)
		Handlebar weight to handlebars	Nm	21
		Pivot screw, handlebar lever	Nm	11
				(Tuflok Blue thread-locking compound; screw
				can be released and tightened a number of
				times)
		Model		R 1150 R
		Connection
		33 Rear wheel drive
		Oil filler plug	Nm	23
		Oil drain plug	Nm	23
		Threaded ring	Nm	160
				(clean thread + Loctite 577)
		Hexagon nut, input bevel gear	Nm	200
				(clean thread + Loctite 2701)
		Cover to rear-wheel drive housing	Nm	35
		Fixed bearing stud bolt, swinging arm to	Nm	160
		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,	Nm	160
		swinging arm to gearbox
		Fixed bearing stud bolt,	Nm	160
		swinging arm to rear axle housing		(clean thread + Loctite 2701)
		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,	Nm	160
		swinging arm to rear axle housing		(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 foot-	Nm	22
rest plate
Model		R 1150 R
Connection
34 Brakes
Brake caliper to fork slider tube, Evo	Nm	30
brakes
Brake caliper to rear wheel drive	Nm	40
Brake disc to front wheel	Nm	21
		(clean thread + Loctite 2701)
Brake disc to rear wheel drive	Nm	21
		(clean thread + Loctite 2701)
Master cylinder to footrest assembly	Nm	9
Footbrake lever to footrest assembly	Nm	21
		(clean thread + Loctite 2701)
Footbrake-lever stop	Nm	9
Ball socket to thrust rod	Nm	9
Brake lines/brake hose to brake compo-	Nm	18
nents
Brake hose to bracket	Nm	9
Brake hose to brake lever fitting	Nm	18
Bracket to front frame	Nm	9
Bracket to rear frame	Nm	9
		(clean thread + Loctite 2701)
Front brake caliper bleed screw	Nm	9
Rear brake caliper bleed screw	Nm	6
Filler adapter to brake line	Nm	18
ABS hydraulic unit to bracket	Nm	8
ABS hydraulic unit to battery carrier	Nm	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	Nm	105
		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
				(clean thread + Loctite 2701)
		Rear frame to gearbox/engine
		to gearbox and footrest plate	Nm	42
				(clean thread + Loctite 2701)
		to engine	Nm	42
		Carrier plate for main stand to engine, right
		M 12 screw	Nm	72
				(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 (ma-	Nm	21
		chine screw)
		Side stand to pivot mount	Nm	58
				(clean thread + Loctite 2701)
		Footrest plate to gearbox	Nm	21
		Rear footrest plate to rear frame	Nm	21
		Front mudguard to fork slider tube bridge	Nm	6
				(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	Nm	3
to slider tube		(Tuflok Blue thread-locking compound; screw
		can be released and tightened a number of
		times
		alternatively: clean thread + Loctite 243)
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
		(micro-encapsulated)
Model		R 1150 R
Connection
61 General electrical equipment
Horn to holder	Nm	8
		(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	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 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
		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 aluminium	83 19 9 407 855	500 ml spray
			housings
		Developer MR 70	Crack testing agent for aluminium	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

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.

• Fit the rear-view mirror.
XTightening torque:
Mirror on handlebar fitting ............................	10 Nm

In case of damage in Germany

71 63 099 Mounting the Speedster fair-

•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. [phone] Fax [phone] without delay.

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.

00 11 Unpacking the motorcycle

ing

R28000010

•Carefully tighten the Speedster fairing securing screws by hand.

XTightening torque:
Fairing on fairing bracket ................................	2 Nm

•Lever off the cover.

•Take out the separate pack of items: 00 11 Inspecting motorcycle for dam-

–Documentation

–Optional Speedster fairing, if applicable

–Optional seat cover, if applicable

• Force off cross-struts with a suitable lever.

eImportant:

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

•Remove the end-walls.

•Remove the side-walls.

eImportant:

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 environmentally responsible manner as described in Circular 23/91 - Sales.

age

•Check for faults.

•“Express handling service” to: BMW Motorrad

UX-VS-1

Fax number [phone]

•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

MIN

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 forwards.

eImportant:

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.

• Remove the fuel tank upwards from the rear.

61 21 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 to the upper mark with pure battery acid of density 1.28.

•Allow the battery to stand for approximately 30 minutes.

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)

•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.

•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.

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 ........................................	22 Nm

00 00 Checking engine oil when engine is cold, topping up if necessary

MAX

MIN

R28000030

• Check oil level with the motorcycle upright.

eImportant:

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

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

MAX

BMW recommends Castrol

00.18

63 10 500 Checking headlight beam angle, adjusting if necessary

Checking tightness of rear wheel studs

2 1

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.

R28000080

Setting for headlight beam angle adjuster

.. .-25 cm (9.8425 in) at a distance of 10 m (32.8 ft)

X Tightening torque:
Securing screws for rear wheel ..................	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)
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)

00.19

[Integral ABS] Performing bleed test with BMW MoDiTeC

dWarning:

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.

dWarning:

Avoid rapid and forceful pumping of the brakes when performing maintenance and repair work on the BMW Integral ABS.

•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.

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 extras:

•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.

00 11 459 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.

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 BMW Integral ABS: 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 intervals

–safety check

–features of BMW Integral ABS: partially integral brake,

brake-fluid levels in the control circuits remain constant despite brake-pad wear.

–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

00.22

............................................................................................32

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)

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

........................................................................................35

Contents

Page

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

(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