Bmw R1150Gs Service Repair Manual-21215B320095.pdf -Bookmark created by https://wimanual.com Introduction Maintenance schedule Pre-delivery check Service data General table of contents 00 Maintenance and general instructions Tightening torques Table of operating fluids Pre-delivery check General view of crated motorcycle Check the shipping crate for damage In case of damage in Germany In case of damage in importer markets Unpacking the motorcycle Inspecting motorcycle for damage Checking that delivery is complete Installing remaining items on motorcycle Install the windscreen Installing sump guard Filling and charging the battery Disengaging and raising the fuel tank Filling and charging the battery Checking engine oil when engine is cold, topping up if necessary Checking headlight beam angle, adjusting if necessary Checking tightness of rear wheel studs Checking tyre pressures Attaching adhesive label Final inspection and function check Final cleaning Handing over the motorcycle Maintenance Key to maintenance intervals Reading out MoDiTeC fault memory Changing engine oil, replacing oil filter element Changing oil in gearbox Changing the oil in the rear wheel drive Replacing fuel filter Checking battery fluid level and topping up if necessary; cleaning and greasing the battery posts Replacing intake air filter element Replacing Poly-V belt Checking brake system for correct operation and freedom from leaks; repairing Checking brake fluid level Front brake Rear brake Checking brake pads and discs for wear Checking front brake pad wear Checking rear brake pad wear Checking brake disc wear Replacing brake pads, front brake Replacing brake pads, rear brake Changing brake fluid and bleeding brake system Bleeding front brake circuit Bleeding rear brake circuit Checking clutch operating fluid level Changing the clutch fluid Checking tightness of rear wheel studs Checking rear wheel bearing play by tilting wheel Checking swinging arm bearings, adjusting if necessary Greasing the side stand pivot Checking function of side stand contact switch Checking Tightening cylinder heads Checking Checking freedom of throttle cable, checking for chaffing and kinks, replacing if necessary Check... Final inspection with road safety and functional check 11 Engine Cutaway drawing of engine Lubricating-oil circuit Cooling-oil circuit Removing engine Disassembling engine Removing cylinder head cover Locking the engine at TDC Removing and installing chain tensioner Remove valve gear carrier Disassembling Removing cylinder head Disassembling, checking, repairing and reassembling cylinder head Removing cylinder Removing and disassembling piston Checking pistons and cylinders Assembling pistons Removing and installing conrod Removing and installing alternator mount cover with engine installed Removing alternator mount cover Replacing radial shaft seal in alternator mount cover Removing auxiliary shaft drive Removing oil pump Removing radial shaft seal from crankshaft with engine installed Disassembling crankcase Removing crankshaft, auxiliary shaft and timing chain tensioning and slide rails Removing and installing oil intake strainers Replacing oil level sight glass Removing and installing oil thermostat Removing conrods Checking conrods Measuring crankshaft bearing play Measuring big end bearing play Assembling engine Installing conrods Installing crankshaft Installing timing chain tensioning and slide rails Installing auxiliary shaft Assembling engine block Installing radial shaft seals on crankshaft Installing clutch housing Installing oil pump Installing auxiliary shaft drive Installing piston Installing cylinder Installing cylinder head Adjusting valve clearances Installing right cylinder head Installing left cylinder head Installing alternator mount cover Installing magnetic gate Installing alternator Installing engine 12 Engine electrics Removing and installing coil and ignition lead Checking ignition coil resistance Removing and installing alternator Disassembling Checking alternator Checking armature for short to ground (earth) Disassembling Checking alternator Checking armature for short to ground (earth) Removing and installing starter motor Disassembling Replacing carbon brushes Checking starter motor Checking starter relay Removing and installing magnetic gate Timing the ignition 13 Fuel preparation and control Removing and installing air filter housing Removing and installing trottle- valve stub pipe Removing and installing throttle- valve potentiometer Removing and installing Motronic control unit 16 Fuel tank and lines Removing and installing fuel tank Removing and installing roll-over valve Removing and installing fuel filter, fuel pump and fuel level sensor Removing and installing fuel filter Removing and installing fuel pump and fuel level sensor Removing and installing fuel distributor and pressure regulator 18 Exhaust system Removing and installing exhaust system Removing and installing silencer and front silencer Removing and installing exhaust manifolds 21 Clutch Removing and installing clutch Removing clutch Installing clutch Removing and installing clutch hydraulic line Removing and installing clutch slave cylinder Filling 23 Transmission Gearbox - sectional drawing Removing and installing gear-shift lever Removing Replacing the shaft sealing rings in the gearbox housing and gearbox cover Disassembling gearbox Removing gearbox housing Removing selector drum Disassembling Removing gearbox shafts Replacing grooved ball bearings of intermediate shaft Disassembling Disassembling Checking endplay Checking Shimming selector shaft Assembling gearbox Installing input, output and intermediate shafts Installing selector shaft Installing selector drum Installing gearbox housing 31 Front forks Removing and installing telescopic fork Removing and installing telescopic fork without fork bridge Removing and installing fork bridge Removing and installing slider tube bridge Checking friction at ball joint Disassembling Disassembling telescopic fork Assembling telescopic fork Measuring telescopic fork Removing and installing leading link Disassembling Removing and installing front spring strut 32 Steering Removing and installing left handlebar fitting Removing and installing right handlebar fitting Removing and installing brake piston in handlebar fitting Removing and installing clutch piston in handlebar fitting Checking and adjusting operating clearance at front brake Removing and installing handlebar Removing and installing Bowden- cable divider, Bowden cable for throttle actuation and starting... Disassembling Bowden-cable divider 33 Rear wheel drive Removing, disassembling, reassembling and installing rear wheel drive Removing rear wheel drive Removing and installing taper roller bearing in rear wheel drive Removing input bevel pinion Disassembling input bevel pinion Assembling input bevel pinion Installing input bevel pinion Removing and disassembling crown wheel Assembling and installing crown wheel Shimming input bevel pinion and crown wheel Checking tooth contact pattern Checking and adjusting backlash Shimming housing cover Installing housing cover Installing sliding element Installing rear wheel drive Removing and installing spring strut Removing and installing rear swinging arm Removing rear swinging arm Removing and installing taper roller bearing Removing and installing flexible gaiter Removing drive shaft Installing drive shaft Installing rear swinging arm 34 Brakes Removing and installing front brake caliper Disassembling and assembling front brake caliper Removing and installing filler adapter Removing and installing rear brake caliper Disassembling and assembling rear brake caliper Removing and installing front brake disc Removing and installing rear brake disc (mounted on rear-wheel hub) Removing and installing front ABS sensor ABS sensor gap, front: adjusting Marking sensor ring Checking and adjusting sensor gap Removing and installing rear ABS sensor Adjusting rear ABS sensor gap Marking sensor wheel Checking and adjusting sensor gap Removing and installing rear brake master cylinder Checking and adjusting play of piston rod Removing and installing footbrake lever Removing and installing ABS unit Removing the ABS unit Installing the ABS unit Removing and installing ABS relay and relay socket Removing ABS relay Installing the ABS relay Removing ABS relay socket Installing the ABS relay base Removing and installing brake line (withABS) Removing and installing front brake line Removing and installing rear brake line 36 Wheels and tyres Removing and installing front wheel Removing front wheel Installing the front wheel Removing and installing wheel bearings Removing Removing rear wheel Installing rear wheel Static balancing of front wheel Checking front Removing Centering the wheel rim Centering lateral runout 46 Frame Overall view, frame Removing and installing main (centre) stand Removing and installing side stand Removing and installing front mudguard Removing and installing bottom section of mudguard Removing and installing top section of mudguard Removing and installing windscreen Removing and installing fairing bracket Removing and installing luggage rack Removing and installing number- plate carrier Removing Removing and installing rear footrest plate Removing and installing front footrest plate Removing and installing right footrest plate Removing and installing left footrest plate Removing Removing and installing frame tail section Checking running gear Measuring wheel track offset Measuring the leading link 51 Equipment Removing and installing ignition switch Removing and installing ignition Removing and installing lock barrel Removing and installing lock barrel for fuel tank filler cap Removing and installing seat lock Removing and installing lock barrel Removing and installing helmet lock 52 Seat Disassembling 61 General electrical equipment Removing and installing central electrical equipment box Disassembling Relay positions Wiring-harness routing, frame [ABS] Wiring-harness routing Wiring-harness routing Wiring-harness routing View from left Wiring-harness routing View from right Removing and installing battery holder 62 Instruments Removing and installing instrument panel 63 Lights Removing and installing headlight Removing and installing front indicators . 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