BMW R 1150 R Operating instructions

BMW Motorrad
After Sales
R 1150 R
Repair Manual

Preface
This Repair Manual is intended to assist you in performing professional maintenance and repair operations.
In its role as a reference source for service personnel, it supplements and expands upon the theoretical
and hands-on instruction provided at our training centres to enhance the quality of our service.
A new edition of this manual will be issued in response to required revisions or the need to incorporate ad-
ditional information (supplements).
The illustrations and descriptions contained in this manual apply exclusively to standard, unmodied BMW
Motorcycles and/or BMW Motorcycles equipped with factory-approved BMW accessories and options.
•The Repair Manual’s structure reects the logical sequence in which the operations it describes will be
performed: removal, dismantling, repairs, assembly and installation.
•The individual chapters in this manual correspond to the motorcycle’s individual assembly groups.
11 . 10
deunitnocegapretpahCretpahC
A reference arrow with chapter and page (such as a 12.5) calls your attention to additional information
contained in another section of the manual
•Group"00"describestheoperationscarriedoutinthecourseofeachInspection.The variousinspectionroutines
are numberedI, II, III and IV. To help in maintaining a continuous, logical work sequence, these same numerical
designations are employed to identify the subsequent sections describing the actual repair operations.
•Use of the BMW special tools needed for certain operations is described in the work instructions.
When the need arises, repair instructions are also issued in the form of Service Information Bulletins. This infor-
mation is then incorporated into the subsequent edition of the repair manual. We also recommend that you take
advantage of the clearly illustrated Electronic Parts Catalogue as a supplementary source of information.
When individual steps within an overall operation only apply to motorcycles with specic accessories or
optional equipment, the options the steps refer to are identied in brackets at the beginning of the line.
Example: [heated grips] .
Please devote your careful attention to the following pages with their explanations describing the symbols
used in the manual and their signicance.
BMW Motorrad
After Sales

How to use this manual
Each chapter starts with a table of contents.
Following the table of contents is a table containing the techical data and specifications for the chapter’s
subject.
Explanation of symbols
This manual for the R 1150 R employss the following symbols; please refer to the table for their meanings.
Special notices for more efficient procedures
LNote:
These special notices help technicians work more efficiently when operating, inspecting, adjusting and
maintaining motorcycles.
eAttention:
Special information and precautionary notices to prevent damage to the motorcycle. Failure to observe
these mandatory precautions may invalidate the warranty.
dWarning:
Precautions intended to protect the rider and/or other individuals against injury as well as potentially fatal
hazards.
Contents
The titles of the operations described in this chapter............. together with page numbers
Operations
•Operations
•A dot or period identifies individual procedures described under a title
–previous operations
–The hyphen identifies procedures described in more detail under a different title or in another chapter
Remove means:
To completely unscrew a retaining component (such as a bolt or screw)
or
to detach a component (such as an injection rail) and move it enough to gain access to assemblies installed
behind it (such as a throttle-valve).
Loosen means:
To unscrew an attachment (such as a bolt or screw) without removing it entirely from its threaded socket
or retainer
X Tightening torques:
These data are indicated whenever torques deviate from the standards defined in DIN EN 24 014 and
DIN 912 ISO.

BMW Motorrad
Maintenance schedule
R 1150 R
Customer Licence No. Mileage
Job Order No. Date Mechanic’s signature
BMW Inspection at 1000 km/600 miles BMW Maintenance Service every 10000 km/6,000 miles BMW Inspection every 20000 km/ 12,000 miles BMW Annual Service
Use BMW MoDiTeC to read stored error codes from fault memory
[Integral ABS] Performing bleed test with BMW MoDiTeC
Change engine oil, warmed to normal operating temperature, replace oil filter
when used exclusively in short-distance operation, or at outside temperatures below 0°C (32 °F),
or no later than every 3 months, or every 3,000 km/1,800 miles *)
Change oil in gearbox, with oil warmed to normal operating temperature
at least every 2 years *)
Change final-drive lubricant, warmed to normal operating temperature
every 40,000 km/25,000 miles, or no later than every 2 years *)
Replace fuel filter *)
Standard replacement interval is 40,000 km/25,000 miles, with substandard fuel quality every 20,000 km/12,000 miles
Check battery electrolyte level, top up with distilled water as necessary
Battery terminals, clean and grease as necessary
Replace intake air filter element
Replace air filter every 10,000 km/6,000 miles when vehicle is exposed to high levels of dirt and dust,
or more frequently as indicated *)
Check front/rear circuit brake fluid
Check operation of brake system, inspect for leaks; repair/replace as indicated *)
Check brake pads and discs for wear, replace as required *)
[Without Integral ABS] Change brake fluid annually
[Integral ABS] Change wheel-circuit brake fluid at least once a year
[Integral ABS] Change control circuit brake fluid at least every 2 years *)
[Integral ABS] Perform bleed test with BMW MoDiTeC
Check clutch operating fluid level
Change clutch hydraulic circuit fluid *)
at least every 2 years
Check rear lug bolts to ensure they are tight
Check rear wheel bearing play by tilting wheel
Check swing arm bearings (no play), adjust as required *)
Check operation of side stand switch
Grease the side stand pivot
Retention poly-V-belt
Re-adjust new poly-V-belt one time at 10,000 km/6,000 miles
Replace poly-V-belt *)
Replace poly-V-belt every 60,000 km/35,000 miles
Inspect spark plugs
Replace spark plugs
Retorque cylinder heads
Check valve clearance and adjust as necessary
Check throttle cable for ease of motion, inspect for abrasion and bends, replace as indicated *)
Check cable free travel
Check synchronisation, adjust as necessary
Final inspection with operation assessment and road safety check:
–Condition of wheels and tyres, tire inflation pressure
–Clutch, shift mechanism, hand and foot brakes, steering
–Lighting and signal indicators, warning and indicator lamps, instruments
–Optional equipment
–Conduct road test as required
*) Write up on separate invoice; Not part of standard service procedure
Order No. 01 71 0 141 316 UX-VS-2, 05.2001 1st edition BMW recommends Castrol

BMW Motorrad
Pre-delivery check
R 1150 R
Customer Licence No.
Job Order No. Mechanic’s signature
BMW
Pre-delivery check
Check the shipping pallet for damage
Unpack the motorcycle
Inspect motorcycle for damage
Check to ensure that consignment is complete:
–Vehicle keys
–Onboard tool kit and literature
–All optional extras
Installing remaining items on motorcycle
Fill and charge battery (record charging date)
[Integral ABS] Perform bleed test with BMW MoDiTeC
Check engine oil when cold, correct as required
Check tyre pressures
Check tightness of rear lug bolts (note torque specification!)
Fill with fuel
Check headlight beam angle, adjusting if necessary
Final inspection and function check
–Clutch, shift mechanism
–Handbrake and footbrake
–Lighting and signal indicators, warning and indicator lamps, instruments
–Check operation of standard and optional equipment
–Road test as indicated
Confirm pre-delivery check in Service and Technical Booklet
Final cleaning
Vehicle delivered on:
Order No. 01 71 0 141 316 UX-VS-2, 05.2001 1st edition BMW recommends Castrol

BMW Motorrad
Service data
R 1500 R
Item Desired value Units / Specifications
Oil capacities
Engine (with filter) 3.75 (6.6) litres (Imp. pints)
[SI 11 048 90]
Engine (without filter) 3.5 (6.15) litres (Imp. pints)
[SI 11 048 90]
Transmission Initial filling
approx. 1.0 (1.76)
up to lower edge
of filler hole
litres (Imp. pints)
Brand-name hypoid gear oil, SAE
class GL 5 SAE 90
Transmission oil change
approx. 0.8 (1.41)
up to lower edge
of filler hole
litres (Imp. pints)
Brand-name hypoid gear oil, SAE
class GL 5 SAE 90
Rear wheel drive Initial filling/oil change
approx. 0.25 (0.44)
up to lower edge
of filler hole
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) mm (in)
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
for cold-start (increased idle) speed no play
for throttle (twistgrip) cable play approx. 0.5 (0.02) mm (in)
for divider cable no play
Brakes
Brake fluid DOT 4
Colour of identification mark on brake calipers/brake pads, front green
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 depending on load
front 2.2 - 2.5 (31.9 –36.26) bar (psi)
rear 2.5 - 2.9 (36.26 –42.06) bar (psi)
Tightening torques
Oil filter 11 Nm
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 5Nm
Poly-V belt preload 8Nm
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
Nut unscrew / 20
180
Nm
°tightening angle
M 10 screw unscrew / 40 Nm
Locknut, valve adjusting screw 8Nm
Cylinder head cover 8Nm
Spark plugs NGK BKR 7 EKC 25 Nm
Order No. 01 71 0 026 973 UX-VS-2, 07.2000 1st edition BMW recommends Castrol

Gruppe / Kapitel
00 Tightening torque Table of operating fluids
00 Pre-delivery check
00 Maintenance
11 Engine
12 Engine electrics
13 Fuel preparation and control
16 Fuel tank and lines
18 Exhaust system
21 Clutch
23 Gearbox
31 Front forks
32 Steering
33 Rear wheel drive
>> Continuation
Contents
<< Back
Group / Chapter

Gruppe / Kapitel
34 Brakes
36 Wheels and tyres
46 Frame
51 Equipment
52 Seat
61 General electrical equipment
62 Instruments
63 Lights
<< Back
>> Continuation
Group / Chapter

00.1
Contents Page
00
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 Tightening torque
Table of operating fluids

00.2

00.3
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
3M6screw 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

00.4
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 Nm 25
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
Model R 1150 R
Connection
11 Engine

00.5
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

00.6
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 Nm22
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

00.7
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

00.8
Model R 1150 R
Connection
32 Steering
Handlebars to fork bridge, tightening se-
quence:
1. Front fastener (as viewed in forward
direction of travel) until seated Nm 21
2. Rear fastener (as viewed in forward
direction of travel) Nm 21
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
gearbox Nm 160 (clean thread + Loctite 2701)
Floating bearing stud bolt, swinging arm to
gearbox
1. initial torque Nm 9
2. slacken
3. final torque Nm 7 (clean thread + Loctite 2701)
Locknut, floating bearing stud bolt,
swinging arm to gearbox Nm 160
Fixed bearing stud bolt,
swinging arm to rear axle housing Nm 160 (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 (clean thread + Loctite 2701)
Locknut, floating bearing stud bolt,
swinging arm to rear axle housing Nm 160

00.9
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-
rest plate Nm 22
Model R 1150 R
Connection
34 Brakes
Brake caliper to fork slider tube, Evo
brakes Nm 30
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-
nents Nm 18
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 pressure modulator to bracket Nm 7
ABS pressure modulator to battery carrier Nm 10
Model R 1150 R
Connection
33 Rear wheel drive

00.10
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
Nm 105
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-
chine screw) Nm 21
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)

00.11
Front and rear sections of front mudguard
to slider tube Nm 3 (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
Model R 1150 R
Connection
46 Frame

00.12
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
bearing grease 83 22 9 407 845 100 g tube
Contact spray Contact spray 81 22 9 400 208 300 ml spray
Chain spray Drive chain 72 60 2 316 676
72 60 2 316 667 50 ml spray 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
housings 83 19 9 407 855 500 ml spray
Developer MR 70 Crack testing agent for aluminium
housings 81 22 9 407 495 500 ml spray
Installation aids
BMW cooling spray Cooling spray 83 19 9 407 762 300 ml spray