User manual BMW R1150GS - REPAIR MANUAL

Repair Manual R 1150 GS BMW Motorrad After Sales Publisher © BMW Motorrad After Sales UX-VS-2 All rights reserved. Not to be reprinted, translated or duplicated either wholly or in part without prior written permission. Errors and omissions excepted; subject to technical amendment. Printed in Germany 02/00 Order number 01 79 0 021 120 Introduction This Repair Manual will help you to perform all the main maintenance and repair work correctly and efficiently. It should be consulted regularly by workshop personnel as an addition to the practical and theoretical knowledge obtained in Training School courses. It is a contribution towards achieving even higher Service quality. A new issue of this repair manual will be published if amendments or additions (supplements) are needed. The latest issue date is shown in the header of the microfiche. Microfiches rendered invalid by the new issue should be destroyed without delay. All information in both text and illustrations refers to motorcycles in standard condition or with genuine BMW accessories installed, and not to motorcycles which have been modified in any way to depart from the manufacturer's specification. q The Repair Manual is structured in the logical sequence of the work to be performed: Removal, Disassembly, Repair, Assembly, Installation. q The entire contents are divided into individual chapters, corresponding to the Construction Groups. 11 . 10 Chap. Page number within chapter q Work to be performed during an Inspection is described in Group "00". The various inspection routines are numbered I, II, III and IV. This numbering is repeated in the work descriptions which follow, so that work can take place without interruption. q Use of the BMW special tools needed for certain tasks is described in the work instructions. If the need arises, repair instructions are also issued in the form of Service Information. This information is of course incorporated into the next issue of the Repair Manual. We also recommend you to consult the detailed illustrations on the Parts microfiches as an additional source of information. BMW Motorrad After Sales Published by: BMW Motorrad Hufelandstr. 6 D - 80937 München All rights reserved. Not to be reprinted, translated or duplicated either wholly or in part without prior written permission. Errors and omissions excepted; subject to technical amendment. Printed in Germany BMW Motorrad Maintenance schedule R 1100 S / R 850/1200 C / R 1150 GS BMW Inspection every 20 000 km (12 000 miles) 40 000 (24 000) 40 000 (24 000) 60 000 (36 000) BMW Inspection at 1000 km (600 miles) BMW Service every 10 000 km (6 000 miles) Customer Licence plate No. Order No. Mechanic's signature Read the fault code memory with the MoDiTeC Change oil while at regular operating temperature and renew the oil filter element if motorcycle is used only for short journeys or at outside temperatures under 0°C (32 °F), every 3 months, but at least every 3 000 km (1 800 miles) *) every 2 years Change oil in gearbox while at operating temperature at least every 2 years*) Change oil in rear wheel drive while at regular operating temperature; if necessary, clean inductive sensor on rear wheel every 40 000 km (24 000 miles) or at least every 2 years *) Renew fuel filter *) normally every 40 000 km (24 000 miles), if fuel quality is poor every 20 000 km (12 000 miles) every 2 years Check battery acid level, if necessary add distilled water Clean and grease the battery terminals, if necessary Renew intake air filter element in very dusty or dirty operating conditions, renew the intake air filter element every 10 000 km (6 000 miles) or even more often if necessary *) Renew Poly-V belt *) renew Poly-V belt every 60 000 km (36 000 miles); do not adjust Check brake fluid level at front and rear Check operation of brake system and freedom from leaks; repair/replace items if nec. *) Examine brake pads and discs for wear, renew if necessary *) Change the brake fluid annually Check clutch fluid level Change the clutch fluid at least every 2 years *) Check tightness of rear wheel studs Check rear wheel bearing play by tilting wheel Check swinging arm bearings (zero play); adjust if necessary *) Grease the side stand pivot Check function of side stand contact switch Check condition of spark plugs Renew spark plugs Check security of cylinder head nuts Check/adjust valve clearances Check throttle cable for free movement, abrasion and kinking; renew if necessary *) Check cable play Check synchronisation and eliminate leaks *) Final inspection with road safety and functional check: ­ Condition of tyres and wheels, rims and spokes if applicable, tyre pressures ­ Lights and signalling equipment ­ Telltale and warning lights ­ Clutch, gear shift ­ Front and rear brakes, steering ­ Instruments ­ If necessary, test ride *) Charged as an additional item UX-VS-2, 04.00 Printed in Germany every 2 years BMW Annual Service BMW Motorrad Pre-delivery check R 1100 S / R 850/1200 C / R 1150 GS Customer Licence plate 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: tools documentation keys correct optional extras Fill and charge the battery (mark with charging date) Check engine oil level when cold; add oil if necessary Check headlight beam angle, adjust if necessary Check security of rear wheel studs (comply with correct tightening torque) Check tyre pressures Fill fuel tank Final inspection as functional check: ­ ­ ­ ­ ­ Clutch, gear shift Front and rear brakes Lights and signalling equipment, telltale and warning lights, instruments Check operation of optional extras, ABS If necessary, test ride Confirm pre-delivery check in Service and Technical Booklet Final cleaning Motorcycle handed over on: UX-VS-2, 04.00 Printed in Germany BMW Motorrad Service data R 1150 GS Item Oil capacities Engine (with filter) (without filter) Desired value 3.75 (6.60) 3.50 (6.16) Unit of measurement/ specification 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 Gearbox Initial filling/oil changes approx. 1.0 (1.76) up to lower edge of filler hole approx. 0.25 (0.44) oil level with bottom of filler neck Inlet: 0.15 (0.006) Exhaust: 0.30 (0.011) adjust at TDC 0.8 (0.03) 1.0 (0.04) 1100± 50 litres (Imp. pints) Brand-name hypoid gear oil, SAE class GL 5 SAE 90 Rear wheel drive Initial filling/oil changes litres (Imp. pints) Brand-name hypoid gear oil, SAE class GL 5 SAE 90 Valve clearances Measured cold (max. 35 °C/95 °F) Ignition timing Static setting Spark plugs Electrode gap Wear limit Idle speed Throttle cable setting for cold-start (increased idle) speed for throttle (twistgrip) cable for divider cable Brakes Minimum Minimum Minimum Minimum front pad thickness rear pad thickness front disc thickness rear disc thickness mm (in) mm (in) mm (in) mm (in) min-1 zero play app. 0.5 (0.02) zero play 1.0 (0.04) wear mark 4.5 (0.18) 4.5 (0.18) front: 2.2 ­ 2.5 (31.3 ­ 35.6) rear: 2.5 ­ 2.9 (35.6 ­ 41.2) 11 32 30 30 23 21 6 8 20 40 initial torque 72 105 slacken/20 180 slacken/40 8 8 20 UX-VS-2, 06.99 mm (in) free travel DOT 4 brake fluid mm (in) mm (in) mm (in) bar (psi) bar (psi) Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm ° tightening angle Nm Nm Nm Nm Printed in Germany Tyre pressures depending on load Tightening torques: Oil filter Engine oil drain plug Gearbox oil filler plug Gearbox oil drain plug Rear wheel drive oil filler/drain plug Fuel tank to rear frame Fuel pump unit to tank Poly-V belt preload Alternator to alternator carrier cover Brake calliper mounting, front/rear Rear wheel studs Tightening cylinder heads Nut M 10 screw Locknut, valve adjusting screw Cylinder head cover Spark plugs Order No. 01 71 0 008 851 General table of contents Group / Section Group / Section << Back 00 Maintenance and general instructions 11 Engine 12 Engine electrics 13 Fuel preparation and control 16 Fuel tank and lines 18 Exhaust system 21 Clutch 23 Transmission 31 Front forks 32 Steering 33 Rear wheel drive >> Next Group / Section Group / Section >> Next 34 Brakes 36 Wheels and tyres 46 Frame 51 Equipment 52 Seat 61 General electrical equipment 62 Instruments 63 Lights << Back 00 00 Maintenance and general instructions Tightening torques and table of consumables Pre-delivery check Maintenance Contents Tightening torques Page .......................................................................................................................5 ......................................................................................................... 12 Table of operating fluids 00.1 Pre-delivery check Contents - Pre-delivery check Pre-delivery check Page ..................................................................................................................... 13 ................................................................................... 13 ............................................................................ 14 General view of crated motorcycle Check the shipping crate for damage In case of damage in Germany ............................................................................................... 14 .............................................................................. 14 In case of damage in importer markets Unpacking the motorcycle .................................................................................................... 14 ................................................................................... 15 .................................................................................. 15 ..................................................................... 16 Inspecting motorcycle for damage Checking that delivery is complete Installing remaining items on motorcycle Install the windscreen Installing sump guard ................................................................................................................. 16 .................................................................................................................. 17 .......................................................................................... 18 ................................................................................. 18 Filling and charging the battery Disengaging and raising the fuel tank Filling and charging the battery .............................................................................................. 18 ............... 19 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 ......................................20 ........................................................................20 ........................................................................................................20 ........................................................................................................20 ................................................................................21 Final inspection and function check Final cleaning ...............................................................................................................................21 ...............................................................................................21 Handing over the motorcycle 00.2 Maintenance Contents - Maintenance Maintenance Page ..................................................................................................................................22 ..............................................................................................22 ................................................................................22 Key to maintenance intervals (Inspections I, II, III and IV) Reading out MoDiTeC fault memory Changing engine oil, replacing oil filter element (Inspections I, II, III and IV) ......................................................22 Changing oil in gearbox (Inspections III and IV) or at the latest every 2 years ..........................................................................................................23 Changing the oil in the rear wheel drive ........................................................................23 (Inspections I, III and IV) Every 40,000 km (24,000 miles) or at the latest every 2 years ...................................................................................................................24 (Inspection III) In normal operating conditions every 40,000 km (24,000 miles); if fuel quality is poor every 20,000 km (12,000 miles) Replacing fuel filter Checking battery fluid level and topping up if necessary; cleaning and greasing the battery posts ....................................................................................................26 (Inspections III and IV) Replacing intake air filter element ....................................................................................26 (Inspection III) In very dirty and dusty operating conditions, replace every 10,000 km (6,000 miles) or even more frequently if necessary Replacing Poly-V belt ...............................................................................................................27 (Inspection III) (every 60,000 km/36,000 miles) Checking brake system for correct operation and freedom from leaks; repairing/replacing if necessary ........................................................................................28 (Inspection III) Checking brake fluid level (Inspections II and III) .....................................................................................................28 Front brake Rear brake .......................................................................................................................................28 ........................................................................................................................................28 ...............................................29 Checking brake pads and discs for wear/replacing (Inspections II and III) Checking front brake pad wear Checking rear brake pad wear Checking brake disc wear ..............................................................................................29 ................................................................................................29 ........................................................................................................29 ........................................................................................30 .........................................................................................30 Replacing brake pads, front brake Replacing brake pads, rear brake 00.3 Contents - Maintenance Changing brake fluid and bleeding brake system Change the brake fluid annually (Inspection IV) Page ....................................................31 Bleeding front brake circuit/changing brake fluid Additional information for [ABS] ...........................................................31 Bleeding rear brake circuit/changing brake fluid Checking clutch operating fluid level (Inspections II and III) ............................................................33 ..............................................................................34 Changing the clutch fluid (Inspections IV) at the latest every 2 years .......................................................................................................34 Checking tightness of rear wheel studs (Inspection I) ........................................................................35 Checking rear wheel bearing play by tilting wheel (Inspection III) ..................................................35 Checking swinging arm bearings, adjusting if necessary (Inspections I and III) ...................................35 Greasing the side stand pivot (Inspections I, II and III) ..............................................................................................36 Checking function of side stand contact switch (Inspections I, II, III and IV) ......................................................36 Checking/replacing spark plugs (Inspection II) check/(Inspection III) replace ........................................................................................36 Tightening cylinder heads (Inspection I) .....................................................................................................37 Checking/adjusting valve clearances (Inspections I, II and III) .............................................................................37 Checking freedom of throttle cable, checking for chaffing and kinks, replacing if necessary Checking throttle-cable play Checking and adjusting idle speed and throttle-valve synchronisation (Inspections I, II and III) ......38 Final inspection with road safety and functional check (Inspections I, II, III and IV) Road safety check Roadworthiness check .......................................39 00.4 00 Tightening torques Model Connection 11 Engine Cylinder head Tightening sequence: 1. Tighten cylinder head nuts (oiled) in diagonally opposite sequence 1.1 Tighten all nuts to closing torque 1.2 Tighten all nuts to correct angle 1.3 Tighten all nuts to correct angle 2. M 10 screw 3. M 6 screw After 1,000 km (600 miles), tighten cylinder head nuts in diagonally opposite sequence: 1. Slacken one nut 2. Tighten nut to initial torque 3. Tighten nut to wrench angle 4. Slacken and retighten M 10 screw Timing gear carrier to cylinder head Bearing cap on rocker shaft Locknut, valve adjusting screw Cylinder head cover to cylinder head Camshaft end cover to cylinder head Air intake connection to cylinder head Camshaft Chain sprocket to camshaft Camshaft bearing cap Alternator mount cover M 6 screw M 8 screw Auxiliary shaft Chain sprocket to crankshaft Chainwheel to auxiliary shaft Chain tensioner housing to engine block Oil filter Oil filter Oil drain plug 11 32 10 70 9 9 20 65 15 180° 40 9 18 8 8 9 9 20 90° 90° 40 9 20 R 1150 GS Nm 00.5 Model Connection 11 Engine Oil pump Mesh filter basket to engine block Oil pump cover Pressure relief valve Oil pressure switch Oil cooler Cooling oil line to engine block Cooling oil line - banjo screw with oil vent valve Oil lines to oil cooler Oil cooler to bracket Oil cooler return line to engine block Oil cooler connection to crankcase Cylinders Tightening sequence: 1. M 8 screw 2. M 6 screw 3. Chain guide rail pivot screw Timing chain Chain tensioner Connecting rod Big end cap Closing torque Wrench angle Crankcase Tightening sequence: M 10 screw (oiled) Initial torque Wrench angle M 8 screw (oiled) M 6 screw 12 Engine electrics Starter motor to engine Starter cover to gearbox housing Positive lead to starter motor Alternator to alternator support cover Tensioning and retaining link to alternator 90° 80° R 1150 GS Nm 10 9 42 30 10 25 25 9 35 9 20 9 18 32 20 25 22 9 20 7 10 20 21 00.6 Model Connection 12 Engine electrics Spacer to alternator Positive lead to alternator Belt pulley to alternator Standard alternator 560 W Special alternator 700 W Belt pulley to crankshaft Poly-V belt preload Spark plug 13 Fuel preparation and control Temperature sensor, oil, in crankcase Temperature sensor, air, in air-filter housing 16 Fuel tank and lines Fuel tank to rear frame Fuel pump assembly to tank 18 Exhaust system Manifold to cylinder head Clamp for manifold Front silencer to manifold Front silencer to main-stand link Silencer to rear frame at top Oxygen sensor to silencer End cap to rear silencer Bracket to rear silencer 21 Clutch Clutch housing Closing torque Wrench angle Housing cover to housing Clutch line to handlebar fitting Slave cylinder to gearbox Grub screw in filler adapter 32° R 1150 GS Nm 21 15 Do not release 50 50 8 20 25 10 21 6 21 45 (apply Optimoly TA to clamp seat) 45 (apply Optimoly TA to clamp seat) 20 35 45 (apply Optimoly TA to thread) 8 (threads greased) 15 (threads greased) 40 (oil screw threads lightly) 12 14 9 10 00.7 Model Connection 23 Transmission Oil drain plug Oil filler plug Gearbox to engine block Shift lever to footrest plate Selector lever to selector shaft Housing cover to housing Frame tube to gearbox 1. to gearbox and left footrest plate 2. clamp block, frame tube to gearbox 3. to gearbox and right footrest plate 31 Front forks Quick-release axle clamp screws Fastener, fixed tube and fork bridge Slider tube bridge to slider tube Threaded stud to frame Ball joint to fork slider bridge Leading link to ball joint Leading link to engine Screw cap to leading link Suspension strut to front frame Spring strut to leading link 32 Steering Handlebar to fork bridge Handlebar weight to handlebar Pivot screw, handlebar lever R 1150 GS Nm 30 30 22 35 9 9 42 (clean thread + Loctite 243) 9 42 (clean thread + Loctite 243) 22 45 (free from oil and grease) 25 (clean thread + Loctite 243) 130 (clean thread + Loctite 243) 230 (apply light coat of Never Seeze to thread) 130 (clean thread + Loctite 2701) right 73 left 42 (apply light coat of Never Seeze to thread) 43 50 21 21 11 (Tuflok Blue thread-locking compound; screw can be released and tightened a number of times) 00.8 Model Connection 33 Rear wheel drive Oil filler plug Oil drain plug Threaded ring Hexagon nut, input bevel gear Cover to rear-wheel drive housing Fixed bearing stud, swinging arm to gearbox/rear axle housing Floating bearing stud, swinging arm to gearbox/rear axle housing Locknut of floating bearing stud bolt Reaction link to rear wheel drive R 1150 GS Nm 23 23 160 (clean thread + Loctite 577) 200 (clean thread + Loctite 2701) 35 160 (clean thread + Loctite 2701) 7 (clean thread + Loctite 2701) 160 43 (load approx. 85 kg (187 lbs) onto motorcycle and tighten loose reaction link) 40 (load approx. 85 kg (187 lbs) onto motorcycle and tighten loose reaction link) 50 58 (clean thread + Loctite 243) 22 Reaction link to gearbox Spring strut to rear frame Spring strut to rear swinging arm Hydraulic spring preload adjuster to footrest plate 34 Brakes Brake caliper to fork slider tube Brake caliper to rear wheel drive Brake disc to front wheel Brake disc to rear wheel drive Master cylinder to footrest assembly Footbrake lever to footrest assembly Footbrake-lever stop Brake lines/brake hose to brake components Brake hose to bracket Brake hose to brake lever fitting Hose bracket to helmet lock Bracket to front frame Bracket to rear frame Bracket to fork bridge ABS sensor 40 40 24 (clean thread + Loctite 243) 21 (clean thread + Loctite 243) 9 21 9 18 9 18 9 9 9 (clean thread + Loctite 2701) 5 (clean thread + Loctite 2701) 4 (handtight) 00.9 Model Connection 34 Brakes Front brake caliper bleed screw Rear brake caliper bleed screw Pressure modulator bleed screw Filler adapter in brake caliper Grub screw in filler adapter ABS unit to holder M 6 screw 36 Wheels and tyres Quick-release axle clamp screws Quick-release axle threaded fastener Rear wheel to rear-wheel drive Hand-tighten wheel studs, then tighten in diagonally opposite sequence Initial tightening Final tightening Sensor ring to front/rear wheel Spoke nipple Grub screw 46 Frame Frame to engine Struts to frame Struts to engine Rear frame to gearbox/engine to gearbox and footrest plate to engine Carrier plate for main stand to engine, right M 12 screw Pivot mount to engine, left M 12 screw M 8 screw Pivot mount of main (centre) stand (stud bolt) Pivot mount of main (centre) stand (machine screw) Side stand to pivot mount R 1150 GS Nm 14 6 14 18 (clean thread + Loctite 243 or new filler adapter) 10 8 (clean thread + Loctite 243) 22 30 72 105 4 (hand tight, clean threads + Loctite 2701) 3.5 + 2 1.1 82 58 58 (clean thread + Loctite 2701) 42 (clean thread + Loctite 243) 42 72 (clean thread + Loctite 2701) 72 (clean thread + Loctite 2701) 21 21 (clean thread + Loctite 243) 21 58 (clean thread + Loctite 2701) 00.10 Model Connection 46 Frame Footrest plate to gearbox/ Rear footrest plate to rear frame M 8 screws Fairing bracket to front frame Front carrier to fairing bracket Mudguard at bottom to slider tube Mudguard at bottom to slider tube bridge 51 Equipment Mirrors Ignition/steering lock to fork bridge 61 General electrical equipment Horn to holder Ground (earth) strap to engine block R 1150 GS Nm 21 21 8 4 (clean thread + Loctite 2701) 5 (clean thread + Loctite 2701) 10 20 (micro-encapsulated) 10 (clean thread + Loctite 243) 9 00.11 Table of operating fluids Item Lubricant Use Order number Quantity Staburags NBU 30 PTM Optimoly MP 3 Optimoly TA Silicone grease 300, heavy Retinax EP2 Contact spray Chain spray Sealants High-performance lubricating paste High-performance lubricating paste High-temperature assembly paste Damping grease 07 55 9 056 992 75 g tube 07 55 9 062 476 100 g tube 18 21 9 062 599 100 g tube 07 58 9 058 193 10 g tube Wheel, steering head and taper roller 83 22 9 407 845 100 g tube bearing grease Contact spray Drive chain 81 22 9 400 208 300 ml spray 72 60 2 316 676 50 ml spray 72 60 2 316 667 300 ml spray 3-Bond 1110 B 3-Bond 1209 OMNI VISC 1002 Loctite 574 Loctite 577 Curil K 2 Surface sealant Surface sealant Surface sealant Surface sealant Thread locking compounds Heat-conductive sealant 07 58 9 056 998 5 g tube 07 58 9 062 376 30 g tube 07 58 1 465 170 90 g tube 81 22 9 407 301 50 ml tube 07 58 2 328 736 5 g tube 81 22 9 400 243 250 g can Adhesives and retaining agents Loctite 648 Loctite 638 Loctite 243 Loctite 270 Loctite 2701 Loctite 454 Cleaners Joint adhesive (low clearance) Joint adhesive (greater clearance) Thread retainer, medium-strength Thread retainer, strong Thread retainer, strong Cyanacrylate adhesive (gel) 07 58 9 067 732 5 g bottle 07 58 9 056 030 10 ml bottle 07 58 9 056 031 10 ml bottle 81 22 9 400 086 10 ml bottle 33 17 2 331 095 10 ml bottle 07 58 9 062 157 20 g tube Brake cleaner Metal Polish Testing agents Brake cleaner Polish for chrome-plated parts 83 11 9 407 848 600 ml spray 82 14 9 400 890 100 g tube Penetrant MR 68 Developer MR 70 Crack testing agent for aluminum housings Crack testing agent for aluminum housings 83 19 9 407 855 500 ml spray 81 22 9 407 495 500 ml spray Installation aids BMW cooling spray Cooling spray 83 19 9 407 762 300 ml spray 00.12 Pre-delivery check General view of crated motorcycle 00.13 Check the shipping crate for damage Unpacking the 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 · Lever off the cover. Take out the separate pack of items: Documentation Windscreen Sump guard with fasteners Force off cross-struts with a suitable lever. · · · Note the damage on the delivery slip. Read the information sheet on damage in transit. Notify the supplier without delay (e.g. freight company or DB) and also Bavaria Wirtschaftsagentur GmbH Abteilung ZW - 12 D-80788 München Tel. 089/14327-632 Fax. 089/14327-709 Caution: Do not knock the cross-struts out or the motorcycle may be damaged. e · · Remove the end-walls. Remove the side-walls. Caution: Remove any nails projecting from the base of the packing or lying on the base or on the floor. e · · 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. +49 (0)89 14327-632 Fax. +49 (0)89/14327-709 Notify the supplier (e.g. freight company) without delay. Loosen the front tensioning straps. Release the handlebar and resecure in correct position (punch marks aligned). Caution: Do not push the motorcycle until the handlebar has been secured in the correct position. e X · · · · Tightening torque: Handlebar to fork bridge .............................. 21 Nm Loosen the rear tensioning straps. Push the motorcycle forwards off the pallet. Remove the set of keys from the left rear footrest. Dispose of the packing materials in an environmentally responsible manner as described in Service Information 23/91 - Sales - . 00.14 Inspecting motorcycle for damage · · · · · ­ ­ ­ Check for defects. Use the "express handling service" to notify BMW Motorrad, UX-VS-1 Fax: +49 (0)89 382 33220 Rectify the fault. If parts are needed, order them through the usual channel. Costs are to be processed by the warranty claim system (stage 4). Defect codes: Parts missing 10 01 00 00 00 Parts damaged 10 02 00 00 00 Incorrect parts delivered 10 03 00 00 00 Checking that delivery is complete ­ ­ ­ All optional extras Toolkit Documentation 00.15 R21000070 Installing remaining items on motorcycle Install the windscreen · Carefully tighten the securing screws by hand. 00.16 R21000080 Installing sump guard · Install the spacer bushing at the front left. X Tightening torque: Bushing to engine block............................... 20 Nm · · · Install the front rubber mounts with the long thread down. Install the rear rubber mounts. Install the inner plate with the outer guard. 00.17 R21000100 Filling and charging the battery Disengaging and raising the fuel tank L Note: Follow the instructions for use supplied with the battery charger. Charge current (amps) ......................... 10 % of rated battery capacity (Ah) Charging time ..............................................................5-10 hours e Caution: Fuel is flammable and a hazard to health. Observe relevant safety regulations. · · Remove seat. Remove right side trim. · · Remove the fastener securing the fuel tank at the rear right. Raise the rear of the fuel tank and prop it in this position on a wooden block or similar. · Battery charge can be measured by checking the density of the battery acid. Acid density Battery fully charged .......1.26-1.30 at 20 °C (68 °F) Filling and charging the battery Warning: Battery acid is highly caustic. Protect your eyes, face, hands, clothing and the paintwork. d · · · · · · · · · · Shake the battery slightly to allow the gas bubbles to escape. Wait until the battery acid has settled, check that no more bubbles rise and if necessary, top up the acid to the max. mark. Reinstall the plugs. Make a note of the charging date on the battery. Disengage the rubber strap holding the battery. Disconnect the battery breather hose. Remove the battery. Fill all the cells with pure battery acid of density 1.28 to the upper mark. Allow the battery to stand for approximately 30 minutes. The battery does not achieve full charge capacity from being filled, so it has to be charged with a battery charger. Caution: Connect the positive battery terminal first, then the negative terminal. e · · · · · · Install the battery. Apply acid-proof grease to the battery terminal posts. Connect the battery breather line. Secure the fuel tank in position. Install the right side trim panel. Install the seat. 00.18 · · Switch on the ignition. Without starting the engine, fully open the throttle once or twice so that the Motronic control unit can register the throttle-valve positions. Checking engine oil when engine is cold, topping up if necessary 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. MAX MIN X tank to frame ........................................ 21 Nm Tightening torque: Fuel S000040 · Check oil level with the motorcycle upright. e Caution: Never top up the engine-oil level past the "MAX" mark. Required level:............................................... MAX 00.19 Checking headlight beam angle, adjusting if necessary Checking tightness of rear wheel studs X Tightening torque: · Rear wheel studs ....................................... 105 Nm Checking tyre pressures Check/correct tyre pressures. Tyre pressures: Solo ..................................... front 2.2 bar (31.3 psi) ............................................. rear 2.5 bar (35.6 psi) Two-up ................................ front 2.5 bar (35.6 psi) ............................................. rear 2.7 bar (38.4 psi) R21000140 Two-up + luggage ................ front 2.5 bar (35.6 psi) ............................................. rear 2.9 bar (41.2 psi) · · · · · Motorcycle on level surface. Rider's weight on motorcycle (approx. 85 kg/176 lbs). Move swivel lever to horizontal position (basic setting). Turn the adjusting screws to correct the headlight beam throw. Attaching adhesive label · Remove the adhesive label from the package and fix it in position at the bottom of the glass cover of the rev. counter. Lateral adjustment: ........................ Adjusting screw on left of headlight Vertical adjustment: ......................Adjusting screw on right of headlight Turn screw anti-clockwise:............... longer throw Turn screw clockwise: ..................... shorter throw S000080 Setting for headlight beam angle adjuster .................................................... -15 cm (- 5.9 in) .......................... . over a distance of 10 m (32.8 ft) 00.20 Final inspection and function check 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. · · · · ­ ­ ­ ­ ­ ­ ­ ­ ­ · ­ · · · Clutch Check gear shift action. Handbrake and foot brake Check lights and signalling equipment: Front and rear parking lights Instrument lighting Low and high headlight beams, headlight flasher Brake light (operate brake at front and rear) Turn signals left/right Hazard warning flashers Horn Telltale and warning lights Instruments Where necessary, check function of optional extras: ABS: perform starting test. When a speed of 5 km/h (app. 3 mile/h) is reached, both ABS warning lights must go out. If necessary, take the motorcycle for a test ride. Confirm pre-delivery check in Service and Technical Booklet. See "Checking motorcycle for damage" if defects are found. · ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ · Final cleaning · Clean the motorcycle. The following points must be demonstrated and explained to the customer: documentation and stowage space toolkit and stowage space suspension preload adjustment to suit total weight checking brake fluid/clutch operating fluid provision for adjusting handlebar lever positions how to adjust the mirrors controls instruments and telltale lights optional equipment and accessories fitted noise during the regular ABS self-diagnosis procedure The user must be given the following information: running-in recommendations and inspection intervals safety check the clutch fluid level rises gradually as the motorcycle is ridden (clutch lining wear) before checking the engine oil level, the engine must be switched off for at least 10 minutes and the motorcycle must be standing on a flat, level surface Lnot use a steam or high-pressure water jet. The Note: Do high steam or water pressure could damage seals, the hydraulic system or electrical components. 00.21 Maintenance Key to maintenance intervals ­ ­ ­ ­ BMW Inspection at 1,000 km (600 miles) BMW Service every 10,000 km (6,000 miles) BMW Inspection, every 20,000 km (12,000 miles) BMW Annual Service I II III IV Reading out MoDiTeC fault memory (Inspections I, II, III and IV) 11 4 650 C000030