Maintenance BMW Integral ABS R 1150 RT 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 BMW Inspection at 1,000 km (600 miles) BMW Inspection every 20,000 km (12,000 miles) 40,000 40,000 60,000 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 2 years*) at the latest Change oil in rear wheel drive while at operating temperature if necessary, clean inductive sensor on rear wheel every 40,000 km (24,000 miles) or at the latest every 2 years*) Replace fuel filter *) Normally every 40,000 km (24,000 miles), if fuel is of poor quality every 20,000 km (12,000 miles) Check the battery fluid level, if necessary top up with distilled water Clean and grease battery poles if necessary Replace intake air filter element In very dirty and dusty operating conditions, replace every 10,000 km (6,000 miles) or even more frequently if necessary *) Replace Poly-V belt *) Replace the Poly-V belt every 60,000 km (36,000 miles); do not adjust it 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 every 2 years every 2 years [Integral ABS] perform bleed test with BMW MoDiTeC Check clutch fluid level Change the clutch fluid*) every 2 years at the latest Check tightness of rear wheel studs Check rear wheel bearing play by tilting wheel Check swinging arm bearings (freedom from play), adjust if necessary *) Grease the side stand pivot Check function of side stand contact switch Check condition of spark plugs Replace spark plugs Tighten cylinder head nuts Check/adjust valve clearances Check that the throttle cable moves freely and is free of kinks and chaffing, replace if necessary *) Check throttle-cable play check synchronisation, repair leaks if necessary *) Final inspection with road safety and functional check: ­ Condition of tyres and wheels, tyre pressures ­ Lights and signalling equipment, telltale and warning lights, instruments, ­ clutch, gearshift mechanism, hand brake and foot brake, steering, ­ if necessary, test drive every 2 years *) Charged as an additional item UX-VS-2, 12.2000 Printed in Germany Order No. 01 71 0 029 614 BMW Annual Service BMW Service 10,000 km (6,000 miles) 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 RT Item Oil capacities Engine (with filter) (without filter) Desired value 3.75 (6.6) 3.50 (6.15) 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 Transmission Initial filling Oil changes approx. 1.0 (1.76) approx. 0.8 (1.41) of oil to bottom edge of filler neck litres (Imp. pints) litres (Imp. pints) Brand-name hypoid gear oil, SAE class GL 5 SAE 90 Rear wheel drive Initial filling/oil change approx. 0.25 (0.44) of oil to bottom edge of filler neck 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 Colour of identification mark on brake calipers/brake pads, front Minimum front pad thickness Minimum rear pad thickness Minimum front disc thickness Minimum rear disc thickness Tyre pressures depending on load Inlet: 0.15 (0.006) Exhaust: 0.30 (0.012) adjust at TDC 0.8 (0.0315) 1.0 (0.039) 1,100 ±50 mm (in) mm (in) mm (in) mm (in) rpm zero play approx. 0.5 (0.02) zero play white 1.0 (0.039) 1.0 (0.039) (wear mark) 4.5 (0.177) 4.5 (0.177) front: 2.2 ­ 2.5 (31.9 ­ 36.26) rear: 2.5 ­ 2.9 (36.26 ­ 42.06) 11 32 30 30 23 22 5 8 20 30 40 105 unscrew/20 180 unscrew/40 8 8 25 UX-VS-2, 11.00 mm (in) free travel DOT 4 brake fluid mm mm mm mm (in) (in) (in) (in) bar (psi) bar (psi) 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 assembly to tank Poly-V belt preload Alternator to cover mount Brake caliper fasteners, front Brake caliper fasteners, rear Rear wheel studs Tightening cylinder heads Nut M 10 screw Locknut, valve adjusting screw Cylinder head cover Spark plugs NGK BKR 7 EKC Order No. 01 71 0 029 621 Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm ° tightening angle Nm Nm Nm Nm 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 .........................................................................................................................5 21 Clutch ............................................................................................................................................6 23 Transmission ..............................................................................................................................6 31 Front forks ...................................................................................................................................7 32 Steering ........................................................................................................................................7 33 Rear wheel drive .......................................................................................................................8 34 Brakes ...........................................................................................................................................9 36 Wheels and tyres ......................................................................................................................9 46 Frame .......................................................................................................................................... 10 51 Equipment ................................................................................................................................. 11 61 General electrical equipment ............................................................................................ 11 Table of operating fluids .........................................................................................................12 00.1 00.2 00 Tightening torque 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 wrench angle 1.3 Tighten all nuts to correct wrench 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 Nm Nm Nm 10 70 9 Nm Nm 9 20 Nm Nm 65 15 Nm ° Nm Nm Nm Nm Nm Nm Nm 20 180 40 9 18 8 8 9 9 Nm ° ° Nm Nm 20 90 90 40 9 R 1150 RT 00.3 Model Connection 11 Engine Oil filter Oil filter Oil drain plug 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 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) to initial torque Wrench angle M 8 screw M 6 screw Nm ° Nm Nm Nm ° Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm R 1150 RT 11 32 10 9 42 30 10 25 9 35 9 20 9 18 32 20 80 25 90 22 (oiled) 9 00.4 Model Connection 12 Engine electrics Starter motor to engine Positive lead to starter motor Alternator to generator support cover Tensioning and retaining link to alternator Spacer to alternator Positive lead to alternator Belt pulley to alternator Belt pulley to crankshaft Poly-V belt preload NGK BKR 7 EKC spark plug Model Connection 13 Fuel preparation and control Oil temperature sensor to crankcase Air temperature sensor to air-filter housing Model Connection 16 Fuel tank and lines Fuel tank to rear frame Fuel pump assembly to tank Model Connection 18 Exhaust system Manifold to cylinder head Clamp for manifold Silencer to footrest plate Oxygen sensor to silencer Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm R 1150 RT 20 10 20 21 21 15 50 50 8 25 R 1150 RT 25 10 R 1150 RT 22 5 R 1150 RT 21 45 (apply Optimoly TA to clamp seat) 35 45 (apply Optimoly TA to thread) 00.5 Model Connection 21 Clutch Clutch housing Initial tightening torque + additional wrench angle Housing cover to housing Clutch line to handlebar fitting Slave cylinder to gearbox Grub screw in filler adapter 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. terminal block, frame tube to transmission 3. to gearbox and right footrest plate Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm ° Nm Nm Nm Nm R 1150 RT 40 (oil screw threads lightly) 32 12 14 9 10 R 1150 RT 30 30 22 35 9 9 42 (clean thread + Loctite 243) 9 42 (clean thread + Loctite 243) 00.6 Model Connection 31 Front forks Quick-release axle clamp screws Sliding tube bridge to slider tube Threaded connection, fork fixed tube to fork bridge Threaded stud to frame Ball joint to sliding tube bridge Leading link Leading link to ball joint Initial tightening Final tightening Leading link to engine Right Left-hand screw cap Spring strut Spring strut to front frame Spring strut to leading link Model Connection 32 Steering Handlebars to fork bridge Handlebar weight to handlebars Pivot screw, handle ...