User manual BMW R1150RT - MAINTENANCE BMW INTEGRAL ABS

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, handlebar lever Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm R 1150 RT 22 25 (clean thread + Loctite 243) 45 (free from oil and grease) 130 (clean thread + Loctite 243) 230 (lightly grease threads with Optimoly TA) 80 130 (clean thread + Loctite 2701) 73 42 (lightly grease threads with Optimoly TA 43 50 R 1150 RT 21 21 11 (Tuflok-Blau thread-locking compound; screw can be released and tightened a number of times) 00.7 Model Connection 33 Rear wheel drive Rear axle differential Oil filler plug Oil drain plug Threaded ring Hexagon nut, input bevel gear Cover to rear-wheel drive housing Swinging arm Reaction link to rear wheel drive / gearbox Nm Nm Nm Nm Nm Nm R 1150 RT 23 23 160 (clean thread + Loctite 577) 200 (clean thread + Loctite 2701) 35 43 (load approx. 85 kg (187 lbs) onto motorcycle and tighten loose reaction link) 160 (clean thread + Loctite 2701) Fixed bearing stud bolt, Swinging arm to right rear axle housing Floating bearing stud bolt, Swinging arm to left rear axle housing 1. initial torque 2. slacken 3. final torque Lock nut, floating bearing stud bolt, Swinging arm to left rear axle housing Fixed bearing stud bolt, Swinging arm to right of transmission Floating bearing stud bolt, Swinging arm to left of transmission 1. initial torque 2. slacken 3. final torque Lock nut, floating bearing stud bolt, Swinging arm to left of transmission Spring strut Spring strut to rear frame Spring strut to rear swinging arm Hydraulic spring adjustment on rear frame Nm Nm 9 Nm Nm Nm 7 (clean thread + Loctite 2701) 160 160 (clean thread + Loctite 2701) Nm 9 Nm Nm 7 (clean thread + Loctite 2701) 160 Nm Nm Nm 50 58 (clean thread + Loctite 243) 22 00.8 Model Connection 34 Brakes Front brake Brake caliper to EVO brake sliding tube Front brake caliper bleed screw Brake disc to front wheel Pivot screw, handlebar lever Nm Nm Nm Nm R 1150 RT 30 7 21 (clean thread + Loctite 2701) 11 (Tuflok-Blau thread-locking compound; screw can be released and tightened a number of times) Rear brake Brake caliper to rear wheel drive Rear brake caliper bleed screw Brake disc to rear wheel drive Master cylinder to footrest plate Brake pedal to footrest plate Footbrake-lever stop Brake lines Brake lines/brake hose to brake components Brake hose to brake lever fitting Filler adapter to brake line Bracket to front frame Retainer to rear frame BMW Integral ABS ABS pressure modulator on retainer ABS pressure modulator on battery carrier Model Connection 36 Wheels and tyres Quick-release axle clamp screws Quick-release axle threaded fastener Rear wheel to rear wheel drive screw wheel bolts finger-tight in a crosswise pattern Nm Nm Nm 22 30 105 Nm Nm 7 10 R 1150 RT Nm Nm Nm Nm Nm 18 18 18 9 9 (clean thread + Loctite 2701) Nm Nm Nm Nm Nm Nm 40 5 21 (clean thread + Loctite 2701) 9 21 (clean thread + Loctite 2701) 9 00.9 Model Connection 46 Frame Frame Frame to engine Struts to frame Strut to engine Rear frame to left/right of engine Rear frame with footrest plate to left/right of transmission Fairing bracket to frame Side stand Mounting bracket to right of engine, 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 Footrest plate Footrest plate to left/right transmission Footrest plate to left of rear frame M 10 screw M 8 screw Footrest plate to right of rear frame M 10 screw M 8 screw Shift lever to footrest plate Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm R 1150 RT 82 58 58 (clean thread + Loctite 2701) 42 (clean thread + Loctite 2701) 42 (clean thread + Loctite 2701) 20 72 (clean thread + Loctite 2701) 72 (clean thread + Loctite 2701) 21 (clean thread + Loctite 2701) 21 (clean thread + Loctite 243) 21 58 (clean thread + Loctite 2701) 19 36 19 36 19 35 00.10 Model Connection 51 Equipment Ignition/steering lock to fork bridge Model Connection 61 General electrical equipment Horn to holder Horn to fairing bracket Ground (earth) strap to engine block Battery carrier to rubber-metal element Strut to battery carrier Nm Nm Nm Nm Nm Nm R 1150 RT 20 (micro-encapsulated) R 1150 RT 8 (clean thread + Loctite 243) 10 9 8 10 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 compound 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 (narrow gap) Joint adhesive (wide gap) 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 aluminium housings Crack testing agent for aluminium 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 00 00 Pre-delivery check Contents General view of crated motorcycle Page ...................................................................................15 .............................................................16 Checking the crated motorcycle for damage In case of damage in Germany ...............................................................................................16 ..............................................................................16 In case of damage in importer markets Unpacking the motorcycle ....................................................................................................16 ..................................................................................................17 Assembling the motorcycle Installing the front wheel Installing front mudguard ............................................................................................................17 ...........................................................................................................17 Filling and charging the battery ...............................................................................................18 Installing cover for windscreen adjuster and installing windscreen Installing mirrors Assembling case ........................20 ............................................................................................................................20 ...........................................................................................................................20 ...................................................................................21 ..................................................................................21 ...........................21 Inspecting motorcycle for damage Checking that delivery is complete Checking engine oil level when cold, adding oil if necessary Checking tightness of rear wheel studs ........................................................................21 Checking tyre pressures .........................................................................................................21 Checking headlight beam angle, adjusting if necessary ......................................22 ..................................23 [Integral ABS] Performing bleed test with BMW MoDiTeC Final inspection and function check ................................................................................23 Final cleaning ................................................................................................................................23 Handing over the motorcycle ...............................................................................................24 00.13 00.14 00 General view of crated motorcycle W BM BM W R22009010 00.15 Checking the crated motorcycle for damage Unpacking the motorcycle · When the motorcycle arrives, check the crated motorcycle immediately for damage and, if necessary, examine the contents for consequential damage. · · · ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ In case of damage in Germany · · · 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 80788 München Tel. +49 89/14327-632 Fax. +49 89/14327-709 · · Lever off the cover. Remove plastic covers. Take out the separate pack of items: Front wheel Case lid Aerial Windscreen Covers Engine spoiler Cover for windscreen adjuster Front mudguard Mirrors Small parts/fasteners Documentation Remove the set of keys from the left rear footrest. Force off cross-struts with a suitable lever. 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 89/14327-632 Fax. +49 89/14327-709 Notify the supplier (e.g. freight company) without delay. Attention: Do not knock the cross-struts out or the motorcycle may be damaged. e · · Remove the end-walls. Remove the side-walls. Attention: Remove any nails projecting from the base of the crate or lying on the base or on the floor. e · Dispose of the packing materials in an environmentally responsible manner as described in Circular 23/91 - Sales. 00.16 Assembling the motorcycle Installing the front wheel 1 3 2 A e Attention: · Degrease all brake discs. Remove front straps. B R22000020 · Install the front wheel with spacer (1) and speedometer drive (2). e Attention: R22000010 Locate stop on slider tube (A) in recess in speedometer drive (B). · Using the straps, secure the front of the motorcycle to the assembly crane, BMW No. 46 5 640. · · · · · Tighten the retaining screw (3). Install the front brake calipers. Release the motorcycle from the assembly crane, BMW No. 46 5 640. Compress the front fork firmly several times. Tighten the clamp screws. e Attention: the brake lines, Bowden cables and d Warning: Do not damage fairing panels. · Raise the front of the motorcycle. The brakes are not ready for use until the brake pads have been bedded against the brake discs with the ignition switched on. e Attention: · · · Make sure that the motorcycle cannot topple sideways. Remove rear straps. Using the assembly crane, BMW No. 46 5 640, carefully push the motorcycle forward off the pallet. Extend the main stand and lower the motorcycle until it is resting firmly on the main stand and the rear wheel. X of quick-release axle ............................ 30 Nm Tightening torque: Bolt Clamping screws of quick-release axle ....... 22 Nm Brake caliper to fork slider ........................... 30 Nm Installing front mudguard Warning: Integral ABS When removing and installing the brake calipers, carefully force back the pistons only far enough to ensure that the wheel-circuit reservoir does not overflow. If fluid escapes, top up the level in the wheel-circuit reservoir to "MAX" mark. d · Remove screws securing the front brake calipers. R22000030 Lnot apply handbrake lever or footbrake lever with Note: Do brake calipers removed/front wheel removed. 00.17 4x 2x 4x 3x 4x R22460020 Filling and charging the battery · · · · · Remove seat. Remove left side fairing panel. Remove the air filter cover. Remove air intake pipe. Disengage the rubber strap holding the battery. Warning: Battery acid is highly caustic. It must not contact the eyes, face hands, clothing or the motorcycle's paintwork. d · · 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. R22000040 · · Disconnect the battery breather hose. Pull the battery to the left to remove. 00.18 · The battery does not achieve full charge capacity from being filled, so it has to be charged with a battery charger. · Switch on the ignition. L Note: L Note: on the ignition, always wait for the After switching BMW Integral ABS to complete its self-diagnosis. Do not operate the brake lever until self-diagnosis has completed. Follow the instructions for use supplied with the battery charger. Charge current (amps) .........................10 % of rated battery capacity (Ah) Charging time ............................................................. 5-10 hours · · With the ignition switched on, bed in the brake pads against the brake discs. Without starting the engine, fully open the throttle once or twice so that the Motronic control unit can register the throttle-valve positions. · Battery charge can be measured by checking the density of the battery acid. L Note: Acid density Battery full charged ............ 1.26-1.30 at a temperature of 20 °C (68 °F) Disconnecting the battery means that the entries in the fault memory of the Motronic MA2.4 control unit are deleted and the adaptation values are reset. This can temporarily impair the operating characteristics when the engine is restarted. · · · · 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. R22000050 e Attention: · · · · · · · Connect the positive battery terminal first, then the negative terminal. Connect the positive cable, coat with acid-proof grease and install the protective cap. Install the battery. Connect the negative cable and coat with acidproof grease. Assembly is the reverse of the disassembly procedure. Install the left side fairing panel. Install the engine spoiler. Install the covers. 00.19 Installing cover for windscreen adjuster and installing windscreen Assembling case R22000070 R22000060 · · · Install the cover for the windscreen adjuster. Install windscreen with washers. Install the aerial. · · ­ ­ Installing mirrors · · Position the lid on the case for alignment. Open the hinges of the lid and guide them into the base with the guide hook. From the inside, insert the pop rivets into the base and the hinges. 2x long rivets in hinge at rear, as viewed in forward direction of travel. 2x short rivets in hinge at front, as viewed in forward direction of travel. Engage riveting tool on rivets, hold the hinge at the outside to keep it in position and secure all four rivets. Oil the seal in the bottom of the case, using the sponge provided for the purpose. Attention: Make sure that the seal is not squeezed out of shape and that the lid closes without catching. e · · RT460280 · Carefully close the case. Insert the lock cylinder into the case with the key in the lock and turn the lock. Affix the stickers. · · · Connect the turn indicators. Position the mirror at the 3 attachment points. Engage by pressing at the front first, then the rear. 00.20 Inspecting motorcycle for damage · · · · · ­ ­ ­ Check for defects. Use the "express handling service" to notify BMW Motorrad, UX-VS-1 Fax: + 49 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 tightness of rear wheel studs Tightening torque: Securing screws for rear wheel .................. 105 Nm X · Checking tyre pressures Check/correct tyre pressures. Tyre pressures: one-up ............................... front 2.2 bar (31.90 psi) ........................................... rear 2.5 bar (36.26 psi) two-up ............................... front 2.5 bar (36.26 psi) ........................................... rear 2.9 bar (42.06 psi) two-up + luggage ............... front 2.5 bar (36.26 psi) ........................................... rear 2.9 bar (42.06 psi) Checking that delivery is complete ­ ­ ­ All optional extras Toolkit Documentation Checking engine oil level when cold, adding oil if necessary L Note: The difference between the oil level indicated when the engine is at operating temperature and the oil level indicated when the engine is very cold due to extremely low outdoor temperatures can be as much as 10 mm (0.3937 in). R22000080 · Check oil level with the motorcycle upright. e Attention: Never top up the engine-oil level past the "MAX" mark. Required level:............................................... MAX BMW recommends Castrol 00.21 Checking headlight beam angle, adjusting if necessary 1 2 R22000110 R22000090 · Turn screw (2) to adjust beam throw, if necessary. · · · · Motorcycle on level surface. Rider's weight on motorcycle (approx. 85 kg/187.4 lbs). Turn knob (1) counter-clockwise as far as it will go. Check headlight beam throw. Direction of rotation, left .....................further/higher Direction of rotation, right.................shorter/deeper R22000100 Setting for headlight beam angle adjuster ... .-10 cm (-3.937 in) at a distance of 10 m (32.8 ft) 00.22 Integral ABS Performing bleed test with BMW MoDiTeC Final inspection and function check Warning: Self-diagnosis is not performed unless both brake levers are in their fully released positions. Prior to conclusion of the self-diagnosis, only RESIDUAL BRAKING FUNCTION is available. Perform BMW Integral ABS self-diagnosis: · Release the brake levers, if necessary. · Switch on the ignition. · With the ignition switched on, bed in the brake pads against the brake discs. ABS warning light.............................flashes at 4 Hz General warning light ........................................ ON ­ Self-diagnosis is in progress d ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ · · · · · · · · 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 Fog lamps Brake light (operate brake at front and rear) Turn signals left/right Hazard warning lights Horn Telltale and warning lights Instruments Check operation 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. ABS warning light.............................flashes at 1 Hz General warning light ....................................... OFF ­ Self-diagnosis successfully completed. Perform bleed test with BMW MoDiTeC: · Remove front and rear seats. · Connect the BMW MoDiTeC to the diagnosis connector. Final cleaning · Clean the motorcycle. 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. Warning: When performing maintenance and repair work on BMW Integral ABS, never pump quickly or vigorously. d · · · Perform bleed test. Perform all requisite repair work. Perform BMW Integral ABS pull-away test: When a speed of 5 km/h (3 mph) is reached, the ABS warning light must go out. L Note: The ABS warning light and the general warning light must both be OFF after successful self-diagnosis and the pull-away test. 00.23 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 handlebars lever positions procedure for adjusting seat how to adjust the mirrors controls instruments and telltale 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: fully 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) Always check the oil level when the engine is at operating temperature, because the difference between the oil level indicated when the engine is at operating temperature and the oil level indicated when the engine is very cold due to extremely low outdoor temperatures can be as much as 10 mm (0.3937 in). After switching off the engine at operating temperature, wait at least 5 minutes for the oil to drain back into the sump. Checking the oil level just after the engine has been run or when it is not properly warm will falsify the reading. · ­ ­ ­ ­ ­ 00.24 00 00 Maintenance Contents Page Key to maintenance intervals ...............................................................................................29 Reading the BMW MoDiTeC fault code memory .......................................................29 (Inspections I, II, III and IV) .................................................................................................................29 Integral ABS: Performing bleed test with BMW MoDiTeC ....................................29 (Inspections I, II, III and IV) .................................................................................................................29 Changing engine oil, replacing oil filter element Changing oil in gearbox ......................................................30 (Inspections I, II, III and IV) .................................................................................................................30 ..........................................................................................................31 (Inspections III and IV) .......................................................................................................................31 or at the latest every 2 years ..............................................................................................................31 Changing the oil in the rear wheel drive ........................................................................31 (Inspections I, III and IV) ....................................................................................................................31 every 40,000 km (24,000 miles) or at the latest every 2 years ............................................................31 ...................................................................................................................32 (Inspection III) ....................................................................................................................................32 In normal operating conditions every 40,000 km (24,000 miles); if fuel quality is poor every 20,000 km (12,000 miles) ..................................................................................................................32 Replacing fuel filter Checking battery fluid level and topping up if necessary; cleaning and greasing the battery posts......................................................................................................34 (Inspections III and IV) .......................................................................................................................34 Replacing intake air filter element ....................................................................................35 (Inspection III) ....................................................................................................................................35 in very dirty and dusty operating conditions, replace every 10,000 km (6,000 miles) or even more frequently if necessary ..........................................................................................................................35 ...............................................................................................................35 (Inspection III) ....................................................................................................................................35 every 60,000 km (36,000 miles) .........................................................................................................35 .....................................................................................................36 (Inspections II and III) ......................................................................................................................36 .......................................................................................................................................36 ........................................................................................................................................36 Replacing Poly-V belt Checking brake fluid level Front brake Rear brake Checking brake system for correct operation and freedom from leaks; repairing/replacing if necessary ........................................................................................36 (Inspection III) ..................................................................................................................................36 00.25 Contents Checking brake pads and discs for wear/replacing Checking brake pads for wear Page ...............................................37 (Inspections II and III) .........................................................................................................................37 ................................................................................................37 Brake pads, front brake .....................................................................................................................37 Brake pads, rear brake ......................................................................................................................37 Checking brake disc wear .........................................................................................................38 Replacing brake pads .................................................................................................................38 Brake pads, front brake .....................................................................................................................38 Brake pads, rear brake ......................................................................................................................39 .........................................................40 Change brake fluid in wheel circuit once a year .................................................................................40 (Inspection IV) ....................................................................................................................................40 Changing/bleeding brake fluid in wheel circuit Bleeding/changing brake fluid in front wheel circuit ......................................................40 Instructions for filling front wheel circuit reservoir ..............................................................................42 Bleeding/changing brake fluid in rear wheel circuit