BMW R 1150 RT Repair Manual
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BMW R 1150 RT Repair Manual

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R 1150 RT
BMW Motorrad
After Sales

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  • Page 1 Repair Manual R 1150 RT BMW Motorrad After Sales...
  • Page 2 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 07/2001...
  • Page 3 A new issue of this repair manual will be published if amendments or additions (supplements) are needed. 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.

  • Page 4: How To Use This Manual

    The list of contents is followed by the Technical Data table. Key to symbols In this Repair Manual for the R 1150 RT model, the following symbols are used; their meanings are ex- plained in the table. Special instructions aimed at improving the work procedures...
  • Page 5 Job Order No. Date Mechanic’s signature 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...

  • Page 6: Pre-Delivery Check

    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!)
  • Page 7 BMW Motorrad Service data R 1150 RT Item Desired value Units / Specifications Oil capacities litres (Imp. pints) Engine (with filter) 3.75 (6.6) [SI 11 048 90] litres (Imp. pints) Engine (without filter) 3.5 (6.15) [SI 11 048 90] approx. 1.0 (1.76) litres (Imp.

  • Page 8: 13 Fuel Preparation And Control

    Contents << Back Gruppe / Kapitel Group / Chapter 00 Tightening torques, Table of operating fluids 00 Pre-delivery check 00 Maintenance 11 Motor 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...
  • Page 9 >> Continuation Gruppe / Kapitel Group / Chapter 34 Brakes 36 Wheels and tyres 46 Frame 51 Equipment 52 Seat 61 General electrical equipment 62 Instruments 63 Lights << Back...

  • Page 10: Table Of Contents

    00 Tightening torques, Table of operating fluids Contents Page Tightening torques ........................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...
  • Page 11 00.2...
  • Page 12 Tightening torques Model R 1150 RT Connection 11 Engine Cylinder head Tightening sequence: 1 Tighten cylinder head nuts (oiled) in di- agonally opposite sequence 1.1 Tighten all nuts to closing torque 1.2 Tighten all nuts an additional ° 1.3 Tighten all nuts an additional °...
  • Page 13 Model R 1150 RT 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 bolt with oil vent...
  • Page 14 Model R 1150 RT Connection 12 Engine electrics Starter motor to engine Positive lead to starter motor Alternator to alternator mount cover Tensioning and retaining link to alternator Spacer to alternator Positive lead to alternator Belt pulley to alternator Belt pulley to crankshaft...

  • Page 15: 21 Clutch

    Model R 1150 RT Connection 21 Clutch Clutch housing Initial torque (oil screw threads lightly) + Additional wrench angle ° Housing cover to housing Clutch line to handlebar fitting Slave cylinder to gearbox Grub screw in filler adapter Model R 1150 RT...

  • Page 16: 31 Front Forks

    Model R 1150 RT Connection 31 Front forks Quick-release axle clamp screws Slider tube bridge to slider tube (clean thread + Loctite 243) Threaded fastener, fixed tube to fork bridge (free from oil and grease) Threaded stud to frame (clean thread + Loctite 243)

  • Page 17: 33 Rear Wheel Drive

    Model R 1150 RT Connection 33 Rear wheel drive Crown gear and pinion assembly Oil filler plug Oil drain plug Threaded ring (clean thread + Loctite 577) Hexagon nut, input bevel gear (clean thread + Loctite 2701) Cover to final drive housing...

  • Page 18: 34 Brakes

    Model R 1150 RT Connection 34 Brakes Front brake Brake caliper to EVO brake sliding tube Front brake caliper bleed screw Brake disc to front wheel (clean thread + Loctite 2701) Pivot screw, handlebar lever (Tuflok Blue thread-locking compound; screw...

  • Page 19: Frame

    Model R 1150 RT Connection 46 Frame Frame Frame to engine Struts to frame Strut to engine (clean thread + Loctite 2701) Rear frame to left/right of engine (clean thread + Loctite 2701) Rear frame with footrest plate to left/right...

  • Page 20: 51 Equipment

    Model R 1150 RT Connection 51 Equipment Ignition/steering lock to fork bridge (micro-encapsulated) Model R 1150 RT Connection 61 General electrical equipment Horn to holder (clean thread + Loctite 243) Horn to fairing bracket Ground (earth) cable to engine block...

  • Page 21: Table Of Operating Fluids

    Table of operating fluids Item Order No. Quantity Lubricant Staburags NBU 30 PTM High-performance lubricating grease 07 55 9 056 992 75 g tube Optimoly MP 3 High-performance lubricating grease 07 55 9 062 476 100 g tube Optimoly TA High-temperature assembly grease 18 21 9 062 599 100 g tube Silicone grease 300, heavy...
  • Page 22 83 19 9 407 855 500 ml spray housings Crack testing agent for aluminium Developer MR 70 81 22 9 407 495 500 ml spray housings Installation aids BMW cooling spray Cooling spray 83 19 9 407 762 300 ml spray 00.13...
  • Page 23 00.14...
  • Page 24 Installing cover for windscreen adjuster and installing windscreen ......20 Installing mirrors ..........................20 Filling and charging the battery ..................21 Integral ABS: Performing bleed test with BMW MoDiTeC ........23 Checking engine oil level when cold, adding oil if necessary ......23 Checking tyre pressures ......................24 Checking tightness of rear wheel studs ................24...
  • Page 25 00.16...

  • Page 26: General View Of Crated Motorcycle

    General view of crated motorcycle R22009010 00.17...

  • Page 27: Checking The Crated Motorcycle For Damage

    DB) and also Check for defects. • Bavaria Wirtschaftsagentur GmbH Use the “express handling service” to notify Abteilung ZW - 12 BMW Motorrad 80788 München UX-VS-1 Tel. +49 89/14327-632 Fax: + 49 89 382 33220 • Fax. +49 89/14327-709 Rectify the fault.

  • Page 28: Assembling The Motorcycle

    Remove rear straps. The brakes are not ready for use until the brake • Using the assembly crane, BMW No. 46 5 640, pads have been bedded against the brake discs carefully push the motorcycle forward off the with the ignition switched on.

  • Page 29: Installing Front Mudguard

    Installing front mudguard Installing cover for windscreen adjuster and installing windscreen R22000030 R22000060 • Install the cover for the windscreen adjuster. • Assembling case Install windscreen with washers. • Install the aerial. Installing mirrors R22000070 • Position the lid on the case for alignment. Open RT460280 the hinges of the lid and guide them into the base with the guide hook.

  • Page 30: Filling And Charging The Battery

    R22460020 Filling and charging the battery Warning: Battery acid is highly caustic. • Remove seat. It must not contact the eyes, face hands, clothing or • Remove left side fairing panel. the motorcycle’s paintwork. • Remove the air filter cover. •...
  • Page 31 Note: After switching on the ignition, always wait for the Note: BMW Integral ABS to complete its self-diagnosis. Follow the instructions for use supplied with the bat- Do not operate the brake lever until self-diagnosis tery charger. has completed.

  • Page 32: Integral Abs: Performing Bleed Test With Bmw Moditec

    Self-diagnosis successfully completed. Perform bleed test with BMW MoDiTeC: R22000080 • Remove front and rear seats. • Connect the BMW MoDiTeC to the diagnosis • connector. Check oil level with the motorcycle upright. Warning: Attention: When performing maintenance and repair work on Never top up the engine-oil level past the “MAX”...

  • Page 33: Checking Tyre Pressures

    Checking tyre pressures • Check/correct tyre pressures. Tyre pressures: one-up ......... front 2.2 bar (31.9 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) ...........

  • Page 34: Motor

    • Confirm pre-delivery check in Service and Tech- – optional equipment and accessories fitted nical Booklet. – features of BMW Integral ABS: • See “Checking motorcycle for damage” if defects brake servo, are found. residual braking function, pump noises, Final cleaning self-diagnosis with pull-away test.
  • Page 35 00.26...
  • Page 36 ....................31 Reading the BMW MoDiTeC fault code memory ............31 (Inspections I, II, III and IV) .........................31 Integral ABS: Performing bleed test with BMW MoDiTeC ........31 (Inspections I, II, III and IV) .........................31 Changing engine oil, replacing oil filter element ............32 (Inspections I, II, III and IV) .........................32...
  • Page 37 Contents Page Checking brake disc wear ......................40 Replacing brake pads .........................40 Brake pads, front brake ........................40 Brake pads, rear brake ........................41 Changing/bleeding brake fluid in wheel circuit ............42 Change brake fluid in wheel circuit once a year .................42 (Inspection IV) ............................42 Bleeding/changing brake fluid in front wheel circuit ............42 Instructions for filling front wheel circuit reservoir ................44...
  • Page 38 Contents Page Tightening cylinder heads .....................58 (Inspection I) ............................58 Checking/adjusting valve clearances ................59 (Inspections I, II and III) ........................59 Checking freedom of throttle cable, checking for chafing and kinks, replacing if necessary Checking throttle-cable play, checking and adjusting idle speed and throttle-valve synchronisation ........59 (Inspections I, II and III) ........................59 Final inspection with road safety and functional check...
  • Page 39 00.30...

  • Page 40: Maintenance Interval Codes

    The codes for service and maintenance intervals in this Repair Manual are as follows: — Break-in Inspection at 1000 km/600 miles ..I — BMW Service at 10 000 km/6,000 miles ... II — BMW Inspection at 20 000 km/12,000 miles..III — BMW Annual Service ........IV...

  • Page 41: Changing Engine Oil, Replacing Oil Filter Element

    Remove oil drain plug and drain off oil. 11 4 650 C000030 • Use oil filter wrench, BMW No. 11 4 650, to re- move the oil filter. • Coat sealing ring on new oil filter element with oil and install filter.

  • Page 42: Changing Oil In Gearbox

    R22000250 R28000100 • Remove oil filler plug (1). • Install oil drain tube, BMW No. 23 4 791, turning it back and forth to seat it. • Remove oil drain plug (2) and allow the oil to drain out. Attention: •...

  • Page 43: Replacing Fuel Filter

    R22160010 Replacing fuel filter • 16 12 008 Disconnect breather and overflow hoses. • Disconnect quick-connect adapters of the fuel (Inspection III) lines. • In normal operating conditions every 40,000 km Disconnect the plug of the fuel pump. • (24,000 miles); if fuel quality is poor every Drain fuel tank.
  • Page 44 Note correct direction of flow through fuel filter. Make sure that breather lines are correctly routed. • Secure non-reusable hose clips with pliers, BMW No. 13 1 500. Tightening torque: Fuel pump unit to fuel tank ......5 Nm Attention: Fuel tank to rear frame .........

  • Page 45: Checking Battery Fluid Level And Topping Up If Necessary; Cleaning And Greasing The Battery Posts

    R22000120 Checking battery fluid level 61 20 029 Note: and topping up if necessary; Disconnecting the battery means that the entries in cleaning and greasing the battery the fault memory of the Motronic MA2.4 control unit posts are deleted and the adaptation values are reset. This can temporarily impair the operating character- (Inspections III and IV) istics when the engine is restarted.

  • Page 46: Replacing Intake Air Filter Element

    Replacing intake air filter 13 72 000 element (Inspection III) in very dirty and dusty operating conditions, replace every 10,000 km (6,000 miles) or even more frequently if necessary R22000130 • Open clips securing air filter cover. • Replace air filter element. •...

  • Page 47: Checking Brake Fluid Level

    • Check brake fluid level at sight glass. Note: After switching on the ignition, always wait for the BMW Integral ABS to complete its self-diagnosis. Do not operate the brake lever until self-diagnosis has completed. Warning: When performing maintenance and repair work on BMW Integral ABS, never pump quickly or vigorously.

  • Page 48: Checking Brake Pads And Discs For Wear/Replacing

    Checking brake pads and discs for Brake pads, rear brake wear/replacing (Inspections II and III) Checking brake pads for wear Brake pads, front brake R22000170 • Visually inspect the brake pads. – Make sure that the brake disc is not visible through the bore (arrow) in the inner brake pad.

  • Page 49: Checking Brake Disc Wear

    4.5 mm (0.177 in) Note: rear: ..........4.5 mm (0.177 in) After switching on the ignition, always wait for the BMW Integral ABS to complete its self-diagnosis. Replacing brake pads Do not operate the brake lever until self-diagnosis has completed.

  • Page 50: Brake Pads, Rear Brake

    • 34 21 200 Brake pads, rear brake Installation is the reverse of the removal proce- dure. • Check operation of the brake system with the ig- Attention: nition switched on. Integral brakes, the front brake must be ready for use.

  • Page 51: Changing/Bleeding Brake Fluid In Wheel Circuit

    Integral brakes, the rear brake must be ready for • use. Use resetting tool, BMW No. 34 1 531, and locator, BMW No. 34 1 532, to force the pistons • Remove fuel tank. in the left and right brake calipers all the way back and hold them in this position.
  • Page 52 The higher the brake pressure the faster the fluid is • Slowly fill container, BMW No. 34 1 581, with pumped through the system, which means that the new brake fluid until it is approximately 1/2 full.

  • Page 53: Instructions For Filling Front Wheel Circuit Reservoir

    • “MAX” if necessary With the ignition switched on, bed in the brake • Install adapters 22, BMW No. 34 1 533, in reset- pads against the brake discs. • ting tool, BMW No. 34 1 531/532, for both front...
  • Page 54 BMW No. 34 2 541. • • Connect 1.5 m silicon hose, Check operation of the brake system with the ig- BMW No. 34 1 561, to the bleed screw of the left nition switched on. brake caliper. Attention: Note:...

  • Page 55: Bleeding/Changing Brake Fluid In Rear Wheel Circuit

    R28000170 stroys paint. • Install adapter, BMW No. 34 1 536, instead of the outboard brake pad. • Install resetting tool, BMW No. 34 1 531, with the handle toward the outside in the rear brake caliper, press the pistons fully back and secure them in this position.
  • Page 56 Note: bleed screw. • After switching on the ignition, always wait for the Disconnect the container from the wheel-circuit BMW Integral ABS to complete its self-diagnosis. reservoir. Do not operate the brake lever until self-diagnosis has completed. Attention: After changing and/or bleeding the brakes, always top up the fluid in the wheel-circuit reservoir to the correct level in accordance with the instructions.

  • Page 57: Instructions For Filling Rear Wheel Circuit Reservoir

    Top up the fluid in the wheel-circuit reservoir until one of the three protrusions in the filler neck just 34 1 531 touches the surface of the fluid (arrow). • Remove resetting tool, BMW No. 34 1 531, and adapter, BMW No. 34 1 536. R28000170 Warning: •...
  • Page 58 BMW No. 34 2 541. • Connect 1.5 m silicon hose, BMW No. 34 1 561, to the bleed screw. Attention: After all the work on the brake system has been completed, run a bleed test using the Note: BMW MoDiTeC.

  • Page 59: Changing/Bleeding Brake Fluid In Control Circuit

    Change brake fluid in control circuit every 2 years (Inspection IV) Warning: All repair and maintenance work on the BMW Integral ABS must be performed by trained, qualified specialists. Comply with all maintenance and repair instructions and always work through the various steps in the correct order.
  • Page 60 (3) and – front metering cylinder (1) for the second time using ring spanner, BMW No. 34 2 532, in accord- ance with instructions for bleeding. Instructions for bleeding: 1. Slowly pull brake lever until brake-light switch clicks (blow-by bore closed).

  • Page 61: Bleeding/Changing Brake Fluid In Rear Control Circuit

    – rear control circuit (3) and – rear metering cylinder (1) for the second time using ring spanner, BMW No. 34 2 532, in accord- ance with instructions for bleeding. R22000151 Instructions for bleeding: 1. Slowly depress brake lever until brake-light •...

  • Page 62: Checking Clutch Operating Fluid Level

    After all the work on the brake system has been completed, run a bleed test using the R22000190 BMW MoDiTeC. • Perform bleed test with BMW MoDiTeC. Specified level with a new clutch liner: 00.31) ........... Half way up sight glass •...

  • Page 63: Changing The Clutch Fluid

    Changing the clutch fluid • 21 52 005 Screw the bleed screw all the way into the filler adapter (valve in filler adapter closed). (Inspection IV) every 2 years at the latest Attention: While bleeding the system, do not allow the brake Note: fluid level to drop below the bottom edge of the ring The description applies to a brake system filling and...

  • Page 64: Checking Tightness Of Rear Wheel Studs

    Checking tightness of rear wheel Greasing the side stand pivot studs (Inspections I, II and III) (Inspection I) • Tighten the rear wheel studs with a torque wrench. Tightening torque: Securing screws for rear wheel ....105 Nm Checking rear wheel bearing play by tilting wheel (Inspection III) •...

  • Page 65: Tensioning Poly-V Belt

    BMW No. 12 3 551. 2 Loosen the alternator mounting bolts (3, 4). 3 Tighten and hold tensioning nut, BMW No. 12 3 551, with torque wrench. 4 Tighten upper retaining nut (4), then remove torque wrench from adjusting screw.

  • Page 66: Replacing Poly-V Belt

    Remove front intake pipe. 3 Tighten and hold tensioning • Disengage fairing bracket from end cover on left. nut, BMW No. 12 3 551, with torque wrench. • Remove front cover (1). 4 Tighten upper retaining nut (4), then remove •...

  • Page 67: Checking/Replacing Spark Plugs

    Remove cylinder head cover. • Pull off spark plug caps with special puller, BMW No. 12 3 520. • Use spark plug wrench, BMW No. 12 3 510, to Attention: remove the spark plugs. Catch escaping oil. Attention: Do not bend electrodes - risk of breakage! Spark plug:........

  • Page 68: Checking/Adjusting Valve Clearances

    Checking/adjusting valve Checking freedom of throttle 11 34 004 13 60 110 clearances cable, checking for chafing and kinks, replacing if necessary Check- (Inspections I, II and III) ing throttle-cable play, checking and adjusting idle speed and throt- tle-valve synchronisation (Inspections I, II and III) •...
  • Page 69 Note: Throttle cable free travel: Zero play can cause the throttle valves to rattle........approx. 2 mm (0.0787 in) • Connect hose of BMW Synchro to vacuum adapter and connect cables to BMW MoDiTeC. • Start the engine. Attention:...

  • Page 70: Final Inspection With Road Safety And Functional Check

    Final inspection with road safety and functional check (Inspections I, II, III and IV) Road safety check • Check wheels and tyres. • Check/correct tyre pressures. • Wait at least 10 minutes after heating the engine to operating temperature in the trial run/road test before checking/correcting engine oil level.
  • Page 71 11 Motor Contents Page Technical Data ..........................5 Cutaway drawing of engine ....................13 Lubricating-oil circuit ....................... 14 Cooling-oil circuit ........................15 Removing and installing engine ..................16 Removing engine .......................... 16 Installing auxiliary frame (raising frame unit clear of engine) ............... 18 Removing auxiliary frame (lowering frame unit onto engine) ...............
  • Page 72 Contents Page Removing and installing alternator mount cover with engine installed ....35 Removing alternator mount cover ..................36 Replacing radial shaft seal in alternator mount cover ..........36 Removing auxiliary shaft drive ....................37 Removing oil pump ........................38 Removing radial shaft seal on crankshaft with engine installed .......39 Disassembling crankcase ......................40...
  • Page 73 Contents Page Installing cylinder ..........................57 Installing cylinder head .......................58 Adjusting valve clearances .......................59 Installing cylinder head, right ....................60 Adjustment specification ........................60 Installing left cylinder head .......................61 Adjustment specification ........................61 Installing alternator mount cover ....................63 Installing magnetic gate/belt pulley ..................63 Timing the ignition ..........................64 Installing alternator ........................65 Poly-V belt adjusting procedure ......................66...
  • Page 74 11.4...
  • Page 75 Technical Data 11 Engine R 1150 RT Engine, general Type Four-stroke opposed twin, air-cooled with oil- cooled exhaust ports, installed longitudinally, 4 valves per cylinder, two overhead camshafts, electronic fuel injection. Location of engine number Crankcase Cylinder bore mm (in) 101 (3.9764) Stroke mm (in) 70.5 (2.77)
  • Page 76 Technical Data 11 Engine R 1150 RT Oil pump Oil pump 2 duocentric pumps Housing depth Cooling oil mm (in) 11.02...11.05 (0.4339...0.4350) Lubricating oil mm (in) 10.02...10.05 (0.3945...0.3957) Height of rotor Cooling oil mm (in) 10.965...10.98 (0.4317...0.4323) Lubricating oil mm (in) 9.965...9.98 (0.3923...0.3929)
  • Page 77 Technical Data 11 Engine R 1150 RT Valve seat ring Valve seat angle Inlet ° 45 Exhaust ° 45 Valve seat width ±0.15 ±0.006 Inlet mm (in) 1.1 (0.043 Wear limit mm (in) 2.5 (0.0984) ± 0.15 ± 0.0059 Exhaust mm (in) 1.4...
  • Page 78 Technical Data 11 Engine R 1150 RT Rocker arm Bore dia. mm (in) 16.016...16.034 (0.6306...0.6312) Rocker shaft dia. mm (in) 15.973...15.984 (0.6289...0.6293) Radial clearance mm (in) 0.032...0.061 (0.0016...0.0024) Wear limit mm (in) 0.1 (0.0039) End float min. mm (in) 0.05 (0.0019) max.
  • Page 79 Technical Data 11 Engine R 1150 RT Crankshaft Marking of main bearing and crankpin on front crank no paint mark Undersize 0 paint mark Undersize 1 (-0.25 mm/-0.0098 in) Undersize 0 (Undersize 1 = —0.25 mm/– 0.0098 in) Guide bearing bore dia.
  • Page 80 Technical Data 11 Engine R 1150 RT Connecting rod Bore dia. for big end bearing mm (in) 51.000...51.013 (2.0079...2.0084) Big end bearing dia. mm (in) 48.016...48.050 (1.8904...1.8918) Radial clearance mm (in) 0.025...0.075 (0.0010...0.0030) Wear limit mm (in) 0.13 (0.0051) Width of big end bearing eye mm (in) 21.883...21.935 (0.8616...0.8636)
  • Page 81 Technical Data 11 Engine R 1150 RT Pistons Piston dia. (Measuring plane A — see Checking pistons and cylinders) mm (in) 100.971...100.983 (3.9753...3.9758) Wear limit mm (in) 100.895 (3.9723) mm (in) 100.983...100.995 (3.9757...3.9763) Wear limit mm (in) 100.905 (3.9727) mm (in) 100.979...100.987 (3.9756...3.9759) Wear limit mm (in) 100.900 (3.9725)
  • Page 82 Technical Data 11 Engine R 1150 RT 3rd groove Coiled-spring ring Height mm (in) 1.97...1.99 (0.0776...0.0783) Wear limit mm (in) 1.9 (0.0748) mm (in) 0.30...0.55 (0.0118...0.0217) Wear limit mm (in) 1.20 (0.0472) Float mm (in) 0.020...0.060 (0.0008...0.0024) Wear limit mm (in) 0.15 (0.0059) Piston pin Piston pin dia.

  • Page 83: Cutaway Drawing Of Engine

    Cutaway drawing of engine 11.13...

  • Page 84: Lubricating-Oil Circuit

    Lubricating-oil circuit 11.14...

  • Page 85: Cooling-Oil Circuit

    Cooling-oil circuit 11.15...

  • Page 86: Removing And Installing Engine

    • Remove the battery. • Use hose clip pliers, BMW No. 17 5 500, to open clamp on crankcase breather hose at engine. 00 1 520 • Disconnect the hose for the crankcase breather from the crankcase.
  • Page 87 Remove fasteners securing fairing bracket to en- • Pull off spark plug cap with special puller, gine on left and right. • BMW No. 12 3 520. Remove front cover. • • Disconnect plugs of injection valves. Disconnect oil cooler line from engine and oil •...

  • Page 88: Installing Auxiliary Frame (Raising Frame Unit Clear Of Engine)

    Remove the gearbox, swinging arm, rear axle and rear wheel together. • Place auxiliary frame, BMW No. 46 5 630, in po- sition and secure to the rear spring-strut mount (2). • Engage the auxiliary frame to the front anchorage point for the fuel tank (3).
  • Page 89 If necessary, mask off the leading link to prevent it from being scratched. • Insert pin, BMW No. 46 5 630, from the left to align the front frame bores with the correspond- ing bores in the engine, insert the bolt from the right and tighten.

  • Page 90: Disassembling And Reassembling Engine

    RS110010 Disassembling and reassem- 11 00 103 bling engine Disassembling engine 11 00 • Secure engine mount, BMW No. 11 0 630, to engine block. • Transfer engine to assembly frame. 11 4 650 RS110950 • Drain oil from engine.

  • Page 91: Removing Cylinder Head Cover

    12 3 510 RS110020 Removing cylinder head cover 11 12 050 • Use spark plug wrench, BMW No. 12 3 510 to remove the spark plugs. Attention: Catch escaping oil. • Remove cylinder head cover. 11.21...

  • Page 92: Locking The Engine At Tdc

    Install locking device, BMW No. 11 5 640, to lock clutch housing. RS110461 Note: The engine can be set to top dead centre with the TDC pin, BMW No. 11 2 650, which is inserted into the clutch housing and the engine block at TDC. 11.22...

  • Page 93: Removing And Installing Chain Tensioner

    RS110060 Removing and installing chain 11 31 120 tensioner Attention: Do not mix up the chain tensioner pistons. When in- stalling, fit a new gasket. Work instructions, timing-chain tensioner Attention: Failure to observe this sequence can cause the chain tensioner piston on the left to drop into the timing-chain chamber.

  • Page 94: Removing And Installing Valve Gear Carrier

    M6 x 60 M6 x 30 M6 x 30 M6 x 30 S110110 Removing and installing valve 11 33 Note: gear carrier If no work is being carried out on the valve gear car- rier, remove it together with the cylinder head. •...

  • Page 95: Disassembling And Assembling Valve Gear Carrier

    RS110080 Disassembling and assem- 11 33 280 bling valve gear carrier • Remove bearing cap. • Insert a suitable pin into the bore (arrow) of the rocker shaft, and turn the shaft back and forth to remove it from its bearing. Attention: Do not mix up the rocker shafts and pushrods.
  • Page 96 RS110090 • Remove camshaft bearing cap (1). • Remove camshaft and bearing (2). Attention: Do not mix up the bucket-type tappets. • Remove bucket-type tappets. • Assembly is the reverse of the disassembly pro- cedure. Attention: Note direction of installation (3) for camshaft bearing cap.

  • Page 97: Removing Cylinder Head

    M10 x 70 M6 x 30 M6 x 30 M6 x 30 RS110110 Removing cylinder head 11 12 090 11.27...

  • Page 98: Disassembling, Checking, Repairing And Reassembling Cylinder Head

    Do not scratch sealing face on cylinder head. Place the head on a clean, non-scratching surface. • Mount valve spring compressor, BMW No. 11 5 690, onto cylinder head. • Compress the valve springs. • Gently tap valve head to release collets from spring retainer.

  • Page 99: Checking Valves For Wear

    Checking valves for wear • Clean combustion residue from valves. • Check valve dimensions ( 11.6). Remachining valve seat RS110890 Attention: Width (B) and diameter (D) must always be main- tained if valve seat is machined ( 11.7). Checking and repairing cylinder head •...

  • Page 100: Replacing Valve Guides

    (approx. 20 °C/68 °F). Mount the chilled valve guide on • Examine valve guide bore for: dia. 5 mm (0.1969 in) drift, BMW No. 11 5 673. • – wear, Drive valve guides into cylinder head with no de- –...
  • Page 101 Shrink a short length of tube (arrow) on to the end of the valve stem. • Install the valve stem seal with a 5 mm (0.1969 in) dia. drift, BMW No. 11 5 602. Attention: Remove the shrink-fit tube. •...

  • Page 102: Removing Cylinder

    RS110170 Removing cylinder 11 11 120 • Remove guide rail bearing screws (1). Attention: When removing the cylinder, use care to prevent the piston from knocking against the engine casing. • Remove cylinder retaining screws, and remove cylinder. Removing and disassembling 11 25 000 piston assembly Attention:...

  • Page 103: Checking Pistons And Cylinders

    Checking pistons and cylinders Assembling pistons 11 25 11 25 Reference temperature for measurements: ............20 ƒC (68 °F) R21110050 RS110180 Measure cylinder bore with internal probe at Note: 20 mm (0.7874 in) and 100 mm (3.9370 in) from the Make sure that the gap of the coiled spring is offset top in direction of piston pin, and again at a right an- approximately 180°...
  • Page 104 Use a felt-tipped pen or similar to mark the installed Note: positions on the conrods. When using tightening angle indicator, BMW No. 11 2 500, make sure the extensions are • Remove connecting rods. of the same length. Use a 3/8" square-drive socket wrench.

  • Page 105: Removing And Installing Alternator Mount Cover With Engine Installed

    11 11 045 Remove the alternator. • Remove poly-V belt. tor mount cover with engine installed • Install locking device, BMW No. 11 5 640, to lock clutch housing. • Attention: Remove pulley (1). Disconnect earth (ground) lead from battery.

  • Page 106: Removing Alternator Mount Cover

    11 11 11 11 047 alternator mount cover • Remove the alternator. • Install locking device, BMW No. 11 5 640, to lock clutch housing. • Remove pulley (1). Note: It is not necessary to remove magnetic gate (2) when removing the alternator mount cover as a unit.

  • Page 107: Removing Auxiliary Shaft Drive

    Remove chain tensioner (2). • Remove chain tensioning rail (3). • Remove chain guide rail (4). • Install locking device, BMW No. 11 5 640, to lock clutch housing. • Remove chain sprocket fastener (5). • Remove sprocket (6) and timing chain (7).

  • Page 108: Removing Oil Pump

    M6 x 45 M6 x 50 M6 x 45 M6 x 45 RS110410 M6 x 50 Removing oil pump 11 41 000 • Remove oil pump cover (1). Attention: Check installed positions of parts which have al- ready been run together. •...

  • Page 109: Removing Radial Shaft Seal On Crankshaft With Engine Installed

    • Attention: Screw the pull rod, BMW No. 00 8 581, into the Take care not to damage the sealing faces of crank- hole and use impact weight, BMW No. 00 8 582, case and crankshaft.

  • Page 110: Disassembling Crankcase

    RS110261 Disassembling crankcase 11 11 • Turn engine on to its side. • Remove screws on right side. 11.40...
  • Page 111 RS110260 • Turn engine on to its side. • Remove screws on left side. • Remove upper section of crankcase. 11.41...

  • Page 112: Removing Crankshaft, Auxiliary Shaft And Timing Chain Tensioning And Slide Rails

    S110050 Removing crankshaft, auxiliary 11 21 shaft and timing chain tensioning and slide rails 11.42...

  • Page 113: Removing And Installing Oil Intake Strainers

    Clamp crankshaft in a vise with protective jaws. • Coat the sealing face of the new oil level sight glass with tyre assembly paste and drive it in with drift, BMW No. 00 5 550. Attention: Do not mix up the conrods. •...

  • Page 114: Measuring Main Bearing Play

    RS110310 Measuring main bearing play 11 21 Measuring radial bearing play • Measure main bearing journal with an external micrometer in two planes, A and B, at right an- gles to each other. • Enter measured values on record sheet 11.9).

  • Page 115: Installing Main Bearing

    00 2 510 RS110910 • Secure measuring device, BMW No. 00 2 500, with dial gauge, BMW No. 00 2 510, in tapped hole for alternator mount cover. • Move crankshaft back and forth and read axial play from dial gauge ( 11.9).

  • Page 116: Measuring Big End Bearing Play

    11.10). RS110350 • Install bearing shells and assemble conrods. • Using tightening angle indicator, BMW No. 11 2 500, tighten the big end bolts. Tightening torque: Big end bolts, oiled Initial torque ..........20 Nm Tightening angle..........80 ° 11.46...

  • Page 117: Assembling Engine

    • Oil the big end bolts, screw them in by hand and tighten with tightening angle indicator, BMW No. 11 2 500. Tightening torque: Connecting rod bolts (oiled) Initial torque ..........20 Nm Tightening angle..........80°...

  • Page 118: Installing Crankshaft

    S110080 Installing crankshaft Installing auxiliary shaft/timing 11 21 11 31 chains • Attention: When installing the auxiliary shaft (2), ensure that Oil the bearings. its dowel pin socket is aligned with the housing flange on the side toward the crankshaft. Installing timing chain tensioning 11 31 Attention:...

  • Page 119: Assembling Engine Block

    RS110920 Assembling engine block 11 00 • Clean and degrease sealing faces (arrow) and coat with 3-Bond 1209. • Secure the timing chain with rubber band (1) to the timing chain tensioner and slide rail. 11.49...
  • Page 120 RS110391 • Bolt the crankcase sections together. Tightening torque/tightening order: 1. M 10 screw (oiled) to initial torque ..25 Nm Tightening angle..90° 2. M 8 screw (oiled) ........22 Nm 3. M 6 screw ..........9 Nm 11.50...

  • Page 121: Installing Radial Shaft Seals On Crankshaft

    Installing radial shaft seals on crankshaft 11 11 11 5 702 11 5 703 11 5 703 11 5 703 11 5 702 11 5 703 11 5 703 11 5 701 00 5 500 00 5 500 11 5 661 11 5 661 11 5 662 11 5 662...

  • Page 122: Installing The Crankshaft-End Radial Shaft Seal

    Remove assembly sleeve (3). • Mount sleeve complete with radial shaft seal on crankshaft (4). • Use drift, BMW No. 11 5 701, together with the sleeve (5) to drive the radial shaft seal onto the crankshaft. • Remove sleeve (6).

  • Page 123: Installing Clutch Housing

    Always use new screws for housing and cover. • Install clutch housing with mark (1) aligned with crankshaft mark (2). • Install locking device, BMW No. 11 5 640, to lock clutch housing. • Insert all screws by hand and tighten. Tightening torque: Clutch housing to crankshaft (threads lightly oiled)........

  • Page 124: Installing Oil Pump

    M6 x 45 M6 x 50 M6 x 45 M6 x 45 M6 x 50 RS110411 Installing oil pump 11 41 000 Attention: Oil the friction faces. • Install outer rotor (1) of oil pump in pump hous- ing. Attention: O-ring (3) must be in perfect condition.

  • Page 125: Installing Auxiliary Shaft Drive

    Align crankshaft mark with mark on auxiliary Tightening torque: shaft. M 6 screw (7) ..........9 Nm • Install locking device, BMW No. 11 5 640, to M 6 screw ............ 10 Nm lock clutch housing. Banjo bolt for cooling oil line •...

  • Page 126: Installing Piston

    R21110060 Installing piston 11 25 000 Attention: Always install piston and cylinder as a matched pair. Do not mix up pistons and piston pins. • Turn oil scraper ring so that gap (arrow) is at top. • Install piston rings with gaps offset by 120°. Assembly position X = installation toward exhaust side Attention:...

  • Page 127: Installing Cylinder

    • Oil the cylinder wall. • Compress the piston rings with a clamping strap, BMW No. 11 2 900. • Install the cylinder and at the same time pass the timing chain and the tensioner and guide rails through the timing case cavity.

  • Page 128: Installing Cylinder Head

    Fit camshaft chain sprocket in accordance with adjustment specification. • • Install cylinder head gasket. Install locking device, BMW No. 11 5 640, to • Fit cylinder head and insert correctly positioned lock clutch housing. • camshaft chain sprocket (1) and timing chain into Tighten camshaft chain sprocket.

  • Page 129: Adjusting Valve Clearances

    RS110980 Adjusting valve clearances 11 34 004 • Set piston to firing TDC on the ignition stroke. • Measure valve clearance with feeler gauge. • Correct valve clearance with adjusting screw and tighten locknut. Valve clearances with engine cold (max. 35 ƒC/95 ƒF): Inlet ...........

  • Page 130: Installing Cylinder Head, Right

    Note: With engine installed, set engine to TDC with dial gauge holder, BMW No. 00 2 650, and dial gauge, BMW No. 00 2 510. Right cylinder = at firing TDC: Locating pin (arrow) on right camshaft sprocket points downwards.

  • Page 131: Installing Left Cylinder Head

    Note: With engine installed, set engine to TDC with dial gauge holder, BMW No. 00 2 650, and dial gauge, BMW No. 00 2 510. Left cylinder = at firing TDC: Locating pin (arrow) on left camshaft sprocket points upwards.
  • Page 132 RS110050 RS110940 • Install the cover, ensuring that the O-ring is in perfect condition. Attention: Make sure that gaskets are correctly seated. Gas- kets and sealing faces must be free from oil and Tightening torque: grease. M 6 screw ............9 Nm •...

  • Page 133: Installing Alternator Mount Cover

    11 5 640 11 5 680 S110090 Installing alternator mount 11 11 045 cover • Place assembly sleeve, BMW No. 11 5 680, on crankshaft. • Clean and degrease sealing face (arrow) and ap- ply 3-Bond 1209. • Install alternator mount cover.

  • Page 134: Timing The Ignition

    11 2 650 RS110461 12 11 004 Timing the ignition Note: With engine installed. • Using TDC locating pin, BMW No. 11 2 650, lock the clutch housing. • Connect BMW MoDiTeC with adapter cable to Hall-effect gate plate. •...

  • Page 135: Installing Alternator

    R22120020 Installing alternator 12 31 • Install alternator. • Adjust poly-V belt in accordance with the adjust- ing procedure ( 11.66). 11.65...

  • Page 136: Poly-V Belt Adjusting Procedure

    BMW No. 12 3 551. 2 Loosen the alternator mounting bolts (3, 4). 3 Use torque wrench to tighten and hold tension- ing nut BMW No. 12 3 551. 4 Tighten upper retaining nut (4), then remove torque wrench from adjusting screw.

  • Page 137: Installing Engine

    Installing engine 11 00 050 Note: Integral ABS After switching on the ignition, always wait for the BMW Integral ABS to complete its self- diagnosis. Do not operate the brake lever until the self-diagnosis routine has been completed. • Switch on the ignition.

  • Page 138: Engine Electrics

    12 Engine electrics Contents Page Technical Data ..........................3 Removing and installing coil and ignition lead ............5 Checking ignition coil resistance .....................5 Removing and installing alternator ..................6 Poly-V belt adjusting procedure ......................7 Disassembling and assembling alternator ..............8 Checking alternator ........................8 Checking armature for short to ground (earth) ..............8 Removing and installing starter motor...
  • Page 139 12.2...
  • Page 140 Technical Data 12 Engine electrical system R 1150 RT Starter motor Type Permanent-magnet motor with planetary gear drive Gear ratio Planetary gears 5.5 : 1 Power rating kW 1.1 Alternator Type Bosch three-phase alternator with integrated, ful- ly electronic voltage regulator Gear ratio 1:1.5...
  • Page 141 12.4...

  • Page 142: Removing And Installing Coil And Ignition Lead

    Disconnect plug. • Disconnect ignition lead. • Remove spark plug covers. • Pull off spark plug cap with special puller, BMW No. 12 3 520. • Remove ignition leads. • Installation is the reverse of the removal proce- dure. •...

  • Page 143: Removing And Installing Alternator

    R22120020 Removing and installing 12 31 022 Note: alternator Disconnecting the battery deletes all entries (e.g. faults, settings) stored in the Motronic control unit’s • Remove the seat. memory. • Remove side panels ( 46.8). Loss of settings can temporarily impair the operat- ing characteristics when the engine is restarted.

  • Page 144: Poly-V Belt Adjusting Procedure

    BMW No. 12 3 551. 2 Loosen the alternator mounting bolts (3, 4). 3 Use torque wrench to tighten and hold tension- ing nut BMW No. 12 3 551. 4 Tighten upper retaining nut (4), then remove torque wrench from adjusting screw.

  • Page 145: Disassembling And Assembling Alternator

    RS120050 Disassembling and assembling Checking alternator 12 31 61 00 alternator • Test with BMW MoDiTeC. Checking armature for short to • Remove the cover retaining screws (1). 61 00 • Release clips (2) and remove the cover. ground (earth) •...

  • Page 146: Removing And Installing Starter Motor

    R22120010 Removing and installing 12 41 025 starter motor • Remove the seat. • Remove left side section of fairing ( 46.8). Attention: Disconnect earth (ground) lead from battery. Insulate earth (ground) lead. • Disconnect cables (1) . • Remove securing screws (2) and remove the starter.

  • Page 147: Disassembling And Assembling Starter Motor

    61 00 • Remove the starter gear (10) from the shaft. • • Installation is the reverse of the removal proce- Test with BMW MoDiTeC. dure. Checking starter relay • Coat the Bendix gear and pull-in 61 00 ring with grease.

  • Page 148: Removing And Installing Magnetic Gate

    ( 12.7). Insulate the ground (earth) lead. • Remove the starter motor. • Install locking device, BMW No. 11 5 640, to lock clutch housing. • Remove poly-V belt pulley (3) with rotor gate from crankshaft. • Disconnect plug of magnetic gate.

  • Page 149: Timing The Ignition

    RS110461 to alternator mount cover ......20 Nm Belt pulley to crankshaft ....... 50 Nm • Using TDC locating pin, BMW No. 11 2 650, lock the clutch housing. • Connect BMW MoDiTeC with Y adapter cable to Hall-effect transmitter plug.

  • Page 150: Fuel Preparation And Control

    13 Fuel preparation and control Contents Page Technical Data ..........................3 Removing and installing air filter housing ..............5 Removing and installing throttle-valve stub pipe ............6 Removing and installing throttle-valve potentiometer ..........7 Removing and installing Motronic control unit ............7 13.1...
  • Page 151 13.2...
  • Page 152 Technical Data 13 Fuel system R 1150 RT Fuel grade Super (premium), unleaded, 95 octane (RON) Fuel-injection system Motronic MA 2.4 Fuel pressure bar (psi) 3.0 (42.69) Max. engine speed rpm 7,900 Throttle valve stub pipe inside dia. mm (in) 45 (1.7717)
  • Page 153 13.4...
  • Page 154 R28130020 Removing and installing air 13 72 110 filter housing Preparatory work See “Instructions for removing and installing clutch” 21.5) 13.5...
  • Page 155 (1) and disconnect plug. pipe. • Push intake neck into air filter box and remove throttle-valve assembly. Note: Do not remove throttle-valve potentiometer unless due for replacement (basic setting is necessary — see BMW MoDiTeC) • Remove screws (2). 13.6...
  • Page 156 (basic setting is necessary — see BMW MoDiTeC) • Remove the throttle-valve potentiometer. • Adjust throttle-valve potentiometer with BMW MoDiTeC after installing. • Mark screws with a paint spot. R28130010 • Disconnect plug from Hall transmitter. •...
  • Page 157 16 Fuel tank and lines Contents Page Technical Data ..........................3 Removing and installing fuel tank ..................5 Removing and installing roll-over valve ................6 Removing and installing fuel-pump unit ................7 Fuel filter removal and installation ....................7 Removing and installing fuel pump ..................7 Checking fuel pump pressure ......................8 Removing and installing fuel distributor and pressure regulator...
  • Page 158 16.2...
  • Page 159 Technical Data 16 Fuel tank R 1150 RT Fuel tank Type Plastic tank Fuel grade Super (premium), unleaded, 95 octane (RON) Tank capacity (usable) l (Imp. gal/US gal) 25.2 (5.55/6.66) including reserve of l (Imp. gal/US gal) approx. 4 litres (0.88/1.06)
  • Page 160 16.4...

  • Page 161: Removing And Installing Fuel Tank

    R22160010 Removing and installing fuel 16 11 030 tank • Remove the seat. • Remove fairing side sections. • Release the radio compartment and secure it to the motorcycle. • Disengage fuel tank. • Disconnect quick-action couplings (1) in fuel flow and return lines.

  • Page 162: Removing And Installing Roll-Over Valve

    Remove tank cover. • Remove the reducer unit with roll-over valve (1). • Release the hose clips with pliers, BMW No. 17 5 500, and disconnect hoses. • Remove the reducer unit with roll-over valve. • Remove the roll-over valve.

  • Page 163: Removing And Installing Fuel-Pump Unit

    • Disconnect plug (2). BMW No. 13 1 500. • Release the hose clips with pliers, BMW No. 17 5 500, and disconnect hoses. • Carefully remove the fuel-pump unit. Attention: Make sure O-ring (6) is in perfect condition. Fuel filter removal and installa- 16 12 008 After installing, check fuel pump unit for leaks.

  • Page 164: Removing And Installing Fuel Distributor And Pressure Regulator

    Installation is the reverse of the removal proce- (bottom line). dure. • Connect pressure gauge, BMW No. 16 1 500, with adapter hose, BMW No. 16 1 503, for quick-action couplings. • Start engine and allow to idle. Attention: Do not allow the engine to idle for longer than is nec- essary, because the trim panels near the exhaust could be damaged.

  • Page 165: Removing And Installing Immersed Level Sensor

    • Disconnect plug (2). • Release the hose clips (3) with pliers, BMW No. 17 5 500, and disconnect hoses. • Release immersed level sensor (4) and lift out complete with hoses. • Installation is the reverse of the removal proce- dure.

  • Page 166: Exhaust System

    18 Exhaust system Contents Page Technical Data ..........................3 Removing and installing exhaust system ................5 Removing and installing silencer and oxygen sensor .............5 Removing and installing exhaust manifold ................6 18.1...
  • Page 167 18.2...
  • Page 168 Technical Data 18 Exhaust system R 1150 RT Type 2 in 1 Emission control 3-way catalytic converter with lambda control Silencer (muffler) Stainless steel reflection silencer with aluminium- coated inner surface 18.3...
  • Page 169 18.4...
  • Page 170 • Remove rear silencer. • Remove the oxygen sensor with special socket wrench insert, BMW No. 11 7 020. • Installation is the reverse of the removal proce- dure. Attention: Note position of cable for oxygen sensor.
  • Page 171 Rs180030 Removing and installing exhaust 18 11 manifold Attention: • Remove side panels. After a trial run, read out Motronic fault memory. • Slacken clamp (1) holding the rear silencer. Note position of cable for oxygen sensor. • Remove fasteners securing exhaust manifold (2). Attention: Tightening torque: Secure rear silencer in such a way that it cannot fall.
  • Page 172 21 Clutch Contents Page Technical Data ..........................3 Removing and installing clutch ....................5 Removing clutch ..........................5 Removing clutch from vehicle ......................5 Removing clutch from engine ......................7 Installing clutch ..........................7 Installing clutch in engine ........................7 Installing clutch in vehicle ........................7 Removing and installing clutch hydraulic line ..............8 Removing and installing clutch slave cylinder .............9...
  • Page 173 21.2...
  • Page 174 Technical Data 21 Clutch R 1150 RT Type Single dry plate with high-leverage pressure plate Clutch plate dia. mm (in) 165 (6.4960) Wear limit mm (in) 4.8 (0.1890) (Measured with caliper tips pressed by hand against rivets of clutch plate)
  • Page 175 21.4...

  • Page 176: Removing Clutch

    Fuel is flammable and a hazard to health. Observe all applicable safety regulations. • Remove fuel tank ( 16.5). • Secure stand, BMW No. 00 1 520, to motorcycle with spacers, BMW No. 00 1 529. • Disconnect plug for air-temperature sensor from R22210020 air filter cover.

  • Page 177: Gearbox

    • Disconnect clutch-system bleed line from rear R21110020 frame. • Use hose clip pliers, BMW No. 17 5 500, to dis- connect hose for crankcase breather from air-fil- ter box. • Remove air filter box. • Remove the fuel distributor.

  • Page 178: Removing Clutch From Engine

    Install clutch housing with crankshaft pin (2) lo- Tightening torque: cated in bore (1). Clutch housing to crankshaft • Install locking device, BMW No. 11 5 640, to (threads lightly oiled) lock clutch housing. Initial torque ..........40 Nm Tightening angle..........32°...

  • Page 179: Removing And Installing Clutch Hydraulic Line

    R22210050 Removing and installing clutch 21 52 Attention: hydraulic line Do not allow brake fluid to come into contact with painted parts of the motorcycle - brake fluid de- • Remove the seat. stroys paint. • Remove side panels ( 46.8).

  • Page 180: Removing And Installing Clutch Slave Cylinder

    Removing and installing 21 52 012 clutch slave cylinder • Remove the seat. • Remove side panels ( 46.8). Attention: Fuel is flammable and a hazard to health. Observe all applicable safety regulations. • Remove fuel tank ( 16.5). • Remove screw from intake air pipe.
  • Page 181 Filling and bleeding clutch • Remove rear brake fluid reservoir from its holder. 21 52 005 • Loosen the fasteners securing the left footrest line plate. • Remove top screw of left footrest plate. • Remove rear screw of left footrest plate. See instructions for changing clutch fluid ( 00.54).
  • Page 182 23 Gearbox Contents Page Technical Data ..........................3 Gearbox - sectional drawing ....................5 Removing and installing gear-shift lever .................7 Removing and installing gearbox ..................7 Replacing shaft sealing rings in gearbox housing and gearbox cover ....10 Replacing input shaft sealing ring at input end .................. 10 Replacing output shaft sealing ring ....................
  • Page 183 Contents Page Installing selector drum ......................26 Installing gearbox housing ......................27 23.2...
  • Page 184 Technical Data 23 Gearbox R 1150 RT Type 6-speed gearbox with dog-clutch engagement mechanism and integral vibration damper Gearshift type Foot shift lever and gear selector drum with over- shoot detent Oil grade (all-year) Brand name SAE 90 API GL5 hypoid oil or...
  • Page 185 23.4...

  • Page 186: Gearbox - Sectional Drawing

    Gearbox - sectional drawing R21239010 23.5...
  • Page 187 23.6...
  • Page 188 Fuel is flammable and a hazard to health. Observe all applicable safety regulations. • Remove fuel tank ( 16.5). • Secure stand, BMW No. 00 1 520, to motorcycle with spacers, BMW No. 00 1 529. • Disconnect the air temperature sensor plug. • Remove air filter cover.
  • Page 189 R22210020 R22210040 • • Disconnect gear-indicator plug (3) and remove Remove cable ties (6) from left air filter box. the cable. • Remove hydraulic spring adjuster. • Remove rear brake fluid reservoir from its holder. RS230310 • Tilt the rear frame up and secure it in this position R22210030 with a strap attached to the handlebars.
  • Page 190 23 1 820 R21110020 RS230011 • • Use hose clip pliers, BMW No. 17 5 500, to dis- Always use oiled guide pins, BMW No. 23 1 820, connect hose for crankcase breather from air-fil- when removing or installing the gearbox. •...

  • Page 191: Replacing Shaft Sealing Rings In Gearbox Housing And Gearbox Cover

    • Use puller, BMW No. 00 8 590, to remove the shaft sealing ring, or alternatively pry out carefully with a screwdriver. Attention: Drive in the output-shaft sealing ring flush with the housing.
  • Page 192 BMW No. 23 4 740. • Carefully lever out the shaft sealing ring with a screwdriver. • Install the new sealing ring with the sealing lips facing inwards, using guide, BMW No. 23 4 722, and impact driver, BMW No. 23 4 723. 23.11...

  • Page 193: Disassembling Gearbox

    R21230020 Disassembling gearbox 23 00 043 Removing gearbox housing 80 …100 23 11 • Remove oil filler/level check screw (1). • Remove oil drain plug (2) and drain the oil from the gearbox into a suitable tray. • Remove selector lever (3). •...

  • Page 194: Removing Selector Drum

    R21230040 Removing selector drum Disassembling and assembling 23 31 23 31 selector shaft • Pull selector shafts (1) out of the selector forks. • Swing the selector forks (3/8) out towards the edge of the cover (arrows). • Remove locking pin (9). •...

  • Page 195: Removing Gearbox Shafts

    80…100 R21230070 Removing gearbox shafts • Pull off both grooved ball bearings with a univer- sal puller, BMW No. 00 7 500. • • Remove breather tube (1). Press the output-side grooved ball bearing on to • Heat bearing points in gearbox cover to the intermediate shaft.

  • Page 196: Disassembling And Assembling Input Shaft

    R21230080 Disassembling and assembling • 23 12 Use universal puller, BMW No. 00 7 500, and pressure head (arrow) to pull off grooved ball input shaft bearing (11). Disassembling input shaft 00 7 500 KR230090 • Clamp the input shaft into a vise with soft jaws.

  • Page 197: Assembling Input Shaft/Checking And Adjusting End Float Of Spring Cluster

    KR230081 • Assembling input shaft/checking and adjusting Check the fully assembled length and adjust if end float of spring cluster necessary ( 23.22). • Place a spacing washer (8) of the correct thick- • Lightly oil the bearing surface for constant-speed ness in position and press grooved ball gear (1) on input shaft (10), and install the con- bearing (9) into position.

  • Page 198: Disassembling And Assembling Output Shaft

    Turn output shaft (6) other way round and clamp into the vise with soft jaws. • Using universal puller, BMW No. 00 7 500, pull off deep-groove ball bearing (1) together with shift gearwheel for 2nd gear (4). 00 7 500 •...

  • Page 199: Assembling Output Shaft

    1st gear 4th gear 3rd gear 2nd gear 5th gear 6th gear KR230120 Assembling output shaft Attention: To avoid damaging the needle roller bearing on the Note: splines of the shaft, spread it carefully at the end Assembly starts at the shift gearwheel for 4th gear. face when installing.

  • Page 200: Checking Endplay

    Install sliding gearwheel for 6th gear (17) with the 23 11 recess for the selector fork facing the 2nd gear • shift wheel (3). Secure dial gauge, BMW No. 00 2 510, to dial • Install backup washer (5) and needle roller bear- gauge stand. •...

  • Page 201: Checking And Adjusting Fully Assembled Length Of Gearbox Shafts And Selector Drum

    Remove the intermediate shaft from the measur- ing fixture. • • Position dial gauge, BMW No. 23 4 762, in rear Remove spacing washer, grooved ball bearing locating bore of stand, BMW No. 23 4 761, and and reference washer.
  • Page 202 • Place a spacing washer (1) of the correct thick- • Position dial gauge, BMW No. 23 4 762, in rear ness on the output shaft and press on the locating bore of stand, BMW No. 23 4 761, and grooved ball bearing.
  • Page 203 • • Position dial gauge, BMW No. 23 4 762, in front Place spacer (1) of the correct thickness in posi- locating bore of stand, BMW No. 23 4 761, and tion and press the grooved ball bearing onto the set to 0.2 mm (0.078 in) preload.
  • Page 204 KR230190 23 11 Checking and adjusting fully assembled length of selector drum • Place spacing washer and both thrust washers on the selector drum. • Using slide gauge, determine fully assembled length “A”. • If necessary, adjust fully assembled length “A” with a shim washer (arrow).

  • Page 205: Shimming Selector Shaft

    Shimming selector shaft 23 31 Attention: If the housing or the complete selector shaft is re- placed, the selector shaft must be measured and shimmed. KR230220 • Measure distance “C” from the shoulder on the selector shaft to the back of the sleeve. •...

  • Page 206: Assembling Gearbox

    This is necessary only if the shaft sealing ring is in- 23 21 stalled. mediate shafts • Push assembly sleeve, BMW No. 23 4 712, on to the input shaft splines. • Heat the bearing points in the cover to 100…120 °C (212... 248 °F).

  • Page 207: Installing Selector Shaft

    R21230040 Installing selector shaft Installing selector drum 23 31 23 31 • Place a spacing washer of the correct thickness and the input-side thrust washer on selector drum (6) and secure with a small amount of grease. • Swing locking lever (8) toward the input shaft and install the selector drum.

  • Page 208: Installing Gearbox Housing

    • Apply Loctite 574 sealing compound to the mat- ing face of the cover. R21230030 • Place assembly sleeve, BMW No. 23 4 732, on the output shaft. • • Place slip-over sleeve, BMW No. 23 4 612, on Heat the bearing seats in the housing the selector shaft.
  • Page 209 R21230020 • Insert screws (1) and tighten in diagonally oppo- site sequence. • Drive home dowel pins (2). • Install switch of gear indicator (3) and clip cable (4) into position. • Remove metal particles from the magnet in oil drain plug (5).
  • Page 210 31 Front forks Contents Page Technical Data ..........................3 Removing and installing telescopic fork .................5 Removing and installing telescopic fork without fork bridge ........5 Removing and installing fork bridge ..................6 Removing and installing pot-type joints ....................7 Removing and installing angular-contact ball bearing ................7 Removing and installing slider tube bridge .................8 Removing and installing ball joint in slider tube bridge .................8...
  • Page 211 31.2...

  • Page 212: Steering

    Technical Data 31 Front suspension R 1150 RT Type BMW Telelever with external suspension strut Running gear Total spring travel at wheel mm (in) 120 (4.7245) Castor in normal position mm (in) 122 (4.8032) (full fuel load and 85 kg/187 lbs...
  • Page 213 31.4...

  • Page 214: Removing And Installing Telescopic Fork Without Fork Bridge

    31 5 603 31 5 601 R22310010 Removing and installing tel- • 31 42 025 Place a support beneath the telescopic fork. • Heat leading link mount at front to escopic fork max. 120 °C (248 °F) and remove. • Remove both handlebars from fork bridge.
  • Page 215 Installation is the reverse of the removal proce- dure. • Tighten the ball joint in the leading link using socket, BMW No. 31 5 601, and Allen key, BMW No. 31 5 603. Attention: To prevent grease from escaping and the ingress of dirt, ensure that sleeve is correctly located on ball joint.

  • Page 216: Removing And Installing Pot-Type Joints

    BMW No. 31 5 651, as a support. • Install snap ring (2). • Install dust covers (1). 31 5 651 GS310120 • Press the threaded stud into the angular-contact ball bearing using mandrel, BMW No. 31 5 651, as a support. 31.7...

  • Page 217: Removing And Installing Ball Joint In Slider Tube Bridge

    Heat the fork bridge to 100 °C (212 °F) and press R22310050 in the angular-contact ball bearing with pin, BMW No. 31 5 651, and bushing, • BMW No. 31 5 653. Mount the slider tube bridge in retaining fixture, •...
  • Page 218 • Assembly instructions for telescopic fork Secure fixed tubes to the fork bridge. • Tighten slider tube bridge. • Check that the system moves freely by com- Attention: pressing and extending the suspension (but To ensure that the forks are installed without without the suspension strut) in the straight- trapped stresses, follow the instructions below to ahead and left/right steering lock positions.

  • Page 219: Disassembling Telescopic Fork

    • Remove the fixed tube. • Remove wiper (3) and retaining ring (4). Oil grade in telescopic fork: .......... BMW telescopic fork oil Attention: Do not damage fork slider tube. Note: No oil changes required during services: unit is •...

  • Page 220: Measuring Telescopic Fork

    Place both ends of fixed tube in V-blocks. • expander, BMW No. 31 5 612, Turn fixed fork tube slowly and measure it with a and reducing adapter, BMW No. 31 5 613. dial gauge, BMW No. 00 2 510. • Install retaining ring and dust wiper.

  • Page 221: Disassembling And Assembling Leading Link

    Installation is the reverse of the removal proce- dure. • Apply a light coating of grease to the shaft before installing. • Tighten the ball joint in the leading link using socket, BMW No. 31 5 601, and Allen key, BMW No. 31 5 603. 31.12...

  • Page 222: Measuring The Leading Link

    Check runout of shaft (1). • Secure the leading link with shaft (1) to leading link gauge, BMW No. 31 5 640. • Tighten the shaft until the leading link is located in the gauge with no end float.
  • Page 223 32 Steering Contents Page Technical Data ..........................3 Removing and installing handlebar grip unit ..............5 Removing and installing left handlebar grip unit ...............5 Removing and installing left multi-function switch ................6 Removing and installing clutch switch ....................6 Removing and installing clutch piston in handlebar fitting ...........7 Adjusting blow-by clearance at handlebar fitting for clutch ..............8 Removing and installing right handlebar grip unit...
  • Page 224 32.2...
  • Page 225 Technical Data 32 Steering R 1150 RT Type Forged handlebar Steering lock angle ° 2 X 34 Handlebar width with weights mm (in) 773 (30.433) 32.3...
  • Page 226 32.4...

  • Page 227: Removing And Installing Handlebar Grip Unit

    R22320010 Removing and installing 32 72 handlebar grip unit Removing and installing left 32 72 065 handlebar grip unit R22610060 • [Heated grips] Open cable ties of left heated grip up to plug (4). • [Heated grips] Disconnect plug from heated grip.
  • Page 228 • Remove securing screw (5) and remove handle- 61 31 063 Removing and installing left multi- bar weight. function switch • Remove screws (6) securing handlebar grip. Note: [Heated grips] When removing the heated grip, at- tach a wire to the end of the cable and pull the wire into the hole in the handlebar.

  • Page 229: Removing And Installing Clutch Piston In Handlebar Fitting

    R22320060 Removing and installing clutch • 32 72 Remove pivot screw (1) of lever and remove the lever. piston in handlebar fitting • Remove rubber boot (2). Attention: Do not allow brake fluid to come into contact with Attention: painted parts of the motorcycle - brake fluid de- Note that clutch piston (3) is spring-loaded.

  • Page 230: Adjusting Blow-By Clearance At Handlebar Fitting For Clutch

    • Installation is the reverse of the removal proce- dure: pay particular attention to the following. • Prior to installation, coat the piston and the boots (6) with brake fluid. Attention: Sealing lips of the boots (6) toward the pressure chamber.
  • Page 231 R22320020 Removing and installing right • 32 72 110 [Heated grips] Open cable ties of right heated grip up to plug (5). handlebar grip unit • [Heated grips] Disconnect plug from heated • Remove securing screw (1) and remove handle- grip.
  • Page 232 61 32 073 Removing and installing right multi- function switch Attention: Do not allow brake fluid to come into contact with painted parts of the motorcycle - brake fluid de- stroys paint. • Integral ABS Drain front control circuit 34.19). •...

  • Page 233: Removing And Installing Brake Piston In Handlebar Fitting

    R22320070 Removing and installing brake • 32 72 Remove pivot screw (1) for lever. • Remove rubber boot (2). piston in handlebar fitting Attention: Attention: Do not allow brake fluid to come into contact with Note that brake piston (3) is spring-loaded. painted parts of the motorcycle - brake fluid de- •...

  • Page 234: Adjusting Blow-By Clearance At Handlebar Fitting For Brake

    • Prior to installation, carefully press back the Adjusting blow-by clearance at handlebar fitting brake piston using an Allen key with T-bar han- for brake dle, for example. • • Use cranked-tip snap-ring pliers to install the re- Remove cover from throttle-cable relay. •...
  • Page 235 R22320040 Removing and installing • 32 71 165 Installation is the reverse of the removal proce- dure. handlebars • Align the grip unit with the punch mark (arrow) on the handlebar. Removing and installing left 32 71 150 handlebar Attention: Make sure that all lines and cables are correctly routed.
  • Page 236 Removing and installing right 32 71 160 handlebar Warning: Do not disassemble the handlebars. • Remove the lower section of the right grip unit. • Release right multi-function switch from grip unit. • [Heated grips] Remove right heated grip. • Release fastener securing right handlebar to fork bridge.

  • Page 237: Removing And Installing Bowden-Cable Divider, Bowden Cable For Throttle Actuation And Starting-Speed Increase

    R22320050 Removing and installing • 32 73 056 Press down tab (1) and pull cable divider (2) out of its retainer in direction indicated by arrow. Bowden-cable divider, Bowden • Installation is the reverse of the removal proce- cable for throttle actuation and dure.

  • Page 238: Disassembling Bowden-Cable Divider

    R28320050 Disassembling Bowden-cable 32 73 divider • Remove fasteners of Bowden cables at entry to Bowden-cable divider. • Remove Bowden cable for starting-speed in- crease (1). • Remove retainer (2) and remove roller of Bow- den-cable divider. • Remove Bowden cables. •...
  • Page 239 33 Rear wheel drive Contents Page Technical Data ..........................3 Removing, disassembling, reassembling and installing rear wheel drive ..5 Removing rear wheel drive ......................5 Removing and installing taper roller bearing in rear wheel drive .......6 Removing input bevel pinion ......................7 Disassembling input bevel pinion ....................8 Removing needle roller bearing for input bevel pinion ................9...
  • Page 240 Contents Page Installing rear swinging arm ....................22 33.2...
  • Page 241 Technical Data 33 Rear wheel drive R 1150 RT Rear wheel drive Type Bevel gears Oil grades Brand name hypoid-gear lubricant SAE 90 API GL 5 Capacity l (Imp. pint/US quart) approximately 0.25 (0.44/0.27) (to the bottom of the filler neck thread)
  • Page 242 33.4...

  • Page 243: Removing, Disassembling, Reassembling And Installing Rear Wheel Drive

    R22330010 Removing, disassembling, reas- 33 10 Note: sembling and installing rear wheel Do not damage the inner races of the needle roller drive bearings; remove separately if necessary. Removing rear wheel drive 33 10 • Remove rear wheel drive from universal shaft. •...

  • Page 244: Removing And Installing Taper Roller Bearing In Rear Wheel Drive

    00 8 572 RT330090 • Remove needle roller bearing with counter-sup- port 22/1, BMW No. 00 8 572, and internal puller 21/4, BMW No. 00 8 573, with ring support. • Heat neck of housing to 120 °C (248 °F).

  • Page 245: Removing Input Bevel Pinion

    S330030 Removing input bevel pinion • 33 12 Bolt the final-drive unit to the assembly stand, BMW No. 33 1 510/511. • Bolt the locking arm (1) to the retaining fixture. • Tighten grub screws until they are seated. Attention: The grub screws must not project, or the neck of the housing could be damaged.

  • Page 246: Disassembling Input Bevel Pinion

    • Remove the input bevel pinion and the spacer. 00 7 500 KR330100 • Using puller, BMW No. 00 7 500, pull off both bearings at the same time. • Remove thrust ring (3). • Remove ball thrust bearing (4), inner race (5), roll- er bearing cage (6) and outer race (7).

  • Page 247: Assembling Input Bevel Pinion

    • Remove the outer ring of the needle roller bear- ing using internal puller, BMW No. 00 8 573, threaded ex- tension, BMW No. 00 8 575, and counter-sup- port, BMW No. 00 8 572. 33 12 Installing needle roller bearing for input bevel pinion •...

  • Page 248: Installing Input Bevel Pinion

    33 1 510 Insert outer race (3). R21330070 • Clamp holder, BMW No. 33 1 510, in the vise in such a way that the input neck of the housing is pointing vertically upward. • Heat the neck of the housing to max.
  • Page 249 Press/drive sealing ring into threaded ring (5) with drift, BMW No. 33 1 770. • Coat the cleaned threaded ring with Loctite 577 and tighten with pin wrench, BMW No. 33 1 700. • Install thrust ring (6). Note: Make sure that the lip of the shaft seal is seated cor- rectly on the thrust ring.

  • Page 250: Removing And Disassembling Crown Wheel

    00 7 511 • Insert thrust block, BMW No. 11 0 561. • Using puller, BMW No. 00 7 500, pull taper roller bearing off crown wheel. • Turn the housing upside down and heat it until the outer ring is released and drops out (max.

  • Page 251: Assembling And Installing Crown Wheel

    Heat the housing to 80 °C (176 °F). • Insert the outer race in the bearing seat with drift, Note: BMW No. 23 4 670, and handle, Install spacer with bevel on inside diameter toward BMW No. 00 5 500. crown wheel.

  • Page 252: Shimming Input Bevel Pinion And Crown Wheel

    Shimming input bevel pinion and crown wheel • It is important to shim the input bevel pinion and the crown wheel if the gear set or housing has been replaced. Note: The set number (1) for the gearset on the crown- wheel and pinion gears must always match! R213300120 •...

  • Page 253: Checking Tooth Contact Pattern

    Coat three tooth flanks of the crown wheel with marking ink. • Install measuring fixture, BMW No. 33 2 600, centre crown wheel and use the balls of your hands to press it into the housing and turn it back and forth a few times.

  • Page 254: Checking And Adjusting Backlash

    (1). • Secure measuring device, BMW No. 33 2 600, with dial gauge to crown wheel and secure to housing with the knurled screw. Note: •...

  • Page 255: Shimming Housing Cover

    Using drift, BMW No. 33 1 860, and handle, • Using depth gauge, BMW No. 00 2 550, meas- BMW No. 00 5 500, drive in the sealing ring. • ure distance “a”. Heat housing cover to 80 °C (176 °F) and install.

  • Page 256: Installing Rear-Wheel Drive Unit

    R22330010 Installing rear-wheel drive unit • 33 10 050 Screw in floating bearing stud (2) with Loctite. Note: Attention: Do not lay oil-filled rear-wheel drive on its side prior When tightening threaded fasteners coated with to installation, as this will cause oil to escape when Loctite 2701, always apply final torque without de- the motorcycle is on the road (suction effect).

  • Page 257: Removing And Installing Spring Strut

    Removing and installing spring 33 53 strut Warning: Integral ABS When removing and installing the brake caliper, force back the pistons carefully to en- Note: sure that the wheel-circuit reservoir does not over- flow. To remove the spring strut, support the rear axle. If fluid escapes, proceed in accordance with “In- •...

  • Page 258: Removing Rear Swinging Arm

    R22330030 Removing and installing rear 33 17 350 swinging arm Removing rear swinging arm. 33 17 • Remove side panels ( 46.8). • Remove final-drive unit. • Remove rear spring strut. • Remove the footrest plates. • Remove holder for brake hose on the swinging arm.

  • Page 259: Removing Drive Shaft

    LT330370 • Remove taper roller bearing with counter-sup- port, BMW No. 00 8 572, and internal Attention: puller 21/2, BMW No. 00 8 571, with support for Avoid scratching painted parts; use an underlay if ring. necessary. • Pull out outer race with internal puller 21/5, •...

  • Page 260: Installing Rear Swinging Arm

    R22330030 Installing rear swinging arm • 33 17 Install footrest plates. • Install the rear wheel drive. • • Slide swinging arm over drive shaft as far as pos- Install fairing side sections. sible until rubber gaiter connects on housing neck.
  • Page 261 34 Brakes Contents Page Technical Data ..........................3 Removing and installing front brake caliper ..............5 Disassembling and assembling front brake caliper ..........6 Removing and installing rear brake caliper ..............7 Disassembling and assembling rear brake caliper ...........8 Disassembling rear brake caliper ....................8 Assembling rear brake caliper ....................8...
  • Page 262 Instructions for filling front wheel circuit reservoir ................26 Filling and bleeding rear wheel circuit ....................27 Instructions for filling rear wheel circuit reservoir ................29 Integral ABS Reading fault memory with BMW MoDiTeC ..............30 Integral ABS Performing bleed test with BMW MoDiTeC ..............30...
  • Page 263 Technical Data 34 Brakes R 1150 RT Brake fluid DOT 4 Front wheel Type Hydraulically operated twin disc brake with 4-pis- ton fixed calipers and floating brake discs Colour of identification mark on brake white calipers/brake pads Brake pad lining...
  • Page 264 34.4...

  • Page 265: Removing And Installing Front Brake Caliper

    Removing and installing front 34 11 brake caliper Attention: Do not allow brake fluid to come into contact with painted parts of the motorcycle as brake fluid de- stroys paint. • Integral ABS Drain front wheel circuit 34.17). Suds R28340010 •...
  • Page 266 – Integral ABS Drain front wheel circuit ( 34.17). Press back the pistons fully using the resetting – Remove the brake caliper. tool, BMW No. 34 1 531. • Install brake caliper. • • Remove the brake pads. Integral ABS Fill and bleed front wheel circuit •...

  • Page 267: Removing And Installing Rear Brake Caliper

    R22340090 Removing and installing rear 34 21 Tightening torque: brake caliper Brake caliper to rear wheel drive ....40 Nm Brake hose to brake caliper ......18 Nm Bleed screw to brake caliper ......5 Nm Attention: Do not allow brake fluid to come into contact with painted parts of the motorcycle as brake fluid de- stroys paint.

  • Page 268: Disassembling And Assembling Rear Brake Caliper

    • • Inspect the brake caliper piston for hairline Press back the pistons fully using the resetting cracks, score-marks and other damage. tool, BMW No. 34 1 531. • Integral ABS Fill and bleed rear wheel circuit 34.27). Tightening torque: Bleed screw to brake caliper ......

  • Page 269: Removing And Installing Front Brake Discs

    Removing and installing front Removing and installing rear 34 11 34 21 brake discs brake disc Warning: Warning: When removing and installing the brake calipers, When removing and installing the brake caliper, force back the pistons carefully to ensure that the force back the pistons carefully to ensure that the wheel-circuit reservoir does not overflow.

  • Page 270: Removing And Installing Integral Abs Sensor

    R22340060 Removing and installing Integral ABS sensor Removing and installing front 34 52 044 Integral ABS sensor • Remove the cable ties securing the sensor ca- ble. • Disconnect plug (1) of sensor cable. • Guide the sensor cable down until clear. •...
  • Page 271 R22340070 Removing and installing rear 34 52 111 Integral ABS sensor • Remove front and rear seats. • Remove right case, if necessary. • Remove small right side fairing panel. • Remove the cable ties securing the sensor ca- ble. •...

  • Page 272: Removing And Installing Footbrake Lever

    Installation is the reverse of the removal proce- dure. • Tightening torque: Tighten non-reusable hose clip (7) with pliers, Footbrake lever to footrest plate BMW No. 13 1 500. • (clean thread + Loctite 2701)......21 Nm Integral ABS Fill and bleed rear control circuit 34.22). Attention: Bleed the brake system carefully.

  • Page 273: Checking And Adjusting Blow-By Clearance Of Piston Rod

    Checking and adjusting blow-by clear- Adjusting blow-by clearance at piston rod ance of piston rod Checking blow-by clearance of piston rod R22340010 • Set the adjusting screw of the footbrake lever to R22340020 distance A. • Press the footbrake lever. Distance A: .

  • Page 274: Checking And Adjusting Setting Of Rear Brake Light Switch

    • Switch on the ignition. Note: After switching on the ignition, always wait for the BMW Integral ABS to complete its self-diagnosis. Do not operate the brake lever until self-diagnosis has completed. • Depress the footbrake lever (brake light comes on and pump starts up).

  • Page 275: Removing And Installing Integral Abs Pressure Modulator

    Warning: Do not allow brake fluid to come into contact with All repair and maintenance work on the painted parts of the motorcycle as brake fluid de- BMW Integral ABS must be performed by trained, stroys paint. qualified specialists. •...

  • Page 276: Installing Integral Abs Pressure Modulator

    34.20). • After all the work on the brake system has been completed, run a bleed test using the BMW MoDiTeC ( 34.30). Note: 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.

  • Page 277: Draining The Integral Abs Brake System

    • Remove fuel tank. Use resetting tool, BMW No. 34 1 531, and locator, BMW No. 34 1 532, to force the pistons Drain both wheel circuits in the left and right brake calipers all the way back and hold them in this position.

  • Page 278: Draining Rear Wheel Circuit

    34 1 536 34 1 531 R28000170 • Install adapter, BMW No. 34 1 536, instead of the outboard brake pad. • Install resetting tool, BMW No. 34 1 531, with the handle toward the outside in the rear brake caliper, press the pistons fully back and secure them in this position.

  • Page 279: Draining Control Circuits

    Draw off old brake fluid and clean the reservoir. R28340110 • Draw off the brake fluid from the circuits in the correct sequence, using ring spanner, BMW No. 34 2 532: – rear metering cylinder (4), – rear integral circuit (5) and –...

  • Page 280: Filling And Bleeding Integral Abs System

    All repair and maintenance work on the the brake system. BMW Integral ABS must be performed by trained, qualified specialists. Comply with all maintenance and repair instructions and always work through the various steps in the correct order.

  • Page 281: Bleeding Front Control Circuit

    (3) and – front metering cylinder (1) for the second time using ring spanner, BMW No. 34 2 532, in accord- ance with instructions for bleeding. Instructions for bleeding: 1. Slowly pull brake lever until brake-light switch clicks (blow-by bore closed).

  • Page 282: Filling The Rear Control Circuit

    – rear metering cylinder (1) for the second time • Top up the brake fluid level to the “MAX” mark. using ring spanner, BMW No. 34 2 532, in accord- ance with instructions for bleeding. Attention: Instructions for bleeding: While filling and bleeding the system, do not allow 1.
  • Page 283 Recheck the brake-fluid level. – Place the motorcycle on its centre stand. R22000150 Specified level not below ............MIN Attention: After all the work on the brake system has been completed, run a bleed test using the BMW MoDiTeC. Brake fluid............DOT 4 34.23...

  • Page 284: Filling And Bleeding Wheel Circuits

    Do not scrape the wheel – mask it off if necessary. • Use resetting tool, BMW No. 34 1 531, and locator, BMW No. 34 1 532, to force the pistons in the left and right brake calipers all the way back and hold them in this position.
  • Page 285 • Pump off brake fluid until it emerges clear and free from air bubbles. • Close the bleed screw. • Release the brake. • Disconnect the brake bleeding device from the bleed screw. • Connect the brake bleeding device to the bleed screw of the right brake caliper, but do not switch on the device.

  • Page 286: Instructions For Filling Front Wheel Circuit Reservoir

    With the ignition switched on, bed in the brake “MAX” if necessary pads against the brake discs. • • Install adapters 22, BMW No. 34 1 533, in reset- Disconnect the container from the wheel-circuit ting tool, BMW No. 34 1 531/532, for both front reservoir. •...

  • Page 287: Filling And Bleeding Rear Wheel Circuit

    Screw container, BMW No. 34 1 581, onto rear wheel circuit reservoir. • Slowly fill container, BMW No. 34 1 581, with new brake fluid until it is approximately 1/3 full. • Connect the brake bleeding device to the bleed screw, but do not switch on the device.
  • Page 288 • Close the bleed screw. • Release the brake and switch off the ignition. • Disconnect the brake bleeding device from the bleed screw. • Disconnect the container from the wheel-circuit reservoir. Attention: After changing and/or bleeding the brakes, always top up the fluid in the wheel-circuit reservoir to the correct level in accordance with the instructions.

  • Page 289: Instructions For Filling Rear Wheel Circuit Reservoir

    R28000170 • Top up fluid in rear wheel-circuit reservoir to “MAX” if necessary. • Fully tighten resetting tool, BMW No. 34 1 531, and adapter, BMW No. 34 1 536. R28340090 • Attention: Top up the fluid in the wheel-circuit reservoir until...

  • Page 290: Integral Abs

    • Remove front and rear seats. • Attention: Connect the BMW MoDiTeC to the diagnosis After all the work on the brake system has been connector. • completed, run a bleed test using the Read out the fault memory.

  • Page 291: Integral Abs

    R22340080 Integral ABS 34 51 Removing and installing bleed lines, wheel circuit reservoirs • Remove caps of wheel circuit reservoirs com- plete with bleed lines. • Installation is the reverse of the removal proce- dure. Pay particular attention to the following: •...

  • Page 292: Integral Abs: Removing And Installing Brake Lines

    Always replace the seals (square-section rings) be- tween the brake lines and the pressure modulator when you replace the brake lines. • Carefully remove square-section rings (3) using disassembly tool, BMW No. 34 2 561. • Install square-section rings with brake lines. 34.32...

  • Page 293: Installed Position Of Front Brake Line

    Installed position of front brake line R22340100 34.33...

  • Page 294: Installed Position Of Rear Brake Line

    Installed position of rear brake line R22340110 34.34...
  • Page 295 36 Wheels and tyres Contents Page Technical Data ..........................3 Removing and installing front wheel .................5 Removing front wheel ........................5 Installing front wheel ........................6 Removing and installing wheel bearings ................7 Removing wheel bearings ......................7 Installing wheel bearings ......................8 Removing and installing rear wheel ...................9 Removing rear wheel ........................9...
  • Page 296 36.2...
  • Page 297 Technical Data 36 Wheels R 1150 RT Front wheel Type Cast aluminium wheel with 5 double spokes Tyre size 120/70 ZR 17 tubeless Tyre pressure (cold) one-up bar (psi) 2.20 (31.30) two-up bar (psi) 2.50 (35.57) two-up + luggage bar (psi) 2.50 (35.57) Maximum permissible imbalance g (oz.) 60 (2.118 oz.)
  • Page 298 36.4...

  • Page 299: Removing Front Wheel

    R22360010 Removing and installing 36 30 300 front wheel Removing front wheel 36 30 • Remove front wheel cover. Warning: Integral ABS When removing and installing the brake calipers, force back the pistons carefully to ensure that the wheel-circuit reservoir does not overflow.

  • Page 300: Installing Front Wheel

    Integral ABS After switching on the ignition, always is located in the guide of speedometer drive (5). wait for the BMW Integral ABS to complete its self- Make sure that the reaction peg (arrow) on the fork diagnosis. Do not operate the brake lever until the slider tube engages in the recess in the speedome- self-diagnosis routine has been completed.

  • Page 301: Removing And Installing Wheel Bearings

    36 6 640 36 5 511 R28360020 • Clamp a drift, BMW No. 36 5 511, into the vise and place the wheel on it with the wide bearing down. • Place a spacing ring, BMW No. 36 6 640, be- tween the wheel hub at the right and the claws of the internal puller.

  • Page 302: Installing Wheel Bearings

    00 5 500 36 5 512 36 5 511 R360028 • Clamp a drift, BMW No. 36 5 511, into the vise and place the wheel on it with the wide bearing (1) down. S360090 • Install spacer tube (2).

  • Page 303: Removing Rear Wheel

    R22360020 Removing and installing rear 36 30 320 wheel Removing rear wheel 36 20 Warning: Integral ABS When removing and installing the brake caliper, force back the pistons carefully to en- sure that the wheel-circuit reservoir does not over- flow. If fluid escapes, proceed in accordance with “In- structions for filling reservoir”...

  • Page 304: Installing Rear Wheel

    Note: Integral ABS After switching on the ignition, always Attention: wait for the BMW Integral ABS to complete its self- The contact faces on the spacer (3), the rear wheel diagnosis. drive and the wheel hub must be free from grease Do not operate the brake lever until self-diagnosis and clean.
  • Page 305 Slightly tighten nut to preload bearing. • At the rear wheel, secure mounting device, BMW No. 36 3 618, to the centering collar side with wheel studs and taper rings. • Install balancing shaft, BMW No. 36 3 607, and nut, BMW No.

  • Page 306: Checking Front/Rear Wheel Rim For Runout

    • At the rear wheel, secure mounting device, BMW No. 36 3 618, to the centering collar side with wheel studs and taper rings. • Install balancing shaft, BMW No. 36 3 607, and nut, BMW No.
  • Page 307 46 Frame Contents Page Technical Data ..........................3 Exploded view of fairing sections and trim panels ............5 Removing and installing windscreen adjuster .............6 Removing and installing inner trim of fairing ..............7 Removing and installing fairing ....................8 Removing and installing fairing side section ..............8 Removing and installing tank trim ...................9...
  • Page 308 46.2...
  • Page 309 Technical Data 46 Frame R 1150 RT Frame Type Cast aluminium front frame with tubular steel rear frame, load-bearing drive unit Data plate location Front frame, on right Vehicle identification number location Front frame, on right Vehicle dimensions Maximum length mm (in) 2,230 (87.7968)
  • Page 310 46.4...

  • Page 311: Exploded View Of Fairing Sections And Trim Panels

    Exploded view of fairing sections and trim panels R22469010 46.5...

  • Page 312: Removing And Installing Windscreen Adjuster

    R22460030 Removing and installing wind- 46 63 screen adjuster • Remove the seat. • Remove side mirrors. • Remove fairing side sections. • Remove windscreen (1). • Remove cover for windscreen adjuster (2). • Remove inner trim of fairing. • Remove upper section of fairing.

  • Page 313: Removing And Installing Inner Trim Of Fairing

    R22460040 Removing and installing inner 46 63 trim of fairing • Remove knob for headlight beam throw adjustment. • Remove windscreen. • Remove cover for windscreen adjuster. • Remove mirrors. • Remove inner cover. • Installation is the reverse of the removal proce- dure.

  • Page 314: Removing And Installing Fairing

    R22460020 Removing and installing fairing • 46 63 Installation is the reverse of the removal proce- dure. Removing and installing fairing • Position the mirror at the 3 attachment points. 46 63 Tap the mirror housing gently to engage it, first at side section the front and then at the rear.

  • Page 315: Removing And Installing Tank Trim

    R22460130 Removing and installing tank trim 46 63 Attention: Fuel is flammable and a hazard to health. Observe all applicable safety regulations. • Remove side panels. • Remove screws securing fuel filler cap. • Remove fuel filler cap. • Remove tank trim. •...

  • Page 316: Removing And Installing Upper Section Of Fairing

    R22460050 Removing and installing upper • 46 63 Disconnect plug for headlight. • Remove upper section of fairing. section of fairing • Installation is the reverse of the removal proce- dure. Attention: Switch off ignition. Disconnect earth (ground) lead from battery. Note: Insulate earth (ground) lead.

  • Page 317: Removing And Installing Rear Trim Panels

    RT460331 Removing and installing rear trim 46 63 panels • Remove the seat. • Remove small side panels. • Remove luggage rack and case holders. • Remove the tail light. • Remove rear trim panels (1) and (2). • Installation is the reverse of the removal proce- dure.

  • Page 318: Removing And Installing Front Mudguard

    R22460010 Removing and installing front 46 61 mudguard • Remove front section of front mudguard. • Remove the rear section of the front mudguard. • Installation is the reverse of the removal proce- dure. 46.12...

  • Page 319: Removing And Installing The Rear Section

    RT460350 Removing and installing the 46 62 rear section Attention: Switch off ignition. Disconnect earth (ground) lead from battery. Insulate earth (ground) lead. • Remove seat. • Remove small side panels. • Remove rear light cluster. • Remove luggage rack and case carriers. •...

  • Page 320: Removing And Installing Number-Plate Carrier

    RT460340 Removing and installing 46 62 number-plate carrier • Remove the seat. • Remove the number-plate carrier. • Installation is the reverse of the removal proce- dure. 46.14...

  • Page 321: Removing And Installing Luggage Rack/Case Holder

    RT460320 Removing and installing lug- 46 63 gage rack/case holder • Remove the seat. • Remove small side panels. • Remove luggage rack and case holders. • Installation is the reverse of the removal proce- dure. 46.15...

  • Page 322: Removing And Installing Footrest Plates

    R22460070 Removing and installing footrest plates Removing and installing left foot- 46 71 rest plate • Remove the seat. • Remove small left fairing panel. • Remove left side section of fairing. • Remove retainer (arrow) and remove gearshift linkage. •...
  • Page 323 R22460080 Removing and installing right • 46 71 Remove securing screws for brake master cylin- der from footrest plate. footrest plate • Remove holder (2). • • Remove the seat. Remove the footrest plate. • • Remove small right fairing panel. Installation is the reverse of the removal proce- •...

  • Page 324: Removing And Installing Fairing Bracket

    R22460060 Removing and installing fairing • 46 63 Remove fairing bracket. • Installation is the reverse of the removal proce- bracket dure. Attention: Switch off ignition. Attention: Disconnect earth (ground) lead from battery. Make sure that connector strips, wiring harness and Insulate earth (ground) lead.

  • Page 325: Removing And Installing Frame

    • • Remove fuel tank. Remove front spring strut. • Secure stand with overlength bushes, BMW No. 00 1 520/529, to motorcycle. • Remove distributor for brake lines from frame. • Remove screws (1). • Slacken screws (2) and pivot the handlebars in- ward.
  • Page 326 Attention: Use cloths to protect the windscreen and painted components from damage. • Secure the fairing bracket to workshop crane, BMW No. 46 5 640. • Remove left and right oil cooler lines from fairing bracket. • Release the fairing bracket from the frame and pull it slightly forward with the workshop crane.
  • Page 327 R22460110 Removing and installing frame • 46 51 Remove holder of brake line. • Remove rear brake fluid reservoir from its holder. rear section • Remove the silencer from the rear frame section. • Remove fasteners securing footrest plate to rear Attention: frame, slacken fasteners securing it to gearbox Switch off ignition.

  • Page 328: Removing And Installing Main (Centre) Stand

    00 1 529 R28110060 R21460150 • Secure stand, BMW No. 00 1 520, to motorcycle with bushes and screws, BMW No. 00 1 529. Note: When installing the springs, make sure that the thick spring is on the inside and the thin spring on the outside (arrow).
  • Page 329 Removing and installing side 46 53 000 Tightening torque: stand Pivot mount to engine, right, M 12 screw (clean thread + Loctite 2701)......72 Nm Pivot mount to engine, left M 12 screw (clean thread + Loctite 2701)......72 Nm M 8 screw (clean thread + Loctite 2701).......

  • Page 330: Measuring Wheel Track Offset

    • Place the track offset gauge, Permissible wheel track offset (S): BMW No. 36 3 920, against the left or right side ..........± 9 mm (± 0.3543 in) of the motorcycle. based on + 3.5 mm (+ 0.1378 in)

  • Page 331: Measurement Record, Wheel Track Offset

    Measurement record, wheel track offset Front wheel Example Distance A ___ mm (in) Distance A 98.5 mm (3.8780 in) + ½ rim ___ mm (in) + ½ rim 41.4 mm (1.6299 in) = Front ___ mm (in) = Front 139.9 mm (5.5079 in) Rear ___ mm (in) Rear...
  • Page 332 51 Equipment Contents Page Removing and installing ignition switch/steering lock ...........3 Removing and installing ignition/light switch ..............3 Removing and installing lock barrel ..................3 Drilling out lock barrel ..........................3 Removing and installing lock barrel for fuel tank filler cap ........4 Drilling out lock barrel ..........................4 Removing and installing seat lock ..................5 Removing and installing seat lock...
  • Page 333 51.2...
  • Page 334 • Install steering lock with socket wrench insert for Drilling out lock barrel • non-removable screws, BMW No. 51 0 531. Use a 4-5 mm (0.1574-0.1968 in) dia. drill bit to drill the full length of the lock barrel. •...
  • Page 335 GS510040 Removing and installing lock 51 25 020 barrel for fuel tank filler cap Note: Make sure that screws do not fall into fuel tank: cov- er fuel tank filler neck with cloth. • Open cap and remove lower part of cap (1). •...
  • Page 336 Removing and installing seat Removing and installing cover of 51 25 050 51 25 lock radio compartment/stowage compart- ment • Remove the rear seat. • Remove the seat lock. Removing and installing seat 51 25 060 lock RT510100 • Remove retaining pin (arrow) with a length of wire or similar tool.
  • Page 337 52 Seat Contents Page Disassembling and assembling seat .................3 52.1...
  • Page 338 52.2...
  • Page 339 R22520010 Disassembling and assembling 52 53 seat 52.3...
  • Page 340 61 General electrical equipment Contents Page Technical Data ..........................3 Removing and installing central electrical equipment box ........5 Disassembling and assembling central electrical equipment box ....5 Relay positions/fuse assignments (central electrical equipment box) ...6 Relay positions ............................6 Fuse assignments ..........................6 Wiring-harness routing, frame ....................7 Wiring-harness routing/connection in central electrical equipment box...
  • Page 341 61.2...
  • Page 342 Technical Data 61 Electrical system R 1150 RT Battery Voltage V 12 Rated battery capacity Amp/h 19 Low temperature test current A 170 Fuses (4 of) 7.5 (1 of) 10 (2 of) 15 (2 of) Document 61.3...
  • Page 343 61.4...

  • Page 344: Removing And Installing Central Electrical Equipment Box

    R22610050 Removing and installing central • 61 13 Switch on the ignition. • Without starting the engine, fully open the throttle electrical equipment box once or twice so that the Motronic control unit can register the throttle-valve positions. Attention: Switch off ignition. Note: Disconnect earth (ground) lead from battery.

  • Page 345: Relay Positions/Fuse Assignments (Central Electrical Equipment Box)

    Relay positions/fuse assign- 61 31 Fuse assignments (No. 1 on left, looking forwards) ments (central electrical equipment box) Relay positions R22610040 1. Instrument cluster (telltale lights, revolution counter), indicator damping, windscreen R22610040 adjuster ............4 A 2. Parking light, tail light ........4 A 3.

  • Page 346: Wiring-Harness Routing, Frame

    Wiring-harness routing, frame 61 11 Attention: Use (yellow) galvanized screws for the ground (earth) connection to the engine. Screws with unsuitable corrosion proofing can cause the electrical resistance to rise as high as Ω . Run wiring harness without kinking and avoid risk of abrasion.

  • Page 347: Wiring-Harness Routing/Connection In Central Electrical Equipment Box

    R28610070 Wiring-harness routing/connec- 61 11 tion in central electrical equipment box 61.8...

  • Page 348: Wiring-Harness Routing/Central Electrical Equipment Box/Output

    RS610110 Wiring-harness routing/central 61 11 electrical equipment box/output Note: The white mark (arrow) must be covered by the grommet. 61.9...

  • Page 349: Wiring-Harness Routing

    Wiring-harness routing 61 11 View from left 61.10...
  • Page 350 R22619011 61.11...
  • Page 351 R22619012 61.12...

  • Page 352: Wiring-Harness Routing

    Wiring-harness routing 61 11 View from right 61.13...
  • Page 353 R22619021 61.14...
  • Page 354 R22619022 61.15...
  • Page 355 R22619023 61.16...

  • Page 356: Front

    Wiring harness 61 11 Front R22610010 61.17...

  • Page 357: Removing And Installing Battery Carrier

    Removing and installing bat- • 61 21 Installation is the reverse of the removal proce- dure. tery carrier Warning: Always replace the spring clips on the brake lines on the pressure modulator when you open the connec- tor. Make sure that positioning is correct ( 34.15).
  • Page 358 62 Instruments Contents Page Technical Data ..........................3 Removing and installing instrument cluster ..............5 Disassembling and assembling instrument cluster ..........6 62.1...
  • Page 359 62.2...
  • Page 360 Technical Data 62 Instruments R 1150 RT Instrument cluster Speedometer type mechanical Speedometer drive ratio I = 2.6 Tachometer type electronic Turn-indicator cancellation manual Instrument lighting A 12V 1.7W Telltale and warning lights Turn indicator A 14V 3.0W High (main) beam headlamp A 14V 3.0W...
  • Page 361 62.4...
  • Page 362 R22620010 Removing and installing • 62 11 200 Disconnect plugs. • Installation is the reverse of the removal proce- instrument cluster dure. • Remove the seat. • Raise the windscreen. • Remove left side section of fairing ( 46.8). Attention: Switch off ignition.
  • Page 363 Disassembling and assem- 62 11 623 bling instrument cluster • Remove instrument fastener (2). • Disconnect reset shaft (3) of trip meter from speedometer. • Remove adapter (4) from reset shaft. • Remove instrument lighting. • Remove control unit (5). •...
  • Page 364 63 Lights Contents Page Technical Data ..........................3 Removing and installing headlight ..................5 Adjusting headlight ........................6 Removing and installing Bowden cable for headlight beam throw adjustment ..........................7 Removing Bowden cable ......................7 Installing and adjusting Bowden cable ..................7 Removing and installing rear light cluster ..............7 63.1...
  • Page 365 63.2...
  • Page 366 Technical Data 63 Lights R 1150 RT Headlamp type Halogen tandem headlamp with two fog lights Bulbs Low (dipped) beam headlight H7 halogen bulb, 12V 55W High (main) beam headlamp H3 halogen bulb, 12V 55W Fog lamps H3 halogen bulb, 12V 55W...
  • Page 367 63.4...
  • Page 368 R22630010 Removing and installing 63 12 090 headlight Attention: Switch off ignition. Disconnect earth (ground) lead from battery. Insulate earth (ground) lead. • Remove the seat. • Remove side panels ( 46.8). • Remove upper section of fairing ( 46.10). •...
  • Page 369 Adjusting headlight 63 10 004 R22630020 • Turn screw (2) to adjust beam throw, if neces- R22000090 sary. • Motorcycle on level surface. Direction of rotation, • Rider’s weight on motorcycle counter-clockwise......further/higher (approx. 85 kg/187 lbs). Direction of rotation, • Turn knob (1) counter-clockwise as far as it clockwise .........shorter/deeper will go.
  • Page 370 R22630030 Removing and installing • 63 10 150 Install inner trim of fairing. • Turn adjuster (5) counter-clockwise as far as it Bowden cable for headlight beam will go. throw adjustment Removing Bowden cable 63 10 Attention: Make sure that lever (6) is not held by Bowden cable (1).

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