Maintenance BMW Integral ABS R 1150 R BMW Motorrad After Sales
Published by: © BMW Motorrad After Sales UX-VS-2 All rights reserved. Not to be reprinted, translated or duplicated either wholly or in part without prior written permission. Errors and omissions excepted; subject to technical amendment.
Mechanic’s signature BMW Annual Service Order No. BMW Inspection every 20,000 km (12,000 miles) Registration No.
BMW Motorrad Pre-delivery check R 1100 S EVO / R 1150 R / R 1150 RT Customer Registration No. Order No. Mechanic’s signature BMW Pre-delivery check Check the shipping crate for damage Motorcycle: – – – – unpack install remaining items inspect for damage check that delivery is complete: Toolkit On-board literature Ignition keys Scope of optional extras Fill and charge the battery (mark with charging date) Check engine oil level when cold and correct if necessary.
BMW Motorrad Service data R 1150 R Item Desired value Oil capacities Engine (with filter) (without filter) 3.75 (6.6) 3.50 (6.15) Unit of measurement/specification litres (Imp. pints) litres (Imp. pints) [SI 11 048 90] Engine oil grade: brand-name HD oil for four-stroke spark-ignition engines, API classes SE, SF, SG; combination with CC or CD specification Transmission Initial filling Oil changes Rear wheel drive approx. 1.0 (1.76) approx. 0.8 (1.41) litres (Imp. pints) litres (Imp.
00 00 Tightening torque Table of operating fluids Contents Page Tightening torque .........................................................................................................................3 11 Engine ...........................................................................................................................................3 12 Engine electrics ........................................................................................................................
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00 Tightening torque Model R 1150 R Connection 11 Engine Cylinder head Tightening sequence: 1 Tighten cylinder head nuts (oiled) in gonally opposite sequence 1.1 Tighten all nuts to closing torque Nm 20 1.2 Tighten all nuts to correct angle ° 90 1.
Model R 1150 R Connection 11 Engine Oil filter Oil filter Nm 11 Oil drain plug Nm 32 Mesh filter basket to engine block Nm 10 Oil pump cover Nm 9 Pressure relief valve Nm 42 Oil pressure switch Nm 30 Cooling oil line to engine block Nm 10 Cooling oil line - banjo screw with oil vent valve Nm 25 Oil lines to oil cooler Nm 25 Oil cooler to bracket Nm 8 Oil cooler return line to engine block Nm 35 Oil cooler connection to crankcase Nm 9 1 M 8 screw Nm 20 2 M 6 screw Nm
Model R 1150 R Connection 12 Engine electrics Starter motor to engine Nm 20 Starter cover to gearbox housing Nm 7 Positive lead to starter motor Nm 10 Alternator to alternator support cover Nm 20 Tensioning and retaining link to alternator Nm 21 Spacer to alternator Nm 21 Positive lead to alternator Nm 15 Belt pulley to alternator Nm 50 Belt pulley to crankshaft Nm 50 Poly-V belt preload Nm 8 Spark plug NGK BKR 7 EKC Nm 25 Model R 1150 R Connection 13 Fuel preparation an
Model R 1150 R Connection 18 Exhaust system Manifold to cylinder head Nm 21 Clamp for manifold Nm 45 (apply Optimoly TA to clamp seat) Front silencer to manifold Nm 45 (apply Optimoly TA to clamp seat) Silencer to main stand lugs Nm 20 Silencer to rear frame at top Nm 35 Oxygen sensor to silencer Nm 45 (apply Optimoly TA to thread) End cap to rear silencer Nm 8 (threads greased) Bracket to rear silencer Nm 15 (threads greased) Model R 1150 R Connection 21 Clutch Clutch housing Cl
Model R 1150 R Connection 23 Transmission Oil drain plug Nm 30 Oil filler plug Nm 30 Gearbox to engine block Nm 22 Shift lever to footrest plate Nm 35 Selector lever to selector shaft Nm 9 Housing cover to housing Nm 9 1. to gearbox and left footrest plate Nm 42 (clean thread + Loctite 243) 2. clamp block, frame tube to gearbox Nm 9 3.
Model R 1150 R Connection 32 Steering Handlebars to fork bridge, tightening sequence: 1. Front fastener (as viewed in forward direction of travel) until seated Nm 21 2.
Model R 1150 R Connection 33 Rear wheel drive Reaction link to rear wheel drive / gearbox Nm 43 (load approx.
Model R 1150 R Connection 36 Wheels and tyres Quick-release axle clamp screws Nm 22 Quick-release axle threaded fastener Nm 30 Rear wheel to rear wheel drive Hand-tighten wheel studs and tighten in diagonally opposite sequence [Integral ABS] Note spacer Nm 105 Model R 1150 R Connection 46 Frame Frame to engine Nm 82 Struts to frame Nm 58 Strut to engine Nm 58 (clean thread + Loctite 2701) to gearbox and footrest plate Nm 42 (clean thread + Loctite 2701) to engine Nm 42 Nm 72 (cl
Model R 1150 R Connection 46 Frame Front and rear sections of front mudguard to slider tube Nm 3 (Tuflok Blue thread-locking compound; screw can be released and tightened a number of times alternatively: clean thread + Loctite 243) Headlight bracket to fork bridge Nm 20 Model R 1150 R Connection 51 Equipment Mirrors Nm 15 Ignition/steering lock to fork bridge Nm 20 (micro-encapsulated) Model R 1150 R Connection 61 General electrical equipment Horn to holder Nm 8 (clean thread + Loctite 2
Table of operating fluids Item Use Order number Quantity Staburags NBU 30 PTM High-performance lubricating paste 07 55 9 056 992 75 g tube Optimoly MP 3 High-performance lubricating paste 07 55 9 062 476 100 g tube Optimoly TA High-temperature assembly paste 18 21 9 062 599 100 g tube Silicone grease 300, heavy Damping grease 07 58 9 058 193 10 g tube Retinax EP2 Wheel, steering head and taper roller 83 22 9 407 845 100 g tube bearing grease Contact spray Contact spray 81 22 9 400 208 3
00 00 Pre-delivery check Contents Page General view of crated motorcycle ...................................................................................15 Checking the shipping pallet for damage In case of damage in Germany ...............................................................................................16 In case of damage in importer markets Unpacking the motorcycle ..................................................................... 16 ........................................
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00 General view of crated motorcycle 00.
Checking the shipping pallet for damage 00 11 Installing • • When the motorcycle arrives, check the packing material immediately for damage and, if necessary, examine the contents for consequential damage. In case of damage in Germany • • • Note the damage on the delivery slip. Read the information sheet on damage in transit. Notify supplier (e.g. freight company or DB) and Bavaria Wirtschaftsagentur GmbH Abteilung ZW - 12 80788 München Tel. 089/14327-632 Fax 089/14327-709 without delay.
MAX MIN MIN R28000020 61 21 Filling 16 11 533 • • • • • and charging the battery Removing the fuel tank Remove front/rear seat. Lever off the right-hand and left-hand front trim sections from the tank. Remove the right-hand and left-hand oil cooler trims. Remove the right-hand cable trim. Remove oil cooler with air ducting and fold forwards. e Important: Fuel is flammable and a hazard to health. Observe 61 21 Filling and charging the battery d Warning: Battery acid is highly caustic.
• The battery does not achieve full charge capacity from being filled, so it has to be charged with a battery charger. 00 00 Checking engine oil when engine is cold, topping up if necessary L Note: Follow the instructions for use supplied with the battery charger. MAX Charge current (A) .........................10 % of rated battery capacity (Ah) Charging time .............................................................
Checking headlight beam angle, adjusting if necessary Checking tightness of rear wheel studs 63 10 500 X Tightening torque: Securing screws for rear wheel .................. 105 Nm 2 1 Checking tyre pressures • Check/correct tyre pressures. Tyre pressures: Solo ..................................... front 2.2 bar (31.3 psi) ............................................. rear 2.5 bar (35.6 psi) R28000070 • • • • • Motorcycle must be on a level surface.
[Integral ABS] Performing bleed test with BMW MoDiTeC d Warning: Self-diagnosis is not performed unless both brake levers are in their fully released positions. Prior to the conclusion of the self-diagnosis, only RESIDUAL BRAKE FUNCTION is available. Performing BMW Integral ABS self-diagnosis: • Release the brake levers if necessary. • Switch on the ignition. ABS warning light.............................flashes at 4 Hz General warning lamp ........................
Handing over the motorcycle This is the ideal opportunity to familiarise the customer with the motorcycle in order to ensure the customer’s satisfaction and safety.
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00 00 Maintenance Contents Key to maintenance intervals Page ..............................................................................................27 Reading the BMW MoDiTeC fault code memory .......................................................27 (Inspections I, II, III and IV) [Integral ABS] Performing bleed test with BMW MoDiTeC ..................................27 (Inspections I, II, III and IV) Changing engine oil, replacing oil filter element ......................................
Contents Page Checking brake system for correct operation and freedom from leaks; repairing/replacing if necessary ........................................................................................35 (Inspection III) Checking brake pads and discs for wear/replacing ...............................................35 (Inspections II and III) Checking front brake pad wear ...............................................................................................35 Checking rear brake pad wear .
Contents Page Checking rear wheel bearing play by tilting wheel ..................................................55 (Inspection III) Checking swinging arm bearings, adjusting if necessary ...................................55 (Inspections I and III) Greasing the side stand pivot ..............................................................................................55 (Inspections I, II and III) Checking function of side stand contact switch ...............................................
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00 Key to maintenance intervals – – – – BMW Inspection at 1,000 km (approximately 600 miles) BMW Service every 10,000 km (approximately 6,000 miles) BMW Inspection every 20,000 km (approximately 12,000 miles) BMW Annual Service Reading the BMW MoDiTeC fault code memory 00 13 624 I (Inspections I, II, III and IV) II • • III IV • • Remove front/rear seat. Connect the BMW MoDiTeC to the diagnostic connector. Read all fault code memories. Perform all requisite repair work.
00 11 209 Changing engine oil, replacing oil filter element • (Inspections I, II, III and IV) Important: Never top up the engine-oil level past the “MAX” mark. L Note: If the motorcycle is ridden only for short distances or outside temperatures are below 0°C (32 °F), change the oil and replace the oil filter element every 3 months, or not less than every 3,000 km (1,800 miles). • Change the engine oil at operating temperature. Insert and tighten the screw plug. e X Tightening torque: Oil filter..
00 11 229 Changing the transmission oil (Inspections III and IV) or at least every 2 years • Changing the oil in the rear wheel drive 00 11 229 (Inspections I, III and IV) Every 40,000 km (24,000 miles) or at the latest every 2 years Change the transmission oil at operating temperature. • Change the transmission oil at operating temperature. 1 1 2 2 R28000090 R28000100 • • • • • Remove oil filler plug (1). Remove oil drain plug (2) and allow the oil to drain out.
B MW R28160021 16 12 008 Replacing fuel filter (Inspection III) In normal operating conditions every 40,000 km (24,000 miles); if fuel quality is poor every 20,000 km (12,000 miles) • • • • • Remove front/rear seat. Lever off the right-hand and left-hand front trim sections from the tank. Remove the right-hand and left-hand oil cooler trims. Remove the right-hand cable trim. Remove oil cooler with air ducting and fold forwards. e Important: Fuel is flammable and a hazard to health.
1 2 3 R28160010 • • Disconnect hoses from fuel filter (1). Replace the fuel filter After installing, check fuel pump unit for leaks. e Important: Note correct direction of flow through fuel filter. • e Important: Tighten one-time hose clips with pliers, BMW No. 13 1 500. e Important: L Note: Make sure that breather lines are correctly routed. L Note: Pay attention to washers (3). Make sure that O-ring (2) is in perfect condition. • Installation is the reverse of the removal procedure.
MAX MIN MIN R28000020 61 20 029 Checking battery fluid level and topping up if necessary; cleaning and greasing the battery terminals (Inspections III and IV) • • • • • Replacing intake air filter element 13 72 000 (Inspection III) In very dirty and dusty operating conditions, replace every 10,000 km (6,000 miles) or even more frequently if necessary If necessary, disengage fuel tank and lift it at rear. Disengage the rubber strap holding the battery. Check the battery fluid level.
12 31 240 Replacing poly-V belt (Inspection III) every 60,000 km (36,000 miles) • Remove left-hand oil cooler trim. RS110490 • • Remove front cover. Slacken alternator mounting screws and nuts (1,3,4) and install a new poly-V belt if necessary. . 3 2 4 1 RS110480 Poly-V belt adjustment procedure: Poly-V belt installation procedure: • Place the poly-V belt in position, tension it and turn the engine over once, then relieve belt tension.
[Without Integral ABS] Checking brake fluid level • Turn the handlebars to the left. (Inspections II and III) MIN L Note: The volume of the brake fluid (MIN/MAX) is sufficient for lining thicknesses from new to the wear limit. It is not normally necessary to top up the fluid to accommodate lining wear. If the level drops below the MIN mark, this indicates some other fault. Front brake • • R28000110 Place the motorcycle on its centre stand. Turn the handlebars to the right.
[Integral ABS] Checking brake fluid level (Inspections II and III) L Note: The brake fluid level in the sight glass/brake fluid level remains constant despite wear of the brake pads. If the level drops below the MIN mark, this indicates some other fault. Checking brake system for correct operation and freedom from leaks; repairing/replacing if necessary (Inspection III) • Check brake system for leaks.
Checking rear brake pad wear Checking brake disc wear R28000130 • • Make sure that the brake disc is not visible through the bore (arrow) in the inner brake pad. If necessary, check/measure thickness of brake pads. e Important: Brake pad thickness must not fall below the minimum value. Always replace the brake pads as a complete set. Minimum pad thickness: ........ 1.0 mm (0.
34 11 008 Replacing brake pads, front brake • e Important: Integral brakes, the rear brake must be ready for use. • • Installation is the reverse of the removal procedure. Perform a function check on the brake system with the ignition switched on. Colour code: Brake pads, brake calipers............................ green Remove retaining plate. R28000150 • • Remove keeper (arrow) from retaining pin. Remove retaining pin.
34 21 200 Replacing brake pads, rear brake • Installation is the reverse of the removal procedure. L Note: Always wait for the BMW Integral ABS to complete its self-diagnosis after the ignition is switched on. Do not operate the brake lever until self-diagnosis is complete. • Perform a function check on the brake system with the ignition switched on. X Tightening torque: Brake caliper to rear wheel drive .................. 40 Nm R28000160 • • • • Remove keeper (arrow) from retaining pin.
[Without Integral ABS] Changing brake fluid and bleeding the brake system 34 00 010 • Remove reservoir cap with rubber diaphragm, draw off the old brake fluid and clean the reservoir. Change the brake fluid annually (Inspection IV) [Without Integral ABS] Bleeding/changing brake fluid in front system 34 00 033 L Note: This description applies to brake filling and bleeding devices with vacuum extraction of the brake fluid at the brake caliper.
• • • • • • • • • • • Close the bleed screw. Disconnect the brake bleeding device from the bleed screw. The procedure for changing the brake fluid in the right brake caliper is the same as that for the left caliper. Assembly is the reverse of the disassembly procedure. Top up the brake fluid until the level reaches the “MAX” mark. Wipe the rim of the reservoir, the rubber gaiter and the cover to remove brake fluid, and carefully reassemble the components.
• • • Assembly is the reverse of the disassembly procedure. Check the function of the brake system. Recheck the brake-fluid level. Minimum fluid level Brake pads worn not less than ..................................................................... “MIN” Brake fluid ...................................................DOT 4 MAX MIN X R28000050 • Tightening torque: Rear brake caliper bleed screw ...................... 6 Nm Brake caliper to rear wheel drive ..................
34 00 090 [Integral ABS] Changing/ bleeding brake fluid in wheel circuit Change brake fluid in wheel circuit once a year (Inspection IV) d Warning: All repair and maintenance work on the BMW Integral ABS should be carried out by specially trained personnel. Maintenance and repair procedures and processes should be strictly observed. Use only new brake fluid from an unopened container. • • Draw off the old brake fluid from the wheel circuit reservoir. Remove the front left and right brake pads.
• • Switch on the ignition. L Note: Always wait for the BMW Integral ABS to complete its self-diagnosis after the ignition is switched on. Do not operate the brake lever until self-diagnosis is complete. L Note: If necessary, use a cable tie to secure the bleed hose to the bleed screw. • • • • MAX Connect the brake bleeding device to the bleed screw of the right brake caliper, but do not switch it on.
Front wheel circuit reservoir filling instructions e Important: Integral brakes, the rear brake must be ready for use. MAX MIN 34 1 534 R28340090 34 1 531 • 34 1 532 R28000190 • • Top up fluid in front wheel circuit reservoir to “MAX” Use adapter 23, BMW No. 34 1 534, in the reset device, BMW No. 34 1 531/532, on both front brake calipers, and screw on the reset device until the adapter is secure.
The front wheel circuit should be bled only – – – Draw off the old brake fluid from the wheel circuit reservoir. Remove the front right and left brake pads, press back and position the pistons. Wrap cloths around the left and right brake calipers. d Warning: The brake fluid must not foam in the hose. If this should happen, follow the procedure for bleeding/changing brake fluid in the front wheel circuit. (a 00.42) • e Important: Integral brakes, the rear brake must be ready for use.
34 00 080 [Integral ABS] Bleeding/changing brake fluid in front wheel circuit • • • Remove fuel tank. – e Important: Do not allow brake fluid to come into contact with painted motorcycle parts as brake fluid destroys paint. • • • With the handle outwards, use the reset device, BMW No. 34 1 531, on the rear brake caliper to press back the pistons completely and to position them. Wrap a cloth around the brake caliper. [bleed only] The rear wheel circuit should be bled only. (a 00.
MAX MIN R28340090 e Important: The piston in the base of the wheel circuit reservoir must always be covered by the fluid, as otherwise air can be drawn into the brake system. Bleed the system again if this happens. • • • Very gently press the footbrake until the pump just starts up. Open the bleed screw, while continuously topping up the wheel circuit reservoir with new brake fluid. Pump out the brake fluid under virtually no pressure to begin with, then vary the brake pressure.
Rear wheel circuit reservoir filling instructions MAX 34 1 536 MIN 34 1 531 R28340090 R28000170 • • Top up fluid in rear wheel circuit reservoir to “MAX”. Screw the reset device, BMW No. 34 1 531, to the adapter, BMW No. 34 1 536. • • Top up the fluid in the wheel circuit reservoir until one of the three protrusions in the filler neck just touches the surface of the fluid (arrow). Remove the reset device, BMW No. 34 1 531 with adapter, BMW No. 34 1 536.
The front wheel circuit should be bled only – – – Draw off the old brake fluid from the wheel circuit reservoir. Remove the rear brake pads, press back and position the pistons. Wrap a cloth around the rear brake caliper. d Warning: The brake fluid must not foam in the hose. If this should happen, follow the procedure for bleeding/changing brake fluid in the rear wheel circuit. (a 00.46) • • • • 34 1 561 • 34 2 541 Pump brake fluid through the system until it is clear and free from air bubbles.
34 00 091 [Integral ABS] Changing/ bleeding brake fluid in control circuit Change brake fluid in control circuit every 2 years (Inspection IV) d Warning: All repair and maintenance work on the BMW Integral ABS should be carried out by specially trained personnel. Maintenance and repair procedures and processes should be strictly observed. Use only new brake fluid from an unopened container.
e Important: During the fluid-change and bleeding procedure, make sure that the fluid replenishing hole is always below the level of the brake fluid, otherwise air will be drawn into the brake system. Bleed the system again if this happens. • • • • Recheck the brake fluid level. Place the motorcycle on its centre stand. Turn the handlebars to the left. MIN Shift the handbrake lever to position 4.
34 00 082 [Integral ABS] Bleeding/changing brake fluid in rear control circuit • • Place motorcycle on its centre stand. Remove fuel tank. e Important: Do not allow brake fluid to come into contact with painted motorcycle parts as brake fluid destroys paint. • • e Important: While bleeding the system, do not allow the brake fluid level to drop below the “MIN” mark, as otherwise air will be drawn into the brake system. Bleed the system again if this happens.
• • • Correct the brake fluid level. Wipe the rim of the reservoir, the rubber gaiter and the cover to remove brake fluid, and carefully reassemble the components. Place the motorcycle on its centre stand. Checking clutch operating fluid level (Inspections II and III) e Important: Keep the brake fluid in the clutch operating system away from painted motorcycle parts as brake fluid attacks paint. • • Support the motorcycle on its side stand. Turn the handlebars to the right.
21 52 005 Changing the clutch fluid • (Inspection IV) at least every 2 years L Note: The description applies to a brake system filling and bleeding device with vacuum extraction of brake fluid at the bleed line. If other devices are used, comply with their manufacturers’ instructions. • • • Place motorcycle on its centre stand. Place the handlebars and the clutch fitting so that the clutch fluid expansion tank is level. Tighten the clutch fitting and secure the front wheel in the position.
Checking tightness of rear wheel studs Checking function of side stand contact switch (Inspection I) (Inspections I, II, III and IV) • • • • • Tighten the rear wheel studs with a torque wrench. X Tightening torque: Securing screws for rear wheel .................. 105 Nm Checking rear wheel bearing play by tilting wheel • Place the motorcycle on its centre stand. Retract the side stand, if extended. Disengage the clutch and select a gear. Start the engine, without releasing the clutch lever.
11 12 009 Tightening cylinder heads (Inspection I) Checking/adjusting valve clearances 11 34 004 (Inspections I, II and III) R21000330 R21000340 • Remove cylinder head cover. • e Important: Catch escaping oil. Check valve clearance with feeler gauge and, if necessary, correct with adjusting screw. Valve clearances with engine cold (max. 35 °C/95 °F): Intake valve ............................. 0.15 mm (0.0059 in) Exhaust valve .......................... 0.30 mm (0.
Checking throttle cable freedom of movement, checking for chafes and kinks, replacing if necessary, checking throttle cable play Checking/adjusting idle speed and throttle valve synchronization 13 60 110 (Inspections I, II and III) • Test-ride the motorcycle until the engine is warm, or allow the engine to idle for approximately 10 minutes. e Important: Do not allow the engine to idle for longer than S000100 20 minutes. • Oil temperature:...................
• Adjust the right throttle valve in the same way. • L Note: If play is zero, the throttle butterflies may chatter. • • Push the rubber cap into position over the adjusting screw. Move the handlebars all the way from left to right and check the settings. Make sure that engine speed does not vary when the handlebars are moved in this way. Repeatedly open the throttle gradually and increase engine speed from idle to approximately n= 2,500 rpm to check throttle-valve synchronisation.
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 the trial run/road test before checking/correcting engine oil level. Tyre pressures: Solo ....................................front 2.2 bar (31.3 bar) ............................................. rear 2.5 bar (35.6 psi) With pillion passenger ......... front 2.5 bar (35.6 psi) .....................................
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34 Brakes 34 Contents Page Technical Data ............................................................................................................................... 3 Removing and refitting front brake caliper ....................................................................4 Disassembling and assembling front brake caliper Removing and refitting rear brake caliper ..................................................5 ......................................................................
Contents [Integral ABS] Filling the brake system Page .......................................................................................................... 18 Filling control circuits .................................................................................................................. 18 Filling the front control circuit ............................................................................................................ 18 Filling the rear control circuit ......................
34 Technical Data R 1150 R Brake fluid DOT 4 Front wheel Colour of identification mark on brake calipers/brake pads green Brake disc diameter mm (in) 320 (12.5987) Brake disc thickness mm (in) 5.0 (0.1969) Minimum thickness mm (in) 4.5 (0.1772) Brake pad surface area cm2 86 (13.33) (sq in) Piston diameter in brake caliper mm (in) 32/36 (1.2599/1.4173) Piston diameter in handlebar lever cylinder mm (in) 16 (0.6299) Sensor gap, front mm (in) 0.2...1.7 (0.0079...0.
Removing and refitting front brake caliper 34 11 e Important: Do not allow brake fluid to come into contact with painted motorcycle parts as brake fluid destroys paint. • • Drain the brake system. [Integral ABS] Draining front wheel circuit (a 34.15). 1 d Suds 2 R28340010 • • Disconnect brake line (1). Remove screws securing the brake caliper. S340200 • Press the brake pads/pistons back against the brake disc (arrow) by pressing the brake caliper. e Important: Do not damage brake pads.
3 4 5 2 1 S340120 Disassembling and assembling front brake caliper 34 11 521 e Important: Keep the brake pistons parallel with their bores e Important: when fitting them. Do not separate the brake caliper halves. • • • • • • • • • Remove retaining plate. Remove the split-pin keeper (1) from retaining pin. Remove retaining pin (2). Remove brake pads. Close the bleed screw. Use the spacer, BMW No. 34 1 520, to secure the two opposite brake pistons.
2 2 1 S340010 Removing and refitting rear brake caliper 34 21 e Important: Do not allow brake fluid to come into contact with painted motorcycle parts as brake fluid destroys paint. • • • • • • • • • Drain the brake system. [Integral ABS] Drain rear wheel circuit (a 34.16). Disconnect brake line (1) from brake caliper. Carefully press back the brake pads/pistons. Remove the brake caliper. Installation is the reverse of the removal procedure. Fill and bleed the brake system.
1 5 2 3 4 R21340010 Disassembling and assembling rear brake caliper 34 21 Assembling rear brake caliper • Dismantling rear brake caliper • • • • • • Remove retaining washer (1). Drive out retaining pin (2) towards the wheel side. Remove brake pads. Close the bleed screw. Hold a cloth over the brake caliper piston. Using the compressed-air gun on the connection hole, carefully force out the brake pistons (3) using minimum pressure.
Removing and refitting front brake discs 34 11 • • e Important: Note direction of installation for the brake disc (lettering to the outside). Remove the brake caliper. Remove front wheel. X Tightening torque: Brake disc to front wheel (Clean thread + Loctite 2701) ....................... 21 Nm 2 1 1 Removing and refitting rear brake disc 34 21 • • 2 Remove the brake caliper. Remove rear wheel.
1 3 2 R28340040 [Integral ABS] Removing and refitting front ABS sensor 34 52 044 • • • • • Remove fuel tank (a 16.5). Separate plug connector (1) in sensor line. Remove the left brake caliper. Remove the sensor (2). Installation is the reverse of the removal procedure. e Important: Route the sensor cable correctly. Check that the clips (3) are correctly seated. X Tightening torque: Tighten the sensor ...................... hand-tight, 4 Nm Brake caliper to fork slider............................
1 2 R28340050 [Integral ABS] Removing and refitting rear ABS sensor 34 52 111 • • • • • • Remove front/rear seat. Separate plug connector (1) in sensor line. Before removing/refitting, clean the sensor and bore. Remove the sensor (2). Installation is the reverse of the removal procedure. Coat the O-rings with oil before fitting them. e Important: Route the sensor cable correctly. X Tightening torque: Tighten the sensor ...................... hand-tight, 4 Nm 34.
2 1 3 5 4 R28460060 35 21 Removing and refitting footbrake lever 34 31 • • • • e Important: • Release the pin in the brake linkage. Remove fasteners securing footbrake lever. Remove footbrake lever with torsion spring. Installation is the reverse of the removal procedure. Lubricate pivot bushing with Shell Retinax A. e Important: Piston rod play must be checked and adjusted. See removal and refitting of brake master cylinder. The brake light should light up when the rear brake is activated.
Checking and adjusting piston rod play 2 1 A R21340040 • Set the adjusting screw of the footbrake lever to distance A. Distance A:... 14 +/- 0.5 mm (0.5512 +/- 0.1969 in) (Top edge of footbrake lever to top edge of adjusting screw.) • Insert feeler gauge at right angles to direction of travel between the brake-light switch lever and the stop on the footrest plate (arrow). Feeler gauge thickness: .......... 0.2 mm (0.0078 in) • • • • • • Slacken locknut (1).
3 4 2 1 R28340060 34 00 [Integral ABS] Removing/installing the ABS pressure modulator Removing the ABS pressure modulator d Warning: Do not allow brake fluid to come into contact with painted motorcycle parts as brake fluid destroys paint. All repair and maintenance work on the BMW Integral ABS should be carried out by specially trained personnel. Maintenance and repair procedures and processes should be strictly observed. Use only new brake fluid from an unopened container.
Installing the ABS pressure modulator e Important: Do not bend brake lines. • Disconnect the brake lines from the ABS pressure modulator. e Important: • Install in reverse order, noting the following activities. L Note: When replacing the brake lines, always replace the seals (Quad rings) between the brake lines and the pressure modulator. Ensure that there is no brake fluid in the connector. • • • • • Remove the connector (3) for the front and rear wheel circuit reservoirs.
34 00 [Integral ABS] Draining brake system • d e Important: • Warning: All repair and maintenance work on the BMW Integral ABS should be carried out by specially trained personnel. Maintenance and repair procedures and processes should be strictly observed. Use only new brake fluid from an unopened container. Draw off the old brake fluid from the wheel circuit reservoir. Remove front brake pads. Only use the piston reset device, BMW No. 34 1 531, if the wheel circuit reservoir cover is open.
Bleeding rear wheel circuit L 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. • • • • • • 1 R28340110 • Open rear wheel circuit reservoir (1). e Important: To prevent brake fluid from entering the connector, do not release the ABS pressure modulator plug connections. • • Draw off the old brake fluid from the wheel circuit reservoir. Remove rear brake pads.
Bleeding control circuits Bleeding rear control circuit e Important: Do not allow brake fluid to come into contact with • • painted motorcycle parts as brake fluid destroys paint. Remove right-hand rear panel. Remove rear reservoir cap with rubber diaphragm, draw off the old brake fluid and clean the reservoir. Bleeding front control circuit • • • • • • Turn the handlebars to the left. Release clamps securing handlebar. Place the handlebars such that the brake fluid expansion tank is level.
[Integral ABS] Filling the brake system 34 00 e d Warning: All repair and maintenance work on the BMW Integral ABS should be carried out by specially trained personnel. Maintenance and repair procedures and processes should be strictly observed. Use only new brake fluid from an unopened container. Important: During the filling and bleeding procedure, make sure that the fluid replenishing hole is always below the level of the brake fluid, otherwise air will be drawn into the brake system.
• • • • • Switch off the bleed device. Shift the handbrake lever to position 4. d Warning: Avoid rapid and forceful pumping of the brakes when performing maintenance and repair work on the BMW Integral ABS. Recheck the brake-fluid level. Place the motorcycle on its centre stand. Turn the handlebars to the left. MIN 1 3 2 R28000110 Required level not below ......................................................... MIN (Top edge of the marking ring) R28340110 Brake fluid ..............................
Filling the rear control circuit • e Important: Remove rear reservoir cap with rubber diaphragm. On account of the vacuum extraction process, it is not possible to tell whether there is brake fluid in the hose of the brake bleeding device when it is free of bubbles. It is therefore necessary to bleed the hose by hand in the predefined sequence and in accordance with the rules for bleeding. • • – – – – MAX MIN R28000050 • Top up the brake fluid level to the “MAX” mark.
Filling wheel circuits • e Important: Do not allow brake fluid to come into contact with • painted motorcycle parts as brake fluid destroys paint. • Wrap cloths around the left and right brake calipers. Connect the brake bleeding device to the bleed screw of the left brake caliper, but do not switch it on. Switch on the ignition. L Note: Always wait for the BMW Integral ABS to complete Filling the front wheel circuit its self-diagnosis after the ignition is switched on.
Front wheel circuit reservoir filling instructions MAX 34 1 534 34 1 531 MIN 34 1 532 R28340090 R28000190 • • Top up fluid in front wheel circuit reservoir to “MAX” Use adapter 23, BMW No. 34 1 534, in the reset device, BMW No. 34 1 531/532, on both front brake calipers , and screw on the reset device until the adapter is secure. e Important: The piston in the base of the wheel circuit reservoir must always be covered by the fluid, as otherwise air can be drawn into the brake system.
• Filling rear wheel circuit • • • Refill the rear wheel circuit reservoir (1) with new brake fluid. Wrap a cloth around the brake caliper. Connect the brake bleeding device to the bleed screw, but do not switch it on. Switch on the ignition. L 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. 1 R28340110 • • Open rear wheel circuit reservoir (1). Remove rear brake pads.
Rear wheel circuit filling instructions d Warning: The wheel circuit reservoir may not overflow while the brake pads/brake calipers are being fitted. • 34 1 536 • • • 34 1 531 • R28000170 • • Top up fluid in rear wheel circuit reservoir to “MAX”. Screw the reset device, BMW No. 34 1 531, to the adapter, BMW No. 34 1 536. • • • If necessary, carefully press back the pistons until the brake disc just fits between the brake pads. Fit the brake pads and brake caliper at the rear.
R28340121 [Integral ABS] Removing/installing wheel circuit reservoir bleed lines 34 51 • • • • Remove the cover of the wheel circuit reservoir with bleed lines. Install in reverse order, ensuring that: the bleed lines are not kinked, bleed lines which have been shortened and bleed line ends are cut on the diagonal. 34.
34 52 Removing/installing brake lines e Important: Do not allow brake fluid to come into contact with painted motorcycle parts as brake fluid destroys paint. • • • Drain the brake system. Remove brake lines. Installation is the reverse of the removal procedure. e Important: Remove sealing rings for brake line. Secure the brake line to the brake master cylinder such that it is not chafed or bent when the handlebars are turned. • Fill and bleed the brake system. 34.
3 34 2 561 2 1 R28340160 [Integral ABS] Removing/installing brake lines • • • • • Drain the brake system (a 34.15). Push the protective caps (1) upwards. Remove spring clips (2). Remove brake lines. Installation is the reverse of the removal procedure, pay particular attention to the following: d • • • Check that the spring clips (arrows) are seated correctly. Pull the protective caps over the plug connections. Fill and bleed the brake system (a 34.18).
Removing and refitting front brake line 34.
Removing and refitting rear brake line 34.
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