User manual BMW R1150GS REPAIR MANUAL

[. . . ] Repair Manual R 1150 GS BMW Motorrad After Sales Publisher © BMW Motorrad After Sales UX-VS-2 All rights reserved. Not to be reprinted, translated or duplicated either wholly or in part without prior written permission. Printed in Germany 02/00 Order number 01 79 0 021 120 Introduction This Repair Manual will help you to perform all the main maintenance and repair work correctly and efficiently. It should be consulted regularly by workshop personnel as an addition to the practical and theoretical knowledge obtained in Training School courses. [. . . ] 18 Checking endplay Checking/adjusting fully assembled length of gearbox shafts and selector drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Checking/adjusting Checking/adjusting Checking/adjusting Checking/adjusting fully-assembled length of intermediate shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 fully-assembled length of output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 fully-assembled length of input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 fully assembled length of selector drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Shimming selector shaft 23. 1 Contents Assembling gearbox Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Installing input, output and intermediate shafts Installing selector shaft Installing selector drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Installing gearbox housing 23. 2 23 Technical Data Type of gearbox Gear shift type Gear ratios 1st gear 2nd gear 3rd gear 4th gear 5th gear 6th gear Oil grade (all the year round) Capacity Endplay of spring segment at input shaft Endplay at 1st gear, output shaft Endplay at 2nd gear, output shaft Endplay, 3rd/4th gear (total play) output shaft Selector shaft endplay Length of selector drum, fully compressed R 1150 GS 6-speed gearbox with claw-action shift and integral reaction damper for all gears Foot-operated lever and selector drum with overshoot detent 3. 864 3. 022 2. 393 1. 962 1. 700 1. 316 Brand-name SAE 90 hypoid gear oil, API Class GL 5 l (Imp. pint/ approx. 1. 0 (1. 76/1. 06) US quart) (to lower edge of filler screw) mm (in) 0. 4 . . . 4. 406) 23. 3 23. 4 Gearbox - sectional drawing R21239010 23. 5 23. 6 Removing and installing gear-shift lever 2 · · · · · · · · · · · · · · · · · · · · 1 R21460190 · · · Remove retaining clip (1) and unfasten ball head. Installation is the reverse of the removal procedure. Disconnect the air temperature sensor plug. Disconnect hose clamps/throttle stub pipes and push the stubs into the air filter box. Detach retaining clip from ball head/shift linkage and remove ball head. Remove rear-frame fasteners on left and right at front, but only loosen strut fasteners. Disconnect cable from oil pressure switch. Tightening torque: Gear shift pedal to footrest plate . . . . . . . . . . . . . . . . . . 35 Nm X · · Removing/installing gearbox Remove the sump guard. 00 1 527. L Note: · · · Mount a washer on the screw on the right as viewed in the forward direction of travel. Disengage fuel tank. R21610050 · · · · · · e is flammable and a hazard to health. Observe Caution: Fuel relevant safety regulations. Disconnect plug of gear indicator. Take off the footrest plates. · · · · · Seal the fuel feed and return lines with hose clips, BMW No. Remove the battery. L Note: the footrest plates, use the long When installing screws on the right and the short screws on the left. e Caution: · Disconnect the negative battery terminal first, then the positive terminal. Connect the positive battery terminal first, then the negative terminal. Unscrew rear battery mount. · · · Remove rear brake fluid reservoir from its holder. Remove brake line from swinging arm. 23. 7 · · · · · [ABS] Disconnect the plug of the rear ABS sensor. Remove the clutch bleeding/filler adapter from the rear frame. · · Press off drive shaft. Remove the gearbox. 23 1 820 23 1 820 RS230011 · RS230310 Always use oiled guide pins, BMW No. 23 1 820, when removing or installing the gearbox. · · · · · · · · Tilt the rear frame up and secure it in this position with a strap attached to the handlebar. [. . . ] 9. Flasher unit Indicator damping Coded plug for Motronic Starter motor relay Relief relay Horn relay Fuel pump relay Motronic relay ABS warning relay 1. Instrument cluster, indicator damping, brake light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 A A A A A A A 61. 6 Wiring-harness routing, frame [ABS] 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 80 . [. . . ]