Brake system of motorcycle BMW R1150GS (1999-2004)

Brakes specifications
Technical Data R1150GS Brake fluid DOT 4 Minimum lining thickness, front, mm (in) 1.0 (0.04) Minimum lining thickness, rear If the brake disc is visible through the bore in the wheel-side brake pad, the brake lining is worn to its minimum...

Removing and installing front brake caliper
Caution! Do not allow brake fluid to come into contact with painted parts of the motorcycle as brake fluid destroys paint. Drain the brake system. Disconnect brake line (1). Remove screws securing the brake caliper. Force back the brake pads and...

Disassembling and assembling frontbrake caliper
Caution: Do not separate the brake caliper halves! Remove the brake caliper. Remove keeper from retaining pin (1). Drive out the retaining pin (1) from the wheel side. Remove brake pads by pulling downwards. Close the bleed screw. Tightening torque:...

Removing and installing filler adapter
Remove right-hand brake caliper. Remove the brake pads. Secure the brake caliper in a vise. Filler adapter (1) must face down, so that no traces of thread-locking compound can make their way into the brake caliper when the filler adapter is...

Removing and installing rear brake caliper
Caution! Do not allow brake fluid to come into contact with painted parts of the motorcycle as brake fluid destroys paint. Drain the brake system. Disconnect brake line (1) from brake caliper. Remove screws securing the brake caliper. Installation...

Disassembling and assembling rear brake caliper
Remove retaining washer (1). Drive the retaining pin (2) out towards the wheel side. Remove brake pads. Close the bleed screw. Tightening torque: Bleed screw in brake caliper — 6 Nm Hold a cloth over the brake caliper piston. Carefully press out...

Removing and installing front brake disc
Remove screws securing the brake caliper. Remove front wheel. Remove and install brake discs. Degrease brake discs before installing. Note: Installed direction (arrow) of brake discs must be correct. Tightening torque: Brake disc to front wheel...

Removing and installing rear brake disc (mounted on rear-wheel hub)
Remove screws securing the brake caliper. Remove rear wheel. Remove brake disc. Installation is the reverse of the removal procedure. Degrease the brake disc before installing. Caution! [ABS] Check sensor gap and adjust with shims if necessary....

Removing and installing front ABS sensor
Remove front wheel. Remove fuel tank. Disconnect plug (1) of sensor cable. Remove sensor (2) with Torx T25 . Installation is the reverse of the removal procedure. Caution! Route the sensor cable correctly. Check sensor gap and adjust if necessary...

ABS sensor gap, front: adjusting
Marking sensor ring Take load off front wheel/lift clear of ground. Undo clamp screw at left fork tube. Attach dial gauge holder (1), BMW No. 00 2 500, with dial gauge, BMW No. 00 2 510, and measuring shoe (2), BMW No. 34 2 510, to fork slider tube....

Removing and installing rear ABS sensor
Before removing/installing, clean the sensor bore. Using Torx T25, slacken sensor (1). Disconnect plug (2) of sensor cable. Installation is the reverse of the removal procedure. Coat O-rings with oil before installing. Caution! Route the sensor...

Adjusting rear ABS sensor gap
Marking sensor wheel Remove rear brake caliper. Before removing/installing, clean the sensor bore. Using Torx T25, remove the sensor. Screw dial gauge holder with measuring shoe and extension, BMW No. 34 2 520, with dial gauge, BMW No. 00 2 510,...

Removing and installing rear brake master cylinder
Caution! Do not allow brake fluid to come into contact with painted parts of the motorcycle as brake fluid destroys paint. Drain the brake system. Disconnect brake line (1) and hose (2). Release and remove pin (3). Remove brake master cylinder (4)....

Removing and installing footbrake lever
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. Caution! Check/adjust...

Removing and installing ABS unit
Caution! Work on the ABS unit must be performed by an authorised BMW workshop. Removing the ABS unit Remove fuel tank. Disconnect ABS brake lines (1) from ABS unit. Caution! If brake fluid escapes, it may damage paint. Line connections must be...

Removing ABS relay
Caution! Switch off ignition. Disconnect earth (ground) lead from battery. Insulate earth (ground) lead. Remove cover (1) from ABS control unit, press the lock in with a screwdriver and pull the cover up. Scrap the old cover (1). Disconnect lines...

Installing the ABS relay
Insert the ABS relay with the FAG logo facing the detent hook. Tighten the screws at the relay socket. Push the relay socket into the relay housing, at the same time pressing both engine cables into the left cable entries on the relay housing (red...

Removing ABS relay socket
Caution! Switch off ignition. Disconnect earth (ground) lead from battery. Insulate earth (ground) lead. Remove cover (1) from ABS control unit, press the lock in with a screwdriver and pull the cover up. Scrap the old cover (1). Disconnect lines...

Installing the ABS relay base
Bend up the contact interlock on the plug. Insert the contact into the relay socket. Caution! The contact engages with an audible click and must be firmly located. Insert the ABS relay with the FAG logo facing the detent hook. Insert a Torx screw...

Removing and installing brake line (with ABS)
Removing and installing front brake line Removing and installing rear brake line Caution! Do not allow brake fluid to come into contact with painted parts of the motorcycle as brake fluid destroys paint. Drain the brake system. [ABS] Remove the fuel...