Front suspension and handlebars of motorcycle BMW R1150GS (1999-2004)

Front suspension specifications
Technical DataR 1150 GS Front suspension TypeBMW Telelever with external suspension strut Telescopic fork Front wheel caster in normal-load position (85 kg/187 lbs rider), mm (in)115 (4.528) Steering lock angle,°42 Total suspension travel, mm...

Removing and installing telescopic fork without fork bridge
Remove front wheel. Remove mudguard. [ABS] Remove sensor. Remove brake line retainer. Place a support beneath the telescopic fork. Heat leading link mount at front to max. 120°C (248°F) and unscrew. Remove fasteners (cable ties) securing Bowden...

Removing and installing fork bridge
Disengage fuel tank and pull to the rear. Disconnect plug of ignition lock. Attach the handlebar to a crane and release the fastener securing the handlebar to the fork bridge. Remove fasteners (cable ties) securing Bowden cable for starting-speed...

Removing and installing slider tube bridge
Remove telescopic fork. Remove caps (1). Lever out the dust wipers (2). Remove fasteners securing slider tube bridge. Caution! Do not damage the surfaces. Carefully spread the slider tube bridge with a screwdriver and separate it from the slider...

Checking friction at ball joint/angular-contact ball bearing
Raise the motorcycle on its main (centre) stand, make sure front wheel is clear of the ground. Measure the breakaway moment to left and right from the central position of the handlebar using friction meter, BMW # 002570. Note: To determine the...

Disassembling and assembling telescopic fork
Disassembling telescopic fork Remove bleed screw (1). Remove oil drain plug (2) and allow the oil to drain out. Remove the fixed tube. Remove wiper (3) and retaining ring (4). Lever out shaft seal (5). Caution! Do not damage fork slider tube. Remove...

Measuring telescopic fork
Caution! After an accident, always examine the telescopic fork for cracks and signs of damage. Examining slider tube bridge and fork bridge Check slider tube bridge and fork bridge for surface irregularities. Caution! Replace slider tube bridge/fork...

Removing and installing leading link
Disengage spring strut at bottom. Heat ball joint mount (1) at leading link to max. 120°C (248°F) and remove it. Remove covers (2) from leading link pivots. Disconnect the left air intake pipe from the cylinder head. Remove left screw cap (3)....

Disassembling and assembling leading link
Press the bearing out/in with a suitable tool. Caution! Always install bearing by applying pressure to outer race. Removing and installing front spring strut Tightening torque: Spring strut to frame — 43 Nm Spring strut to leading link — 50 Nm

Removing and installing left handlebar fitting
Disengage fuel tank and pull to the rear. Remove securing screw (1) and remove handlebar weight. Pull off the grip. (Heated grips) Disconnect plug of grip heating. (Heated grips) Release cable shoe in connection. Remove lower plastic cover (3) on...

Removing and installing right handlebar fitting
Disengage fuel tank and pull to the rear. Remove securing screw (1) and remove handlebar weight. Remove throttle twistgrip cover (2). Back off the adjuster screw for the throttle cable and disengage the Bowden cable. Remove guide (3) of throttle...

Removing and installing brake piston in handlebar fitting
Drain the brake system. Caution! Do not allow brake fluid to come into contact with painted parts of the motorcycle as brake fluid destroys paint. Remove throttle twistgrip cover. Remove the lower section of the brake lever fitting. Remove pivot...

Removing and installing clutch piston in handlebar fitting
Drain the clutch operating system. Caution! Do not allow brake fluid to come into contact with painted parts of the motorcycle as brake fluid destroys paint. Remove the lower section of the clutch lever fitting. Remove the handlebar weight. Remove...

Checking and adjusting operating clearance at front brake/clutch levers
Front brake Remove cover from throttle-cable relay. Remove the lower section of the brake lever fitting. Back off adjusting screw (1). Note: Thread is secured with Loctite, if necessary heat slightly prior to facilitate removal. Remove pivot screw...

Removing and installing handlebar
Remove left and right handlebar fittings. Remove handlebar. Installation is the reverse of the removal procedure. Caution! Make sure that all lines and cables are correctly routed. Align the punch mark on the handlebar with the gap between the clamp...

Removing and installing Bowden-cable divider
Disengage fuel tank and pull to the rear. Remove actuating cable for starting-speed increase. Disengage Bowden cable (A). Remove Bowden-cable cover from fitting for throttle actuation. Disengage Bowden cable (B). Disengage throttle cables from right...

Disassembling Bowden-cable divider
Remove fasteners of Bowden cables at entry to Bowden-cable divider. Remove Bowden cable for starting-speed increase. Remove retainer (1) for roller of Bowden-cable divider. Remove Bowden cables. Installation is the reverse of the removal procedure....