Motorcycle engine repair BMW R1150GS (1999-2004)

Engine repair specifications
Technical DataR 1150 GS Engine, general Engine designFour-stroke flat twin, air-cooled with oil-cooled exhaust ports, installed longitudinally, 4 valves per cylinder, two overhead camshafts, electronic fuel injection. Location of engine...

Cutaway drawing of engine
Cutaway drawing of engine Lubricating-oil circuit Cooling-oil circuit

Removing and installing engine
Note: Auxiliary shaft, timing chains, chain tensioner/guide rails and crankshaft can only be disassembled after the engine has been removed. All other components can be disassembled with the engine installed. Remove the sump guard. Drain engine oil....

Installing auxiliary frame (raising frame unit clear of engine)
Remove rear wheel. Remove height adjuster from seat on right. Remove hydraulic spring-strut adjuster. Remove rear spring strut. Install the rear wheel. Remove the upper securing screw and the bottom bolt of the engine/frame connecting strut (1)....

Removing auxiliary frame (lowering frame unit onto engine)
Lower the frame unit into position from front. Caution! Make sure that all components are correctly positioned. Do not damage cables, lines and Bowden cables. Install the clutch slave cylinder. Lightly grease the shaft of the leading link, insert it...

Disassembling engine — beginning
Secure engine mount, BMW # 11 0 630, to the engine block. Transfer engine to assembly frame. Drain engine oil. Remove the oil filter, using oil filter wrench, BMW # 114650.

Removing cylinder head cover
Remove spark plugs with the spark plug wrench, BMW # 123510. Remove cylinder head cover. Caution! Catch escaping oil.

Locking the engine at TDC
Remove front cover. Turn the belt pulley to bring the piston to firing TDC. Firing TDC 1. TDC mark is visible, and 2. The inlet and exhaust valves of the cylinder in question are closed. Install locking device, BMW # 11 5 640, to lock clutch...

Removing and installing chain tensioner
Caution! Do not mix up the chain tensioner pistons. When installing, fit a new seal. Work instructions, timing-chain tensioner Removing: Remove timing chain tensioner, then remove camshaft sprocket from camshaft. Installing: First install camshaft...

Remove valve gear carrier
Remove camshaft sprocket cover. Remove/pull off camshaft sprocket. Note: If the camshaft sprocket (1) is not removed after loosening, it must be held firmly and prevented from falling into the engine block (e.g. with a cable strap). Remove valve...

Disassembling/assembling 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. Remove pushrods. Caution! Do not mix up the rocker shafts and pushrods. Remove camshaft bearing cap...

Removing cylinder head
Removing cylinder head

Disassembling, checking, repairing and reassembling cylinder head
Removing and installing valves Caution! Do not scratch sealing face on cylinder head. Place the head on a clean, non-scratching surface. Mount valve spring compressor, BMW # 115690, onto cylinder head. Compress the valve springs. Gently tap valve...

Removing cylinder
Remove guide rail bearing screws (1). Remove cylinder retaining screws, and remove cylinder. Caution! When removing cylinder, make sure that the piston does not strike the engine block.

Removing and disassembling piston
Remove both retaining rings from piston pin. Press out piston pin by hand. Remove piston. Carefully remove piston rings with piston ring pliers. Remove combustion residues from piston crown and clean piston. Caution! Do not mix up pistons, piston...

Removing and installing conrod
Turn crankshaft to TDC position. Install locking device, BMW # 11 5 640, to lock clutch housing. Remove conrods. Note: Conrods can also be removed and installed with the crankshaft removed. Caution! Do not mix up conrods or bearing shells. Use a...

Removing and installing alternator mount cover with engine installed
Caution! Disconnect earth (ground) lead from battery. Insulate earth (ground) lead. Remove the horn. Remove the oil cooler line. Disconnect the Hall sensor. Remove the starter motor. Remove rear leading link mount. Removing alternator mount cover...

Removing auxiliary shaft drive
Align marks (arrows) on timing pinion and chain sprocket. Remove banjo bolt of cooling oil pipe (1) and swing the pipe forwards. Remove chain tensioner (2). Remove chain tensioning rail (3). Remove chain guide rail (4). Install locking device, BMW #...

Removing oil pump
Remove oil pump cover (1). Remove complete oil pump (2) together with cooling oil pipe (3), and disassemble. Caution! Check installed positions of parts which have already been run together.

Removing radial shaft seal from crankshaft with engine installed
Lock clutch housing with special tool, BMW # 115640. Remove the clutch. Carefully lever out radial shaft seal, using a screwdriver. Caution! Take care not to damage the sealing faces of crankcase and crankshaft. Note: The radial shaft seals can be...

Disassembling crankcase
Turn engine on to its side. Remove screws on right side. Turn engine on to its side. Remove screws on left side. Remove upper section of crankcase.

Removing crankshaft, auxiliary shaft and timing chain tensioning and slide rails
Removing crankshaft, auxiliary shaft and timing chain tensioning and slide rails

Removing and installing oil intake strainers
Tightening torque: M6 screw — 9 Nm Caution! Make sure that the O-ring is not omitted, and is installed undamaged.

Replacing oil level sight glass
Pierce the plastic disc with a large screwdriver and lever out the oil level sight glass. Coat the sealing face of the new oil level sight glass with engine oil and drive it in with drift, BMW # 005550.

Removing and installing oil thermostat
Remove screws securing oil cooler line to fairing bracket. Disconnect oil cooler line from crankcase. Remove support plate (1), control element (2) and spring (3). Installation is the reverse of the removal procedure. Tightening torque: M 6 screw —...

Removing and checking conrods
Removing Clamp crankshaft in a vise with protective jaws. Remove conrods. Caution! Do not mix up the conrods. Checking Check conrod dimensions. See Technical Data. Caution! Do not attempt to straighten the steel cracked conrods – risk of fracture.

Measuring crankshaft bearing play
Measuring radial bearing play Measure main bearing journal with an external micrometer in two planes, A and B at right angles. Enter measured values on record sheet. See Technical Data. Caution! The crankshaft can only be reground in grinding stage...

Measuring big end bearing play
Measure crankpin with an external micrometer in the thrust direction and at right angles to the thrust direction. Install bearing shells and assemble conrods. Using tightening angle indicator, BMW # 11 2 500, tighten the big end bolts. Tightening...

Installing conrods
Clamp crankshaft in a vise with protective jaws. Oil the big end bolts, screw them in by hand and tighten with tightening angle indicator, BMW # 112500. Caution! Oil the bearings. Do not mix up conrods or bearing shells. Always use new big end...

Installing crankshaft
Caution! Oil the bearings. Installing timing chain tensioning and slide rails Seal pivot pin for tensioner rail/slide rail at clutch side (arrow) with 3-Bond 1209. Insert pivot screw (1) into chain tensioner rail, using a new seal. Tightening...

Assembling engine block
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. Bolt the crankcase sections together. Tightening torque/tightening sequence: 1. M10 screw...

Installing radial shaft seals on crankshaft
Installing the crankshaft-end radial shaft seal Shape the lip of the radial shaft seal carefully by hand (1). Oil the radial shaft seal at the sealing/contact surface. Using assembly sleeve, BMW # 11 5 702, mount the radial shaft seal with the...

Installing clutch housing
Caution! Always use new screws for housing and cover. Install clutch housing with mark (1) aligned with crankshaft mark (2). Install locking device, BMW # 11 5 640, to lock clutch housing. Insert all screws by hand and tighten. Tightening torque:...

Installing oil pump
Caution! Oil the friction faces. Install outer rotor (1) of oil pump in pump housing. Install oil pump housing with cooling oil pipe (2). Caution: O-ring (3) must be in perfect condition. Install Woodruff key (4), outer rotor (5) and inner rotor (6)...

Installing auxiliary shaft drive
Align crankshaft mark with mark on auxiliary shaft. Caution! Adjust according to the adjusting instructions. See Technical Data. Install locking device, BMW # 11 5 640, to lock clutch housing. Install chain sprocket (1). Tightening torque: M6 screw...

Installing piston
Turn oil scraper ring so that gap (arrow) is at top. Install piston rings with gaps offset by 120°. Production locating point X = install on exhaust side. Caution: Make sure that retaining rings are properly seated on piston pin. Oil the friction...

Installing cylinder
Clean and degrease cylinder base sealing face (arrow) and apply 3-Bond 1209. Oil the cylinder wall. Compress the piston rings with a clamping strap, BMW # 112900. Install the cylinder and at the same time pass the timing chain and the tensioner and...

Installing cylinder head
Install cylinder head gasket. Fit cylinder head and insert correctly positione camshaft chain sprocket (1) and timing chain in chain cavity. Install valve gear carrier (2). Tighten cylinder head securing screws and nu Caution: Install cylinder head...

Adjusting valve clearances
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°C/95°F): Inlet — 0.15 mm (0.0056 in) Exhaust —...

Installing right cylinder head
Adjustment specification Caution! When assembling, always start with the right-hand cylinder. Right cylinder = at firing TDC: marks (arrows) on chainwheel/auxiliary shaft and chain sprocket/crankshaft are aligned. Lock engine at firing TDC by...

Installing left cylinder head
Adjustment specification Caution! When installing, always begin with the right-hand cylinder. Left cylinder = at firing TDC: marks (arrows) on chain sprocket/auxiliary shaft and chainwheel/crankshaft at bottom. Lock engine at firing TDC by inserting...

Installing alternator mount cover
Place assembly sleeve, BMW # 11 5 680, on crankshaft. Clean and de-grease sealing face (arrow) and apply 3-Bond 1209. Install alternator mount cover. Tightening torque: M8 screw — 20 Nm M6 screw — 9 Nm

Installing magnetic gate/belt pulley
Install Hall-effect trigger plate (1). Install locking device, BMW # 11 5 640, to lock clutch housing. Secure rotor (2) of Hall-effect gate to the Poly-V-belt pulley (3) with, for example, Loctite instant adhesive. Install the Poly-V belt pulley....

Installing alternator
Install alternator. Poly-V belt adjusting procedure: Poly-V belt installation procedure: Slightly tighten hex nut (1) on adjusting screw (2) by hand (do not use tools). Tighten adjusting screw (2) with a torque wrench and keep preload applied....