Clutch specifications Technical Data R1150GS Type of clutch Single dry plate with increased-leverage diaphragm spring Actuation Hydraulic, with master and slave cylinders Master cylinder piston dia., mm (in) 13 (0.51) Slave cylinder piston dia., mm (in) 24 (0.94) Clutch...
Removing and installing clutch Removing clutch Removing clutch from vehicle Remove the sump guard. Secure stand, BMW No. 00 1 520, to motorcycle with overlength bushes and screws, BMW No. 001527. Note: Mount a washer on the screw on the right as viewed in the forward direction of...
Removing and installing clutch hydraulic line Remove the seat. Remove fuel tank. Remove rear brake caliper. Remove rear wheel. Remove suspension strut. Drain the clutch operating system. Caution! Do not allow brake fluid to come into contact with painted parts of the motorcycle as brake fluid...
Removing and installing clutch slave cylinder Remove the seat. Remove rear brake caliper. Remove rear wheel. Remove suspension strut. 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....
Transmission specifications Technical Data R1150GS Type of gearbox 6-speed gearbox with claw-action shift and integral reaction damper for all gears Gear shift type Foot-operated lever and selector drum with overshoot detent Gear ratios: - 1st gear 3.864 - 2nd gear 3.022 - 3rd...
Removing and installing gear-shift lever Remove retaining clip (1) and unfasten ball head. Remove retaining screw (2) on gear shift pedal. Installation is the reverse of the removal procedure. Tightening torque: Gear shift pedal to footrest plate — 35 Nm
Removing and installing gearbox Remove the sump guard. Secure stand, BMW No. 00 1 520, to motorcycle with overlength bushes and screws, BMW No. 001527. Note: Mount a washer on the screw on the right as viewed in the forward direction of travel. Depth of thread in tapped bore has...
Removing gearbox housing Remove oil filler/level check screw (1). Remove oil drain plug (2) and drain the oil from the gearbox into a suitable tray. Remove selector lever (3). Carefully drive back centering pins (4), from the cover side or casing side, as applicable. Remove...
Removing gearbox selector drum Pull the selector shafts (1) out of the selector forks. Swing the selector forks (3/8) out towards the edge of the cover (arrows). Remove locking pin (9). Press guide plate (5) in the opposite direction to the spring loading (arrow). Swing locking...
Disassembling and assembling selector shaft Take off spacing washer (1). Remove torsion spring (2) with locking lever (3) from selector shaft (4). Remove torsion spring (5). Disengage coil spring (6) and remove together with guide plate (7). Assembly is the reverse of the disassembly...
Removing gearbox shafts Remove breather tube (1). Heat bearing points in gearbox cover to 80...100°C (176...212°F). Remove input shaft (2), output shaft (3) and intermediate shaft (4) together from the cover. Remove selector fork (5) from intermediate shaft. Mark the...
Replacing grooved ball bearings of intermediate shaft Caution: If the grooved ball bearings are replaced, the fully assembled length must be re-adjusted. Pull off the grooved ball bearings with a universal puller, BMW No. 007500. Press the output-side grooved ball bearing on to the intermediate shaft....
Disassembling and assembling input shaft Disassembling input shaft Clamp the input shaft into a vise with soft jaws. Use universal puller, BMW No. 00 7 500, and pressure head (arrow) to pull off grooved ball bearing (9) with spacing washer (8). Note the thickness of spacing washer (8)....
Disassembling and assembling output shaft Disassembling output shaft Caution! To avoid damaging the needle roller bearing on the splines of the shaft, spread it carefully at the end face when removing. Using universal puller, BMW No. 00 7 500, pull off grooved ball bearing (22) together...
Checking gears endplay Secure dial gauge, BMW No. 00 2 510, to dial gauge stand. Position dial-gauge stylus on edge of the gearwheel and check endplay. Caution! Excessive endplay is due to incorrect assembly or worn needle roller bearings, backup washers or spacing...
Checking and adjusting fully-assembled length of intermediate shaft Caution: Check and adjust the fully assembled length as described below and install a spacing washer of the correct thickness. Before measuring, always make sure that the grooved ball bearings are pressed fully home, even if the shaft has not been...
Checking and adjusting fully-assembled length of output shaft Caution: Check and adjust the fully assembled length as described below and install a spacing washer of the correct thickness. Before measuring, always make sure that the grooved ball bearings are pressed fully home, even if the shaft has not been...
Checking and adjusting fully-assembled length of input shaft Caution! Check and adjust the fully assembled length as described below and install a spacing washer of the correct thickness. Before measuring, always make sure that the grooved ball bearings are pressed fully home, even if the shaft has not been...
Checking and adjusting fully assembled length of selector drum Place spacing washer and both thrust washers on the selector drum. Using slide gauge, determine fully assembled length «A». If necessary, adjust fully assembled length «A» with a shim washer (arrow). Fully assembled length: Selector drum —...
Shimming selector shaft Caution! If the housing or the complete selector shaft is replaced, the selector shaft must be measured and shimmed. Measure distance «A» from shouldered bushing to cover mating face. Measure distance «B» from shouldered bushing to housing mating...
Installing input, output and intermediate shafts Insert marked selector fork (1) into intermediate shaft (2). Align input, output and intermediate shafts so that their gear teeth mesh and the selector fork is in the position illustrated. Push assembly sleeve, BMW No. 23 4 712, on to the input...
Installing selector shaft Place a spacer of correct thickness on the housing. Install selector shaft (1), making sure that spring (2) is correctly positioned.
Installing selector drum Place a spacing washer of the correct thickness and the input-side thrust washer on selector drum (6) and secure with a small amount of grease. Swing locking lever (8) toward the input shaft and install the selector drum. Swing locking lever (8)...
Installing gearbox housing Install the dowel pins in cover and in housing, but do not drive the pins fully home. Install breather tube (1) in housing cover. Caution! Clean and de-grease the sealing faces. The sealing compound sets within 30 minutes; within this time, place...