Elements of transmission motorcycle BMW R1150GS (1999-2004)

Clutch specifications
Technical DataR1150GS Type of clutchSingle dry plate with increased-leverage diaphragm spring ActuationHydraulic, 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 # 00 1 520, to motorcycle with overlength bushes and screws, BMW # 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 DataR1150GS Type of gearbox6-speed gearbox with claw-action shift and integral reaction damper for all gears Gear shift typeFoot-operated lever and selector drum with overshoot detent Gear ratios: - 1st gear3.864 - 2nd gear3.022 - 3rd...

Gearbox sectional drawing
Gearbox sectional drawing

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 # 00 1 520, to motorcycle with overlength bushes and screws, BMW # 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 been...

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 # 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 # 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 # 00 7 500, pull off grooved ball bearing (22) together with...

Checking gears endplay
Secure dial gauge, BMW # 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 washers,...

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 # 23 4 712, on to the input shaft...

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...