Complete map of motorcycle repair instructions BMW

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Repair motorcycles BMW F-series
BMW F 650 GS (2000-2007)
Information for owner

Solving the symbols
General view of crated motorcycle
Unpacking the motorcycle
Installing remaining items on motorcycle
Filling and charging the battery
Reading the fault code memory with the BMW MoDiTeC
Checking tyre pressures
Final inspection and function check

Maintenance schedule of motorcycle
Service data of motorcycle
Table of operating fluids
Tightening torques
Key to maintenance intervals
Reading the fault code memory with the MoDiTeC
Changing the engine oil and oil filter element
Checking coolant, topping up if necessary
Changing coolant
Changing oil in telescopic forks
Checking and adjusting valve clearances
Replacing spark plugs
Emptying drain hose from intake air silencer
Replacing air cleaner element
Replacing fuel filter
Checking clutch play, adjusting if necessary
Checking wheel spoke tension, adjusting if necessary
Checking brake pads and discs for wear, replacing if necessary
Checking the brake fluid level and topping up if necessary
Checking operation of brake system and freedom from leaks, replacing if necessary
Changing brake fluid
Replacing primary sealing boot, front brake master cylinder
Replacing primary sealing boot, rear brake master cylinder
Inspecting front and rear wheel bearings, replacing if necessary
Checking chain, chainwheel and chain sprocket, replacing if necessary
Checking chain tension, adjusting if necessary
Checking battery acid level, adding distilled water if necessary
Cleaning and greasing the battery terminals, if necessary
Checking and adjusting steering head bearing play, replacing if necessary
Greasing the side and main stands and the brake pedal lever
Checking security of threaded fasteners
Final inspection with road safety and functional check
Engine and systems

Technical data of engine motorcycle
Engine design of motorcycle
Removing and installing cylinder head, engine installed
Removing cylinder, engine installed
Removing engine
Lowering engine
Removing cylinder head
Disassembling and assembling cylinder head
Removing and checking cylinder
Removing and checking piston
Removing ignition magnet
Removing countershaft for starter
Disassembling and assembling freewheel
Removing clutch
Removing and installing oil pump
Removing double drive gear
Removing crankshaft and balancing shaft
Removing compensating gear
Removing and installing crankshaft gear
Removing and installing gearbox mainshaft bearings
Removing and installing gearbox compensating shaft bearings
Removing and installing grooved ball bearings of gearbox compensating shaft
Removing and installing main bearings
Installing crankshaft and balancing shaft
Installing double drive gear
Installing oil pump gears
Installing clutch
Installing countershaft for starter motor
Installing magnetic ignition trigger
Installing piston
Installing cylinder
Installing cylinder head
Installing camshaft and adjusting valves
Installing engine

Technical data of ignition system
Ignition magneto design of motorcycle
Removing ignition magnet
Installing magnet wheel
Removing/installing starter motor
Disassembling/assembling starter motor
Replacing ignition lead
Removing/installing ignition coil

Technical data of fuel system
Removing and installing BMS control unit
Removing and installing intake air pipe
Removing/installing air temperature sensor
Removing and installing intake air silencer
Removing and installing injection nozzle
Removing and installing throttle valve actuator
Replacing throttle-valve potentiometer
Removing and installing throttle-valve stub pipe
Removing and installing intake pipe
Checking fuel pressure
Removing and installing fuel hoses
Technical data of fuel tank and lines
Removing fuel tank
Installing fuel tank
Removing and installing fuel filler cap
Removing and installing roll-over valve
Removing and installing fuel pump
Removing and installing fuel-evaporation control valve
Removing and installing activated charcoal filter
Technical data of exhaust system
Removing and installing exhaust system
Removing and installing exhaust manifold and oxygen sensor
Replacing guard for silencer

Technical data of cooling system
Cooling system design of motorcycle
Removing coolant pump
Installing coolant pump
Adding coolant to cooling system
Removing and installing coolant-temperature sensor
Checking cooling system for leaks
Removing and installing coolant hoses
Removing and installing fan
Removing and installing radiator
Removing and installing thermostat

Technical data of clutch
Clutch design of motorcycle
Removing clutch
Installing clutch
Technical data of gearbox
Ggearbox design of motorcycle
Removing/installing gearbox
Removing, disassembling and reassembling gearbox shafts
Technical data of chain drive
Removing and installing chain
Removing chainwheel
Removing chain sprocket
Removing and installing chain guide rail with swinging arm installed
Running gear and frame

Technical data of frame
Removing and installing left/right cover
Removing and installing centre cover
Removing and installing cockpit fairing
Removing and installing fairing bracket
Raising rear frame
Removing and installing front mudguard
Removing and installing rear frame
Removing and installing ignition switch/steering lock
Removing and installing ignition lock barrel
Removing and installing lock for rear stowage compartment
Removing and installing lock barrel for fuel tank filler cap
Replacing mirrors

Technical data of handlebar
Removing and installing left handlebar fitting
Removing and installing clutch switch
Removing and installing right handlebar fitting
Removing and installing handlebar
Removing and installing clutch cable
Removing and installing throttle cable
Checking steering head bearing play
Adjusting steering head bearing play
Removing and installing left and right handlebar levers

Technical data of rear suspension
Removing and installing suspension strut
Removing and installing rear swinging fork
Removing and installing needle roller races in rear swinging fork
Removing and installing struts
Removing and installing needle roller bearing in tension strut
Removing and installing angled lever
Removing and installing needle roller bearings and needle roller races in angled lever

Technical data of brake system
Removing and installing front brake calliper
Removing and installing front brake pistons
Removing and installing front brake disc
Checking front brake disc for lateral runout
Removing and installing rear brake calliper
Removing and installing rear brake piston
Removing and installing rear brake disc
Checking rear brake disc for lateral runout
Removing and installing front brake master cylinder
Removing and installing rear brake master cylinder
Removing and installing footbrake lever
Checking play at piston thrust rod, adjusting if necessary
Removing and installing front ABS sensor
Removing front ABS sensor ring
Removing and installing rear ABS sensor
Removing and installing rear ABS sensor ring
Removing and installing ABS control unit
Removing and installing front brake lines/hoses (with ABS)
Removing and installing rear brake lines/hoses (with ABS)
Checking/adjusting front ABS sensor gap
Checking/adjusting rear speed/ABS sensor gap

Technical data of wheels and tyres
Removing/installing front wheel
Removing/installing front wheel bearing
Removing/installing rear wheel
Removing/installing rear wheel bearings
Removing/installing bearing in chainwheel carrier
Removing/installing front wheel spokes
Removing/installing rear wheel spokes
Checking and centering front and rear wheel rims
Static balancing of front/rear wheel
Electric equipment

Wiring harness of motorcycle
Component positions in electronic equipment box
Removing and installing battery
Removing and installing battery carrier
Replacing fuses
Removing and installing electronic equipment box
Removing and installing side stand switch
Removing and installing rear-brake switch for brake light
Removing and installing front-brake switch for brake light
Removing and installing horn
Removing and installing idle-indicator switch
Telltale/warning lights
Removing and installing instrument panel
Replacing telltale/warning lights
Disassembling and assembling instrument cluster
Removing and installing wiring harness

Technical data of light system
Removing and installing headlight
Removing and installing rear light
Bulb for low-beam/high-beam headlight
Replacing bulb of parking light
Replacing bulb of flashing turn indicator
Replacing bulb of rear lights
Checking and adjusting headlight beam angle

Repair motorcycles BMW R-series
BMW R 1150 GS (1999-2004)
Information for owner

General view of crated motorcycle
Installing remaining items on motorcycle
Filling and charging the battery
Checking engine oil when engine is cold, topping up if necessary
Checking headlight beam angle, adjusting if necessary
Other checkings before riding
Final inspection and function check
Handing over the motorcycle

Maintenance schedule R1100S / R850 / 1200C / R1150GS
Service data of motorcycle
Tightening torques
Table of operating fluids
Key to maintenance intervals
Changing engine oil, replacing oil filter element
Changing oil in gearbox
Changing the oil in the rear wheel drive
Replacing fuel filter
Checking battery fluid level and topping up if necessary
Replacing intake air filter element
Replacing Poly-V belt
Checking brake fluid level
Checking brake pads and discs for wear/replacing
Bleeding front brake circuit/changing brake fluid
Bleeding rear brake circuit/changing brake fluid
Checking clutch operating fluid level
Changing the clutch fluid
Checking tightness of rear wheel studs
Checking rear wheel bearing play by tilting wheel
Greasing the side stand pivot
Checking function of side stand contact switch
Checking/replacing spark plugs
Tightening cylinder heads
Checking/adjusting valve clearances
Checking freedom of throttle cable, checking for chaffing and kinks
Final inspection with road safety and functional check
Engine and systems

Engine repair specifications
Cutaway drawing of engine
Removing and installing engine
Installing auxiliary frame (raising frame unit clear of engine)
Removing auxiliary frame (lowering frame unit onto engine)
Disassembling engine — beginning
Removing cylinder head cover
Locking the engine at TDC
Removing and installing chain tensioner
Remove valve gear carrier
Disassembling/assembling valve gear carrier
Removing cylinder head
Disassembling, checking, repairing and reassembling cylinder head
Removing cylinder
Removing and disassembling piston
Removing and installing conrod
Removing and installing alternator mount cover with engine installed
Removing auxiliary shaft drive
Removing oil pump
Removing radial shaft seal from crankshaft with engine installed
Disassembling crankcase
Removing crankshaft, auxiliary shaft and timing chain tensioning and slide rails
Removing and installing oil intake strainers
Replacing oil level sight glass
Removing and installing oil thermostat
Removing and checking conrods
Measuring crankshaft bearing play
Measuring big end bearing play
Installing conrods
Installing crankshaft
Assembling engine block
Installing radial shaft seals on crankshaft
Installing clutch housing
Installing oil pump
Installing auxiliary shaft drive
Installing piston
Installing cylinder
Installing cylinder head
Adjusting valve clearances
Installing right cylinder head
Installing left cylinder head
Installing alternator mount cover
Installing magnetic gate/belt pulley
Installing alternator

Fuel preparation and control specifications
Removing and installing air filter housing
Removing and installing trottle-valve stub pipe
Removing and installing throttlevalve potentiometer
Removing and installing Motronic control unit
Fuel tank and lines specifications
Removing and installing fuel tank
Removing and installing roll-over valve
Removing and installing fuel filter, fuel pump and fuel level sensor
Removing and installing fuel distributor and pressure regulator
Removing and installing silencer and front silencer
Removing and installing exhaust manifolds

Clutch specifications
Removing and installing clutch
Removing and installing clutch hydraulic line
Removing and installing clutch slave cylinder
Transmission specifications
Gearbox sectional drawing
Removing and installing gear-shift lever
Removing and installing gearbox
Removing gearbox housing
Removing gearbox selector drum
Disassembling and assembling selector shaft
Removing gearbox shafts
Replacing grooved ball bearings of intermediate shaft
Disassembling and assembling input shaft
Disassembling and assembling output shaft
Checking gears endplay
Checking and adjusting fully-assembled length of intermediate shaft
Checking and adjusting fully-assembled length of output shaft
Checking and adjusting fully-assembled length of input shaft
Checking and adjusting fully assembled length of selector drum
Shimming selector shaft
Installing input, output and intermediate shafts
Installing selector shaft
Installing selector drum
Installing gearbox housing
Running gear and frame

Frame and hinged elements specifications
Overall view motorcycle frame
Removing and installing main (centre) stand
Removing and installing side stand
Removing and installing front mudguard
Removing and installing windscreen
Removing and installing fairing bracket
Removing and installing luggage rack
Removing and installing numberplate carrier
Removing and installing rear mudguard
Removing and installing rear footrest plate
Removing and installing front footrest plate
Removing and installing frame
Removing and installing frame tail section
Checking running gear
Removing and installing ignition switch/steering lock
Removing and installing lock barrel for fuel tank filler cap
Removing and installing seat lock
Removing and installing helmet lock
Disassembling and assembling seat

Front suspension specifications
Removing and installing telescopic fork without fork bridge
Removing and installing fork bridge
Removing and installing slider tube bridge
Checking friction at ball joint/angular-contact ball bearing
Disassembling and assembling telescopic fork
Measuring telescopic fork
Removing and installing leading link
Disassembling and assembling leading link
Removing and installing left handlebar fitting
Removing and installing right handlebar fitting
Removing and installing brake piston in handlebar fitting
Removing and installing clutch piston in handlebar fitting
Checking and adjusting operating clearance at front brake/clutch levers
Removing and installing handlebar
Removing and installing Bowden-cable divider
Disassembling Bowden-cable divider

Rear wheel drive specifications
Removing rear wheel drive
Removing and installing taper roller bearing in rear wheel drive
Removing input bevel pinion
Disassembling input bevel pinion
Assembling input bevel pinion
Installing input bevel pinion
Removing and disassembling crown wheel
Assembling and installing crown wheel
Shimming input bevel pinion and crown wheel
Checking tooth contact pattern
Checking and adjusting backlash
Shimming housing cover
Installing housing cover
Installing rear wheel drive
Removing and installing spring strut
Removing rear swinging arm
Removing and installing drive shaft
Installing rear swinging arm

Wheels and tires specifications
Removing front wheel
Installing the front wheel
Removing and installing wheel bearings
Removing and installing rear wheel
Static balancing of front wheel/rear wheel
Checking front/rear wheel rim for runout
Removing and installing spokes
Centering the wheel rim

Brakes specifications
Removing and installing front brake caliper
Disassembling and assembling frontbrake caliper
Removing and installing filler adapter
Removing and installing rear brake caliper
Disassembling and assembling rear brake caliper
Removing and installing front brake disc
Removing and installing rear brake disc (mounted on rear-wheel hub)
Removing and installing front ABS sensor
ABS sensor gap, front: adjusting
Removing and installing rear ABS sensor
Adjusting rear ABS sensor gap
Removing and installing rear brake master cylinder
Removing and installing footbrake lever
Removing and installing ABS unit
Removing ABS relay
Installing the ABS relay
Removing ABS relay socket
Installing the ABS relay base
Removing and installing brake line (with ABS)
Electric equipment

Removing and installing central electrical equipment box
Relay positions/fuse assignments (central electrical equipment box)
Wiring-harness routing, frame [ABS]
Removing and installing battery holder
Removing and installing instrument panel
Headlight and bulbs specifications
Removing and installing headlight
Removing and installing front indicators

Engine electric specification
Removing and installing coil and ignition lead
Removing and installing alternator
Disassembling/assembling alternator
Disassembling/assembling alternator (option 50 A)
Removing and installing starter motor
Disassembling/assembling starter motor
Removing and installing magnetic gate

Repair motorcycles BMW K-series
BMW K 1200 LT (1998-2009)
Information for owner

Tightening torques
Table of operating fluids
Overview: packing materials
Checking the shipping crate for damage
Unpacking the motorcycle
Installing the front wheel
Pushing the motorcycle onto a workshop platform
Inspecting motorcycle for damage
Checking that delivery is complete
Installing remaining items on motorcycle
Filling and charging the battery

Checking brake fluid level
Checking clutch fluid level
Checking tyre pressures
Checking tightness of rear wheel studs
Installing the aerial
Installing the windscreen
Checking and adjusting the motorcycle
Final inspection and function check
Final cleaning

Key to maintenance intervals
General instructions about maintenance
Maintenance schedule
Reading the fault code memory with the Moditec
Checking throttle cable play, adjusting if necessary
Changing engine oil, replacing oil filter element
Changing gearbox oil
Changing the oil in the rear wheel drive
Brake pads/brake discs
Checking the front/rear brake fluid level
Changing brake fluid and bleeding brake system
Checking clutch fluid level
Changing the clutch fluid (every 40000 km/24000 miles)
Replacing fuel filter (every 40000 km/24000 miles)
Checking and topping up, if necessary, coolant level and concentration
Changing coolant
Checking battery
Replacing intake air filter element
Checking function of side stand contact switch
Greasing the side stand
Checking the centre stand, greasing if necessary
Checking the steering damper
Checking tightness of rear wheel studs
Checking swinging arm bearings, adjusting if necessary
Cleaning the inductive sensor on the rear wheel
Checking valve clearances, adjusting if necessary
Replacing spark plugs
Final inspection with road safety and functional check
Engine and systems

Technical data of engine
Cutaway drawing of engine
Preparatory work with engine installed
Removing/installing engine
Disassembling engine
Assembling engine

Technical Data of engine electrics
Removing and installing Hall-effect transmitters
Replacing spark plugs/ignition leads
Timing the ignition
Replacing three-phase generator
Replacing starter motor

Technical Data of fuel preparation and control
Removing and installing Motronic control unit
Replacing air temperature sensor
Removing and installing intake air silencer
Removing and installing fuel injection rail
Removing and installing pressure regulator
Removing and installing throttle valve rail
Removing and installing throttle valve actuator
Replacing and adjusting throttle valve potentiometer
Removing and installing intake stubs
Replacing fuel hoses
Removing and installing throttle cables
Checking fuel pressure
Technical Data of fuel tank and lines
Removing and installing fuel tank
Renewing fuel filter
Removing/installing immersion-tube sensor
Removing/installing roll-over valve
Technical Data of exhaust system
Removing and installing exhaust heat shield
Removing and installing exhaust system

Technical Data of radiator
Coolant circuit
Removing and installing coolant hoses
Checking cooling system for leaks
Removing and installing radiator with fan
Removing and installing coolant stub pipe on engine
Removing and installing thermostat
Troubleshooting of radiator

Technical Data of clutch
Removing and installing clutch
Changing the clutch fluid/bleeding the clutch system
Removing and installing clutch lines
Removing and installing clutch slave cylinder
Removing and installing clutch release rod
Technical Data of gearbox
Gearbox — sectional drawing
Replacing the shaft sealing rings in the gearbox housing and gearbox cover
Removing and installing actuating unit for reverser
Removing gearbox
Disassembling gearbox — preparatory work
Disassembling reverser gear train
Removing gearbox housing
Disassembling/assembling selector shaft
Removing gearbox shafts
Replacing grooved ball bearing on intermediate shaft
Disassembling/assembling input shaft
Disassembling/assembling output shaft
Checking endplay
Checking/adjusting fully assembled length of gearbox shafts
Assembling gearbox
Installing gearbox housing
Installing reverser
Completing assembly of gearbox
Installing gearbox
Removing and installing gearshift lever and linkage
Removing and installing gearshift lever
Aligning rubber mounts
Running gear and frame

Technical Data of frame
Overview of fairing sections
Removing and installing fairing side section
Removing and installing tank cover
Removing and installing engine spoiler
Removing/installing components mounted on side section of fairing
Removing and installing battery cover
Removing windscreen
Removing and installing instrument cover
Removing and installing upper section of fairing
Removing and installing left/right handlebar trim
Removing and installing fork bridge cover
Removing/installing interior trim
Removing and installing left/right wind deflectors
Removing and installing front mudguard
Removing and installing front footrests
Removing and installing front right footrest plate
Removing and installing front left footrest plate
Removing and installing left/right rear footrest plates
Removing and installing rear footrests
Disassembling and assembling side stand
Removing and installing intake air pipe
Removing and installing skirt bracket
Removing and installing radiator holder
Removing and installing rear mounted components
Removing and installing front fairing bracket
Checking running gear
Removing and installing frame
Removing and installing rear frame
Removing and installing cross-tube
Removing and installing left/right engine cross-member
Removing main frame
Installing main frame
Removing and installing ignition switch/steering lock
Disassembling/assembling fuel tank lock
Removing and installing lock barrel of fuel tank cover
Removing and installing locking system for front seat
Removing and installing lock barrel of side case
Removing and installing lock barrel of top case
Removing and installing seat
Disassembling/assembling front seat

Technical Data of front fork
Removing and installing telescopic forks and fork bridge
Removing telescopic fork
Removing fork bridge
Disassembling fork bridge
Installing fork bridge
Installing telescopic fork
Assembly specification for telescopic fork
Disassembling/assembling telescopic fork leg
Measuring telescopic fork
Removing and installing slider tube bridge
Removing and installing front suspension strut
Removing and installing steering damper
Removing and installing leading link
Measuring the leading link

Technical Data of rear wheel drive
Rear wheel drive — cutaway drawing
Removing, disassembling, reassembling and installing rear wheel drive
Removing rear wheel drive
Replacing taper roller bearing in rear wheel drive
Removing input bevel pinion
Disassembling input bevel pinion
Assembling input bevel pinion
Installing input bevel pinion
Removing crown wheel
Installing crown wheel
Checking/adjusting backlash
Checking tooth contact pattern
Shimming housing cover
Installing housing cover
Installing rear drive shaft
Installing rear wheel drive
Removing, disassembling, reassembling and installing rear swinging arm

Technical Data of steering
Removing and installing left grip tube
Removing and installing right grip tube
Removing and installing clutch lever fitting
Removing and installing brake lever fitting
Removing and installing handlebar
Removing and installing piston in brake-lever fitting
Removing and installing left and right handlebar levers

Technical Data of brakes
Front brake calliper
Rear brake calliper
Removing and installing front brake disc
Removing and installing rear brake disc
Removing and installing front ABS sensor
Removing front ABS sensor ring
Adjusting front ABS sensor
Removing and installing rear ABS sensor
Adjusting rear ABS sensor
Removing and installing rear brake master cylinder
Checking/adjusting play at piston rod
Removing and installing ABS control unit
Removing and installing front brake lines/hoses
Removing and installing rear brake lines/hoses

Technical data of wheels and tyre
Removing and installing front wheel
Removing and installing wheel bearings
Removing/installing rear wheel
Static balancing of front and rear wheels
Checking front/rear wheel rim for run-out
Electric equipment

Technical Data of general electrical equipment
Wiring harness
Replacing fuses
Removing and installing electronics box
Disassembling left multi-function switch
Disassembling right multi-function switch
Removing and installing control unit for reverser
Removing and installing inductive sensor for speedometer
Removing and installing water temperature sensor
Replacing side stand switch
Replacing and adjusting foot brake light switch
Removing and installing ignition switch/steering lock cable
Removing and installing fanfare horn
Removing and installing switch for gear indicator
Removing and installing power socket
Removing and installing cable for oil pressure switch/cable for water pump temperature sensor
Technical Data of instruments
Wiring colours of instruments
Removing and installing instrument panel
Replacing telltale/warning lights
Disassembling instrument cluster
Removing and installing wiring harness
Technical Data of lights
Removing and installing headlight
Renewing bulbs
Checking headlight beam angle, adjusting if necessary
Removing and installing speakers
Removing and installing radio/cassette player
Removing and installing radio remote control unit
Removing and installing aerial holder
Removing and installing on-board computer
Removing and installing temperature sensor on upper section of fairing
Removing and installing control unit of cruise-control system