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Complete map of motorcycle repair instructions BMW
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Articles and news
Repair motorcycles BMW F-series
BMW F 650 GS (2000-2007)
Information for owner
Introduction to manual
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
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
Engine repair
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
Ignition system
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
Fuel and exhaust systems
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
Cooling system
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
Transmission
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
Frame and hinged elements
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
Handlebar
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
Rear suspension
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
Brake system
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
Wheels and tires
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
Equipment and devices
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
Lighting and lamps
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
Introduction to manual
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
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
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 and exhaust systems
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
Transmission
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
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 and handlebar
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
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
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
Brake system
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
Equipment and devices
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
Starting and charging system
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 manuals for:
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