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BMW R1150GS Factory Service/Repair/ Workshop Manual

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🏷️ Basic Information Identification Make: BMW Model: R1150GS Generation Generation Designation: Second Generation (R21 platform) Codes Chassis Code: R21 👋 Introduction Market Position Segment: Adventure Touring Motorcycle Reputation: Renowned for...
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SKU: 310675
BMW R1150GS Factory Service/Repair/ Workshop Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
R1150GS
Generation
Generation Designation:
Second Generation (R21 platform)
Codes
Chassis Code:
R21
👋 Introduction
Market Position
Segment:
Adventure Touring Motorcycle
Reputation:
Renowned for its robust engineering, long-distance comfort, and all-terrain capability.
Competitive Analysis
Competitors:
Honda Africa Twin, Yamaha Ténéré, Triumph Tiger, Moto Guzzi Stelvio, Ducati Multistrada (in its era).
Key Features
Engine Layout:
Opposed-twin (Boxer) engine for a low center of gravity and excellent balance.
Drivetrain Type:
Shaft drive for low maintenance.
Suspension Design:
Telelever front suspension for improved ride and handling, especially under braking.
Versatility:
Suitable for long-distance touring, commuting, and off-road exploration.
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive maintenance, diagnosis, and repair for the BMW R1150GS
Page Count
Estimated Page Count:
Approximately 600-800 pages (typical for comprehensive factory service manuals)
Manual Type
Type:
Factory Service / Repair / Workshop Manual
Language
Language:
English
Format
Format:
Instant Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine:
Detailed coverage of the R21 Boxer engine, including cylinder head, valve train, piston and connecting rod, crankshaft, timing chain, oil pump, and lubrication system.
Fuel System:
Fuel injection system (Bosch Motronic MA 2.4), fuel pump, fuel injectors, throttle body, and evaporative emission control system.
Ignition System:
Electronic ignition system, spark plugs, ignition coils, and Motronic control unit diagnostics.
Transmission:
Six-speed gearbox, clutch operation (single dry plate), gearbox oil, and maintenance.
Drivetrain:
Cardan shaft drive, final drive unit, rear axle, and associated bearings and seals.
Brakes:
Front and rear braking systems, including ABS II (optional), brake calipers, master cylinders, brake lines, brake pads, and rotor specifications.
Suspension:
Front Telelever suspension, rear Monolever swingarm with adjustable shock absorber (pre-load and rebound damping).
Electrical System:
Charging system (alternator, voltage regulator), battery specifications, starter motor, lighting system (headlight, tail light, turn signals), horn, and wiring diagrams.
Bodywork:
Fairing, fuel tank, seat, fenders, luggage system mounting points, and general body panel removal/installation.
Chassis And Frame:
Frame structure, steering head bearings, and wheel bearings.
Procedures Included
Maintenance:
Scheduled maintenance checks, oil and filter changes, spark plug replacement, air filter cleaning/replacement, brake fluid flush, clutch fluid check, and tire pressure checks.
Diagnostics:
Troubleshooting guides for common issues, fault code reading (if applicable via diagnostic tools), electrical system troubleshooting, and engine performance diagnostics.
Repair:
Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation for all major systems.
Adjustments:
Valve clearance adjustment, throttle cable adjustment, clutch cable adjustment (if applicable), idle speed adjustment, and suspension adjustments.
Torque Specifications:
Essential torque values for critical fasteners throughout the motorcycle.
Technical Depth
Depth:
Comprehensive from basic service to major overhaul and component rebuilds. Covers detailed schematics and diagnostic procedures.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable for quick information retrieval.
Print Quality
Resolution:
High-resolution scans suitable for printing key pages or the entire manual.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air/oil-cooled, four-stroke, two-cylinder boxer engine
Displacement:
1130 cc (1.13 liters)
Bore X Stroke:
95 mm x 79 mm
Compression Ratio:
9.5:1
Valve Train:
SOHC (Single Overhead Camshaft), 4 valves per cylinder, pushrod actuated
Performance
Horsepower:
Approx. 85 hp (63 kW) at 6750 rpm
Torque:
Approx. 98 Nm (72 lb-ft) at 5250 rpm
Fuel System
Fuel Delivery:
Electronic fuel injection (EFI) with Bosch Motronic MA 2.4
Fuel Type:
Unleaded gasoline, minimum octane rating 91 (RON+MON)/2
🔧 Transmission
Standard
Gearbox Type:
6-speed manual transmission
Clutch Type:
Single dry plate, diaphragm spring clutch
Features
Final Drive:
Shaft drive
Gear Ratios:
1st: 3.46, 2nd: 2.47, 3rd: 1.78, 4th: 1.34, 5th: 1.11, 6th: 0.96 (approximate, check specific model year for exact ratios)
Transmission Oil Capacity:
Approximately 1.0 liter (check manual for exact specification and type)
📐 Dimensions
Exterior
Length:
Approx. 2230 mm (87.8 in)
Width:
Approx. 910 mm (35.8 in) at handlebars
Height:
Approx. 1400 mm (55.1 in) at windscreen
Weights
Dry Weight:
Approx. 230 kg (507 lbs)
Gross Vehicle Weight Rating:
Approx. 450 kg (992 lbs)
Fuel Tank Capacity:
25 liters (6.6 US gallons), including 4-liter reserve
🛡️ Safety Features
Ratings
ABS:
Optional BMW Motorrad Integral ABS II (partially integrated or fully integrated depending on model variant and year).
Active Features
Braking System:
Hydraulic disc brakes front and rear. Dual disc front, single disc rear.
Lighting:
Halogen headlight, integrated turn signals, LED taillight.
Passive Features
Chassis Design:
Robust steel tube frame providing stability and rigidity.
💡 Technology Features
Infotainment
Dashboard Display:
Analog speedometer and tachometer, digital multi-function display (clock, trip meter, gear indicator, fuel level, warning lights).
Driver Assistance
ABS System:
Integral ABS II (optional, with varying levels of integration depending on the specific R1150GS variant).
Connectivity
Diagnostics Port:
On-board diagnostics port for connecting diagnostic tools (requires specific BMW tool or compatible aftermarket scanner).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000 km (6,000 miles) or annually, whichever comes first.
Valve Check Interval:
Typically every 20,000 km (12,000 miles).
Spark Plug Replacement:
Typically every 20,000 km (12,000 miles).
Fluid Specifications
Engine Oil Type:
Refer to manual for specific viscosity grade (e.g., SAE 20W-50 or SAE 15W-50, often semi-synthetic or full-synthetic).
Engine Oil Capacity:
Approx. 3.0 liters (with filter change) / 2.75 liters (without filter change). Consult manual.
Brake Fluid Type:
DOT 4
Transmission Fluid Type:
Refer to manual for specific gear oil grade (e.g., SAE 75W-90 or SAE 80W-90 GL-5 rated).
Final Drive Fluid Type:
Refer to manual for specific gear oil grade (e.g., SAE 75W-90 or SAE 80W-90 GL-5 rated).
Known Issues
Common Wear Items:
Clutch wear, starter motor solenoid issues, fuel pump reliability (early models), rear shock absorber wear, ABS sensor issues (especially on older units).
Common Faults:
Leaking cylinder head gaskets, intermittent electrical connections, paralever seal wear.
📚 Vehicle History
Brand Heritage
Manufacturer:
Bayerische Motoren Werke AG (BMW)
Motorcycle Division Focus:
Long history of producing durable, technologically advanced, and capable motorcycles.
Model Evolution
Lineage:
Successor to the R1100GS, part of the 'GS' family which pioneered the adventure touring segment.
Key Enhancements Over Predecessor:
Increased engine displacement, 6-speed gearbox, improved suspension, and optional integrated ABS.
Production
Production Years:
2000 - 2004
Manufacturing Location:
Berlin, Germany (BMW Motorrad plant)
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