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BMW R1150RT 2001-2005 Service Repair Manual

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The R1150RT, produced for the 2001 through 2005 model years, stands as a premium touring motorcycle, embodying a legacy of engineering excellence. This second-generation model, identified by the model code...
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BMW R1150RT 2001-2005 Service Repair Manual
The R1150RT, produced for the 2001 through 2005 model years, stands as a premium touring motorcycle, embodying a legacy of engineering excellence. This second-generation model, identified by the model code R21, is powered by a horizontally-opposed twin-cylinder Boxer engine with a displacement of 1130 cc, delivering approximately 95 horsepower and 75 lb-ft of torque. Designed for long-distance comfort and performance, the R1150RT features a 6-speed manual transmission with shaft drive, optional Integral ABS, and a sophisticated Telelever front and Paralever rear suspension system. Its robust construction and thoughtful design have made it a respected choice for experienced riders undertaking extended journeys. This comprehensive service and repair manual is meticulously crafted to assist dealer technicians, independent mechanics, and advanced DIY enthusiasts in maintaining and repairing the R1150RT. It covers all essential systems, including the Boxer-twin engine, fuel injection, ignition, clutch, transmission, brakes (including optional ABS), suspension, and electrical systems. The manual provides detailed procedures for routine maintenance, troubleshooting common issues, engine rebuilds, component replacements, and electrical diagnostics, supported by high-resolution diagrams and OEM-level technical data. Its scope ensures that users have the precise information required to keep their R1150RT performing optimally and reliably.
🏷️ Basic Information
Identification
Make:
BMW
Model:
R1150RT
Model Code:
R21
Vehicle Type:
Motorcycle
Body Style:
Touring Motorcycle
Market Segment:
Premium Touring
Generation
Generation Identifier:
Second Generation R1150 Series
Applicable Years For Manual:
2001, 2002, 2003, 2004, 2005
Codes
Vin Code Segment:
Variable, typically starts with WBA...
👋 Introduction
Market Position
Vehicle Positioning:
BMW's flagship luxury touring motorcycle, designed for long-distance comfort and performance.
Target Demographic:
Experienced riders seeking a capable and comfortable touring machine for extended journeys.
Competitive Analysis
Key Competitors:
Honda Gold Wing, Yamaha FJR1300, Harley-Davidson Electra Glide, Kawasaki Concours.
Key Features
Manual Value Proposition:
Provides dealer-level technical data, enabling professional-quality maintenance and repairs.
Manual Advantage:
Empowers owners with the knowledge to maintain their investment, reduce reliance on expensive dealer services, and ensure optimal performance.
Content Credibility:
Utilizes the same information trusted by certified BMW technicians.
📋 Manual Details
Coverage Areas
Primary Coverage:
Comprehensive service, repair, and maintenance for BMW R1150RT
Secondary Coverage:
Scheduled servicing, technical service bulletins (TSB), recall information
Page Count
Estimated Page Count:
Refer to specific PDF content, typically hundreds of pages for a full service manual
Manual Type
Manual Classification:
Service and Repair Manual
Target Audience:
BMW Dealer Technicians, Independent Mechanics, Advanced DIY Enthusiasts
Language
Primary Language:
English
Format
Digital Format:
PDF (Portable Document Format)
Delivery Method:
Digital Download
Compatibility:
Windows, macOS, Linux
📖 Manual Coverage
Systems Covered
Engine:
Detailed inspection, disassembly, assembly, and tuning of the Boxer-twin engine
Fuel System:
Fuel injection system (BMS-K or similar), fuel pump, injectors, pressure regulator
Ignition System:
Ignition coils, spark plugs, ECU control
Clutch:
Single-plate dry clutch system, hydraulic actuation, maintenance, and replacement
Transmission:
Gearbox (5-speed), shifting mechanism, final drive, maintenance, and repair
Brakes:
Hydraulic brake system, ABS (optional Integral ABS), brake calipers, discs, master cylinders, fluid service
Suspension:
Front Telelever fork, rear Paralever swingarm, shock absorbers, adjustments, and service
Electrical System:
Wiring diagrams, battery, charging system (alternator, regulator), starter motor, lighting, instrumentation, ECU diagnostics
Chassis:
Frame, body panels, fairing, seat, fuel tank, mounting
Exhaust System:
Mufflers, catalytic converter, pipes, lambda sensors
Wheels And Tires:
Wheel bearings, tire replacement, specifications
Cooling System:
Oil cooling system (air/oil-cooled engine)
Fuel Tank And Delivery:
Fuel tank maintenance, fuel pump, filter
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug service, brake fluid flush, clutch fluid flush, air filter cleaning/replacement
Troubleshooting:
Diagnostic procedures for common faults, error code interpretation
Engine Repair:
Top-end rebuild (cylinder head, valves), bottom-end overhaul (crankshaft, connecting rods), piston/ring replacement
Transmission Repair:
Gearbox disassembly, component replacement, final drive service
Clutch Repair:
Clutch disc replacement, pressure plate, diaphragm spring inspection
Brake System Repair:
Bleeding procedure, component replacement (calipers, master cylinders), ABS system diagnostics and repair
Suspension Service:
Fork oil change, seal replacement, shock absorber service
Electrical Diagnostics:
Wiring harness inspection, component testing, fault finding using BMW diagnostic tools (e.g., MoDiTec)
Bodywork Repair:
Fairing removal and installation, panel repair, lighting component replacement
Torque Specifications:
All critical fastener torque values
Special Tool Requirements:
Identification of necessary BMW specialized tools
Technical Depth
Depth Level:
Comprehensive Engine-Out Rebuild
Diagnostic Capability:
Advanced electronic diagnostics and troubleshooting
Illustration Quality:
Detailed diagrams and in-depth illustrations
Information Source:
OEM Dealer Technician Level Documentation
📊 Manual Specifications
File Format
PDF Quality:
High Resolution, Searchable Text (assuming original scanned quality)
Printable:
Yes, pages are designed for printing
Print Quality
Text Clarity:
Accurate, clear, and concise text
Binding Type
Binding Format:
Not Applicable (Digital PDF)
Paper Type
Paper Quality:
Not Applicable (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Horizontally-opposed (Boxer) twin-cylinder, four-stroke
Displacement:
1130 cc (69 cu in)
Bore X Stroke:
98 mm x 73 mm (3.86 in x 2.87 in)
Compression Ratio:
10.0:1
Valve Train:
Two valves per cylinder, actuated by pushrods and rocker arms (OHV)
Cooling System:
Air/Oil Cooled
Fuel Delivery:
Electronic Fuel Injection (EFI) - Bosch Motronic (BMS-K or similar)
Ignition System:
Electronic Ignition with Dual Spark Plugs per Cylinder
Performance
Horsepower:
95 hp (71 kW) @ 7250 rpm (approximate)
Torque:
75 lb-ft (102 Nm) @ 5500 rpm (approximate)
Fuel System
Fuel Type:
Unleaded Premium Gasoline (95 RON or higher recommended)
Fuel Tank Capacity:
25 Liters (6.6 US gal), including 4 liters reserve
🔧 Transmission
Standard
Transmission Type:
6-Speed Manual Transmission
Optional
Optional Transmission:
None (standard 6-speed)
Features
Drive Type:
Shaft Drive to Rear Wheel
Clutch Type:
Single-Plate Dry Clutch, Hydraulically Actuated
Final Drive:
Bevel Gear Drive via Driveshaft
📐 Dimensions
Exterior
Length:
2,230 mm (87.8 in)
Width:
900 mm (35.4 in) at handlebars
Height:
1,430 mm (56.3 in) at highest windshield position
Seat Height:
800 mm (31.5 in) standard (adjustable options available)
Weights
Dry Weight:
Approx. 256 kg (564 lbs)
Wet Weight:
Approx. 280 kg (617 lbs) with fluids
Gross Vehicle Weight Rating:
Not explicitly stated, but typically around 500 kg (1100 lbs) considering rider and luggage.
🛡️ Safety Features
Ratings
Crash Test Ratings:
Not Applicable (Motorcycle)
Active Features
ABS:
Optional Integral ABS (Anti-lock Braking System) - combined brake operation
Traction Control:
Not standard, some later models or aftermarket may have had it.
Passive Features
Lighting:
Halogen headlight, LED taillight, turn signals
Instrumentation:
Comprehensive dashboard with speedometer, tachometer, fuel gauge, engine temperature, warning lights.
💡 Technology Features
Infotainment
Audio System:
Optional integrated audio system with handlebar controls was available on some models.
Instrumentation:
Analogue speedometer and tachometer, digital multi-function display for clock, ambient temperature, gear indicator, trip meters, and warning lights.
Driver Assistance
ABS System:
Integral ABS (optional) offering combined braking control for enhanced safety.
Connectivity
Diagnostic Port:
On-board diagnostic port (OBD-II equivalent for motorcycles) allowing connection to diagnostic tools for fault code reading and system analysis.
Cruise Control:
Not standard; typically required aftermarket installation for this generation.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000 km (6,000 miles) or annually, whichever comes first. Consult manual for specific conditions.
Major Service Interval:
Significant service typically around 20,000 km (12,000 miles) or 40,000 km (24,000 miles), involving valve adjustments, fluid changes, and detailed inspections. Consult manual.
Valve Adjustment:
Recommended at intervals such as 20,000 km (12,000 miles) due to pushrod design.
Fluid Specifications
Engine Oil Type:
API SG or higher, SAE 20W-40 or SAE 20W-50. Manual will specify exact viscosity based on ambient temperature.
Engine Oil Capacity:
Approx. 3 liters (3.2 US quarts) with filter change.
Transmission Oil Type:
SAE 75W/90 GL-5 Gear Oil
Transmission Oil Capacity:
Approx. 0.25 liters (0.26 US quarts)
Final Drive Oil Type:
SAE 80W/90 GL-5 Gear Oil
Final Drive Oil Capacity:
Approx. 0.2 liters (0.21 US quarts)
Brake Fluid Type:
DOT 4 Hydraulic Fluid
Clutch Fluid Type:
DOT 4 Hydraulic Fluid
Known Issues
Common Wear Item:
Clutch slave cylinder seals, rear brake light switch, Telelever pivot bearings, Hall sensor.
Electrical Gremlins:
Can sometimes experience intermittent electrical issues, often related to poor grounding or corrosion. The manual's wiring diagrams are crucial here.
Fuel Pump Reliability:
While generally robust, fuel pumps can eventually require replacement. Proper fuel filtration is key.
ABS System:
Integral ABS systems can be complex. Proper bleeding and diagnostic procedures are essential, detailed in the manual.
📚 Vehicle History
Brand Heritage
Bmw Motorcycle Legacy:
BMW has a long and storied history in motorcycle manufacturing, dating back to 1923. Known for its engineering prowess, reliability, and distinctive boxer engines.
Model Evolution
R1150Rt Predecessor:
Succeeded the R1100RT, incorporating engine upgrades and chassis refinements.
R1150Rt Successor:
Followed by the R1200RT, which introduced a larger displacement engine and significant technological advancements.
Production
Production Period:
2001-2006 (model years 2001-2005 covered by manual)
Manufacturing Location:
Berlin, Germany (BMW Motorrad Plant)
🏆 Awards & Recognition
Recognitions
Motorcycle Journalism Reviews:
Consistently praised by motorcycle publications for its comfort, handling, and touring capability during its production run.
Industry Acclaim:
Represents a mature and refined design within BMW's boxer heritage, widely respected in the touring segment.
Certifications
Emissions Standards:
Compliant with relevant emissions standards for the years of production.
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