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BMW R1150GS 1999-2005 Workshop Service Manual for Repair

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🏷️ Basic Information Identification Make: BMW Model: R1150GS Product Name: BMW R1150GS 1999-2005 Workshop Service Manual for Repair Codes Chassis Codes: R21 👋 Introduction Market Position Category: Adventure Touring Motorcycle...
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Type: Motorcycle
Vendor:
Sku: 448329
BMW R1150GS 1999-2005 Workshop Service Manual for Repair
🏷️ Basic Information
Identification
Make:
BMW
Model:
R1150GS
Product Name:
BMW R1150GS 1999-2005 Workshop Service Manual for Repair
Codes
Chassis Codes:
R21
👋 Introduction
Market Position
Category:
Adventure Touring Motorcycle
Segment Description:
The R1150GS is a highly capable adventure touring motorcycle renowned for its ruggedness, versatility, and long-distance comfort, designed for both on-road and off-road exploration.
Competitive Analysis
Competitors:
Honda Africa Twin, Suzuki V-Strom, Kawasaki KLR, Yamaha Super Ténéré (competitor models from the era)
Key Features
Distinctive Features:
Shaft drive, Telelever front suspension, Paralever rear suspension, boxer engine configuration, robust build quality, extensive aftermarket support
📋 Manual Details
Coverage Areas
Applicable Years:
1999, 2000, 2001, 2002, 2003, 2004, 2005
Page Count
Total Pages:
311
Manual Type
Type:
Workshop Service Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Engine teardown, assembly, tuning, troubleshooting, component identification
Fuel System:
Fuel injection system (BMW Motor-Technik Electronic Fuel Injection - BMS-K), fuel pump, injectors, throttle body
Ignition System:
Ignition coils, spark plugs, timing
Transmission:
Gearbox, clutch, final drive, shaft drive maintenance and repair
Suspension:
Front Telelever suspension, rear Paralever swingarm, shock absorbers, fork seals
Brakes:
Hydraulic brake system, ABS (Anti-lock Braking System), brake pads, discs, lines, calipers, master cylinders
Electrical System:
Wiring diagrams, battery, alternator, starter motor, lighting, instrumentation, ECU diagnostics
Bodywork:
Fairing removal and installation, seat, tank, fenders, luggage systems
Wheels And Tires:
Wheel bearing replacement, tire mounting and balancing
Procedures Included
Maintenance:
Oil changes, filter replacements, spark plug service, valve clearance adjustment, brake fluid flush
Troubleshooting:
Diagnostic procedures for common faults and issues
Repair:
Detailed step-by-step repair instructions for all major components
Disassembly Assembly:
Complete instructions for engine, gearbox, and suspension disassembly and reassembly
Diagnostics:
Wiring diagrams, fault codes, diagnostic tool usage (mentioning BMW specific tools if applicable)
Electrical Diagnostics:
Detailed troubleshooting guides for electrical faults, including starter system, charging system, lighting, fuel injection, and ignition systems, supported by wiring diagrams.
Technical Depth
Depth:
Comprehensive, covering from basic maintenance to full engine rebuilds and complex electrical diagnostics
📊 Manual Specifications
File Format
File Type:
Portable Document Format (PDF)
Searchable:
Yes
Print Quality
Printability:
Printable pages
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, horizontally opposed twin-cylinder (Boxer)
Displacement:
1130 cc
Bore X Stroke:
101 mm x 70.5 mm
Compression Ratio:
9.0:1
Valve Train:
SOHC, 2 valves per cylinder
Performance
Horsepower:
85 hp (63 kW) @ 6750 rpm (approx.)
Torque:
70.8 lb-ft (96 Nm) @ 5250 rpm (approx.)
Engine Code:
M254
Fuel System
Fuel Delivery:
Electronic Fuel Injection (BMW Motor-Technik BMS-K)
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON+MON)/2
Cooling System
Cooling Method:
Air-cooled with oil cooling (oil cooler integrated)
🔧 Transmission
Standard
Type:
5-speed manual gearbox
Clutch:
Single dry plate, hydraulically operated
Final Drive:
Shaft drive
Features
Gear Ratios:
1st: 3.47, 2nd: 2.50, 3rd: 1.89, 4th: 1.48, 5th: 1.25
📐 Dimensions
Exterior
Length:
2230 mm (approx.)
Width:
900 mm (approx. incl. mirrors)
Height:
1420 mm (approx. incl. windshield)
Weights
Dry Weight:
220 kg (approx.)
Gross Vehicle Weight Rating:
440 kg (approx.)
Payload Capacity:
220 kg (approx.)
Fuel Capacity
Fuel Tank Capacity:
20.5 liters (including 3-liter reserve)
Chassis
Front Suspension Type:
BMW Telelever
Rear Suspension Type:
BMW Paralever
🛡️ Safety Features
Ratings
ABS Availability:
Optional (BMW Motorrad Integral ABS)
Active Features
Braking System:
Disc brakes front and rear with Integral ABS option
Passive Features
Lighting:
Halogen headlight, LED tail light
💡 Technology Features
Infotainment
Instrumentation:
Analog tachometer and speedometer, digital odometer, trip meters, clock, gear indicator, fuel level warning, oil pressure warning, engine fault indicator.
Driver Assistance
ABS:
Optional Integral ABS system with linked front and rear braking actuation.
Connectivity
Diagnostic Port:
BMW 10-pin diagnostic connector, requiring specific BMW diagnostic tools or adapters for advanced diagnostics.
🔧 Maintenance
Service Intervals
Oil Change:
Every 10,000 km or 12 months
Valve Clearance Check:
Every 20,000 km or 24 months
Brake Fluid Change:
Every 2 years
Gearbox Oil Change:
Every 20,000 km or 24 months
Fluid Specifications
Engine Oil:
SAE 15W-50 API SG or higher (e.g., BMW Advantec Ultimate 15W-50)
Engine Oil Capacity:
Approx. 4 liters (with filter change)
Gearbox Oil:
SAE 80W-90 API GL-5 (e.g., BMW Hypoid Gear Oil)
Final Drive Oil:
SAE 75W-140 API GL-5 (e.g., BMW Hypoid Gear Oil)
Brake Fluid:
DOT 4
Coolant Type:
N/A (Air-cooled)
Known Issues
Common Problems:
Oil leaks (especially around the oil cooler and output shaft seal), embrittlement of fuel lines, potential for ABS modulator issues, occasional clutch slave cylinder leaks.
📚 Vehicle History
Brand Heritage
Manufacturer:
BMW Motorrad, a division of Bayerische Motoren Werke AG
Model Evolution
Predecessor:
R1100GS
Successor:
R1200GS
Production
Production Period:
1999 - 2005
Manufacturing Plant:
Berlin, Germany
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
Widely regarded as one of the best adventure touring motorcycles of its era, praised for its durability, comfort, and capability in varied conditions.
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