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BMW R 1150 GS R1150GS Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: R 1150 GS Model Designation: R1150GS Vehicle Type: Motorcycle Generation Production Years: 1999-2003 Codes Chassis Code: 259E 👋 Introduction Market Position Segment: Adventure Touring Motorcycle Reputation: Renowned for durability, off-road capability, and long-distance comfort. Competitive Analysis Competitors: Honda Africa Twin, Yamaha Ténéré, Triumph Tiger. Key Features Engine Type: Air/oil-cooled, four-stroke flat-twin (boxer) engine. Drivetrain: Shaft drive, integrated 5-speed gearbox. Suspension Front: BMW Telelever system. Suspension Rear: BMW Monolever system with adjustable rear shock. Braking System: Integral ABS II (optional on some models). 📋 Manual Details Coverage Areas Manual Type: Service Repair Manual Language: English Format: PDF Page Count Page Count: 311 Features Indexing: Fully indexed Bookmarking: Bookmarked by topic Searchability: Searchable PDF 📖 Manual Coverage Systems Covered Engine Overhaul: Complete engine disassembly, inspection, repair, and reassembly. Fuel System: Fuel injection system (EFI), throttle bodies, fuel pump, injectors, fuel lines. Ignition System: Ignition coils, spark plugs, ECU control. Transmission: Gearbox disassembly, inspection, repair, clutch operation, final drive, driveshaft. Suspension: Front Telelever suspension, rear Monolever swingarm, shock absorbers, forks. Brakes: ABS II system (if equipped), brake calipers, master cylinders, brake lines, rotor specifications. Electrical System: Wiring diagrams, starter motor, alternator, battery, lighting, instrumentation, diagnostic connectors. Chassis And Frame: Frame inspection, fork triple clamps, steering head bearings. Bodywork And Fairings: Fairing removal and installation, seat, fuel tank, luggage system mounting. Procedures Included Routine Maintenance: Oil changes, filter replacements, valve clearance checks, spark plug replacement, drive shaft lubrication. Troubleshooting: Diagnostic procedures for common performance issues, electrical faults, and starting problems. Component Repair: Detailed step-by-step instructions for repairing or replacing individual components. Rebuilding Procedures: Comprehensive procedures for rebuilding major components like engine and transmission. Wiring Diagrams Interpretation: Guidance on reading and understanding complex electrical schematics. Technical Depth Depth Level: Comprehensive, covering all aspects from basic maintenance to complete engine rebuilds. 📊 Manual Specifications File Format File Type: PDF Resolution: High-resolution scans suitable for clear viewing and printing. Printable: Yes, designed for printing specific sections or the entire manual. Print Quality Image Quality: High-quality images and diagrams for clarity. Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Air/oil-cooled, four-stroke flat-twin (boxer) engine Displacement: 1130 cc (69 cu in) Bore X Stroke: 99 mm x 70.5 mm (3.90 in x 2.78 in) Compression Ratio: 9.0:1 Valve Train: 2 valves per cylinder, pushrod activated Performance Horsepower: 95 hp (70 kW) at 7250 rpm Torque: 98 Nm (72 lb-ft) at 5500 rpm Fuel System Fuel Delivery: Bosch Motronic 2.4 Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline, 91-98 octane (RON+MON)/2 Lubrication Oil Capacity: Approx. 4.0 Liters (4.2 US qt) with filter change Oil Type: SAE 20W-40 or 20W-50 motorcycle oil (API SG or higher) 🔧 Transmission Standard Transmission Type: 5-speed constant mesh gearbox, integrated with engine Clutch: Single dry plate, hydraulically actuated Final Drive: Shaft drive to rear wheel Features Gear Ratios: Refer to manual for specific ratios (e.g., 1st: 3.44, 2nd: 2.40, 3rd: 1.73, 4th: 1.31, 5th: 1.00) Transmission Oil: SAE 75W-90 API GL-5 gear oil for final drive 📐 Dimensions Exterior Length: Approx. 2230 mm (87.8 in) Width: Approx. 905 mm (35.6 in) over handgrips Height: Approx. 1410 mm (55.5 in) over windshield Wheelbase: Approx. 1487 mm (58.5 in) Weights Dry Weight: Approx. 220 kg (485 lbs) Gross Vehicle Weight Rating: Approx. 420 kg (926 lbs) Fuel Tank Capacity: 22 Liters (5.8 US gal) including 3 Liters (0.8 US gal) reserve 🛡️ Safety Features Ratings ABS System: Integral ABS II (optional, can be deactivated) Active Features Braking Performance: Disc brakes front and rear with integral ABS capability. Passive Features Lighting: Halogen headlight, integrated turn signals, taillight. 💡 Technology Features Infotainment Instrumentation: Analog speedometer and tachometer, digital display for odometer, trip meters, clock, gear indicator, fuel level. Driver Assistance ABS: Integral ABS II (optional, with rider-controlled deactivation). Connectivity Diagnostics: On-board diagnostic system with service indicator and fault code reader (requires specific BMW tools). 🔧 Maintenance Service Intervals Oil Change Interval: Every 10,000 km (6,000 miles) or annually. Valve Clearance Check: Every 20,000 km (12,000 miles). Spark Plug Replacement: Every 20,000 km (12,000 miles). Drive Shaft Lubrication: Every 10,000 km (6,000 miles). Fluid Specifications Engine Oil Spec: SAE 20W-40 or 20W-50 motorcycle oil (API SG or higher) Brake Fluid Spec: DOT 4 brake fluid Transmission Oil Spec: SAE 75W-90 API GL-5 gear oil for final drive Coolant Spec: BMW radiator cleaner and antifreeze (glycol-based) or equivalent meeting BMW specifications. Known Issues Common Problem 1: Paralever spline wear (drive shaft output). Common Problem 2: Oil head seal leaks. Common Problem 3: ABS modulator failure (early models). Common Problem 4: Clutch slave cylinder leaks. 📚 Vehicle History Brand Heritage Brand Origin: Bayerische Motoren Werke AG (BMW), German manufacturer with a long history in aviation and automotive. Model Evolution Gs Lineage: Successor to...
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SKU: 241847
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BMW R 1150 GS R1150GS Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
R 1150 GS
Model Designation:
R1150GS
Vehicle Type:
Motorcycle
Generation
Production Years:
1999-2003
Codes
Chassis Code:
259E
👋 Introduction
Market Position
Segment:
Adventure Touring Motorcycle
Reputation:
Renowned for durability, off-road capability, and long-distance comfort.
Competitive Analysis
Competitors:
Honda Africa Twin, Yamaha Ténéré, Triumph Tiger.
Key Features
Engine Type:
Air/oil-cooled, four-stroke flat-twin (boxer) engine.
Drivetrain:
Shaft drive, integrated 5-speed gearbox.
Suspension Front:
BMW Telelever system.
Suspension Rear:
BMW Monolever system with adjustable rear shock.
Braking System:
Integral ABS II (optional on some models).
📋 Manual Details
Coverage Areas
Manual Type:
Service Repair Manual
Language:
English
Format:
PDF
Page Count
Page Count:
311
Features
Indexing:
Fully indexed
Bookmarking:
Bookmarked by topic
Searchability:
Searchable PDF
📖 Manual Coverage
Systems Covered
Engine Overhaul:
Complete engine disassembly, inspection, repair, and reassembly.
Fuel System:
Fuel injection system (EFI), throttle bodies, fuel pump, injectors, fuel lines.
Ignition System:
Ignition coils, spark plugs, ECU control.
Transmission:
Gearbox disassembly, inspection, repair, clutch operation, final drive, driveshaft.
Suspension:
Front Telelever suspension, rear Monolever swingarm, shock absorbers, forks.
Brakes:
ABS II system (if equipped), brake calipers, master cylinders, brake lines, rotor specifications.
Electrical System:
Wiring diagrams, starter motor, alternator, battery, lighting, instrumentation, diagnostic connectors.
Chassis And Frame:
Frame inspection, fork triple clamps, steering head bearings.
Bodywork And Fairings:
Fairing removal and installation, seat, fuel tank, luggage system mounting.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, valve clearance checks, spark plug replacement, drive shaft lubrication.
Troubleshooting:
Diagnostic procedures for common performance issues, electrical faults, and starting problems.
Component Repair:
Detailed step-by-step instructions for repairing or replacing individual components.
Rebuilding Procedures:
Comprehensive procedures for rebuilding major components like engine and transmission.
Wiring Diagrams Interpretation:
Guidance on reading and understanding complex electrical schematics.
Technical Depth
Depth Level:
Comprehensive, covering all aspects from basic maintenance to complete engine rebuilds.
📊 Manual Specifications
File Format
File Type:
PDF
Resolution:
High-resolution scans suitable for clear viewing and printing.
Printable:
Yes, designed for printing specific sections or the entire manual.
Print Quality
Image Quality:
High-quality images and diagrams for clarity.
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air/oil-cooled, four-stroke flat-twin (boxer) engine
Displacement:
1130 cc (69 cu in)
Bore X Stroke:
99 mm x 70.5 mm (3.90 in x 2.78 in)
Compression Ratio:
9.0:1
Valve Train:
2 valves per cylinder, pushrod activated
Performance
Horsepower:
95 hp (70 kW) at 7250 rpm
Torque:
98 Nm (72 lb-ft) at 5500 rpm
Fuel System
Fuel Delivery:
Bosch Motronic 2.4 Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline, 91-98 octane (RON+MON)/2
Lubrication
Oil Capacity:
Approx. 4.0 Liters (4.2 US qt) with filter change
Oil Type:
SAE 20W-40 or 20W-50 motorcycle oil (API SG or higher)
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh gearbox, integrated with engine
Clutch:
Single dry plate, hydraulically actuated
Final Drive:
Shaft drive to rear wheel
Features
Gear Ratios:
Refer to manual for specific ratios (e.g., 1st: 3.44, 2nd: 2.40, 3rd: 1.73, 4th: 1.31, 5th: 1.00)
Transmission Oil:
SAE 75W-90 API GL-5 gear oil for final drive
📐 Dimensions
Exterior
Length:
Approx. 2230 mm (87.8 in)
Width:
Approx. 905 mm (35.6 in) over handgrips
Height:
Approx. 1410 mm (55.5 in) over windshield
Wheelbase:
Approx. 1487 mm (58.5 in)
Weights
Dry Weight:
Approx. 220 kg (485 lbs)
Gross Vehicle Weight Rating:
Approx. 420 kg (926 lbs)
Fuel Tank Capacity:
22 Liters (5.8 US gal) including 3 Liters (0.8 US gal) reserve
🛡️ Safety Features
Ratings
ABS System:
Integral ABS II (optional, can be deactivated)
Active Features
Braking Performance:
Disc brakes front and rear with integral ABS capability.
Passive Features
Lighting:
Halogen headlight, integrated turn signals, taillight.
💡 Technology Features
Infotainment
Instrumentation:
Analog speedometer and tachometer, digital display for odometer, trip meters, clock, gear indicator, fuel level.
Driver Assistance
ABS:
Integral ABS II (optional, with rider-controlled deactivation).
Connectivity
Diagnostics:
On-board diagnostic system with service indicator and fault code reader (requires specific BMW tools).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 10,000 km (6,000 miles) or annually.
Valve Clearance Check:
Every 20,000 km (12,000 miles).
Spark Plug Replacement:
Every 20,000 km (12,000 miles).
Drive Shaft Lubrication:
Every 10,000 km (6,000 miles).
Fluid Specifications
Engine Oil Spec:
SAE 20W-40 or 20W-50 motorcycle oil (API SG or higher)
Brake Fluid Spec:
DOT 4 brake fluid
Transmission Oil Spec:
SAE 75W-90 API GL-5 gear oil for final drive
Coolant Spec:
BMW radiator cleaner and antifreeze (glycol-based) or equivalent meeting BMW specifications.
Known Issues
Common Problem 1:
Paralever spline wear (drive shaft output).
Common Problem 2:
Oil head seal leaks.
Common Problem 3:
ABS modulator failure (early models).
Common Problem 4:
Clutch slave cylinder leaks.
📚 Vehicle History
Brand Heritage
Brand Origin:
Bayerische Motoren Werke AG (BMW), German manufacturer with a long history in aviation and automotive.
Model Evolution
Gs Lineage:
Successor to the R 1100 GS, part of the iconic GS 'Gelände/Straße' (Gravel/Road) series.
Technical Advancements:
Introduced a larger engine, improved chassis, and optional Integral ABS II.
Production
Manufacturing Location:
Berlin, Germany
🏆 Awards & Recognition
Recognitions
Touring Capability:
Widely recognized as one of the most capable and comfortable long-distance adventure touring motorcycles of its era.
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