🏷️ 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...