![BMW R1150GS (2000) [175/311] Assembling gearbox](/img/pdf.png)
BMW R1150GS (2000) [175/311] Assembling gearbox
![BMW R1150GS (2000) [175/311] Assembling gearbox](/views2/1121018/page175/bgaf.png)
23.24
Assembling gearbox
Installing input, output and
intermediate shafts
•
Insert marked selector fork (1) into intermediate
shaft (2).
•
Align input, output and intermediate shafts so
that their gear teeth mesh and the selector fork is
in the position illustrated.
•
Push assembly sleeve, BMW No. 23 4 712, on
to the input shaft splines.
L Note:
This is necessary only if the shaft sealing ring is in-
stalled.
•
Heat the bearing points in the cover to
100 … 120 °C (176 °F ... 212 °F).
•
Insert the input, output and intermediate shafts
together.
e Caution:
Check that the gearbox shafts are correctly seated.
•
Install the 1st/3rd and 2nd/4th shift forks.
R21230120
h
100 … 120
w
23 4 712
C230070
1
2
Содержание
- Repair manual 1
- Introduction 3
- Bmw motorrad maintenance schedule r 1100 s r 850 1200 c r 1150 gs 4
- Bmw motorrad pre delivery check r 1100 s r 850 1200 c r 1150 gs 5
- Bmw motorrad service data r 1150 gs 6
- Item desired value unit of measurement specification 6
- General table of contents 7
- Contents 9
- Maintenance and general instructions 9
- Table of operating fluids 9
- Tightening torques 9
- Tightening torques and table of consumables pre delivery check maintenance 9
- Attaching adhesive label 10
- Check the shipping crate for damage 10
- Checking engine oil when engine is cold topping up if necessary 10
- Checking headlight beam angle adjusting if necessary 10
- Checking that delivery is complete 10
- Checking tightness of rear wheel studs 10
- Checking tyre pressures 10
- Contents pre delivery check 10
- Disengaging and raising the fuel tank 10
- Filling and charging the battery 10
- Final cleaning 10
- Final inspection and function check 10
- General view of crated motorcycle 10
- Handing over the motorcycle 10
- In case of damage in germany 10
- In case of damage in importer markets 10
- Inspecting motorcycle for damage 10
- Install the windscreen 10
- Installing remaining items on motorcycle 10
- Installing sump guard 10
- Pre delivery check 10
- Unpacking the motorcycle 10
- Changing engine oil replacing oil filter element 11
- Changing oil in gearbox 11
- Changing the oil in the rear wheel drive 11
- Checking battery fluid level and topping up if necessary cleaning and greasing the battery posts 11
- Checking brake disc wear 11
- Checking brake fluid level 11
- Checking brake pads and discs for wear replacing 11
- Checking brake system for correct operation and freedom from leaks repairing replacing if necessary 11
- Checking front brake pad wear 11
- Checking rear brake pad wear 11
- Contents maintenance 11
- Front brake 11
- Key to maintenance intervals 11
- Maintenance 11
- Reading out moditec fault memory 11
- Rear brake 11
- Replacing brake pads front brake 11
- Replacing brake pads rear brake 11
- Replacing fuel filter 11
- Replacing intake air filter element 11
- Replacing poly v belt 11
- Bleeding front brake circuit changing brake fluid 12
- Bleeding rear brake circuit changing brake fluid 12
- Changing brake fluid and bleeding brake system 12
- Changing the clutch fluid 12
- Checking adjusting valve clearances 12
- Checking clutch operating fluid level 12
- Checking freedom of throttle cable checking for chaffing and kinks replacing if necessary checking throttle cable play checking and adjusting idle speed and throttle valve synchronisation 12
- Checking function of side stand contact switch 12
- Checking rear wheel bearing play by tilting wheel 12
- Checking replacing spark plugs 12
- Checking swinging arm bearings adjusting if necessary 12
- Checking tightness of rear wheel studs 12
- Contents maintenance 12
- Final inspection with road safety and functional check 12
- Greasing the side stand pivot 12
- Tightening cylinder heads 12
- Tightening torques 13
- Table of operating fluids 20
- General view of crated motorcycle 21
- Pre delivery check 21
- Check the shipping crate for damage 22
- In case of damage in germany 22
- In case of damage in importer markets 22
- Unpacking the motorcycle 22
- Checking that delivery is complete 23
- Inspecting motorcycle for damage 23
- Install the windscreen 24
- Installing remaining items on motorcycle 24
- Installing sump guard 25
- Disengaging and raising the fuel tank 26
- Filling and charging the battery 26
- Checking engine oil when engine is cold topping up if necessary 27
- Attaching adhesive label 28
- Checking headlight beam angle adjusting if necessary 28
- Checking tightness of rear wheel studs 28
- Checking tyre pressures 28
- Final cleaning 29
- Final inspection and function check 29
- Handing over the motorcycle 29
- Changing engine oil replacing oil filter element 30
- Key to maintenance intervals 30
- Maintenance 30
- Reading out moditec fault memory 30
- Changing oil in gearbox 31
- Changing the oil in the rear wheel drive 31
- Replacing fuel filter 32
- Checking battery fluid level and topping up if necessary cleaning and greasing the battery posts 34
- Replacing intake air filter element 34
- Replacing poly v belt 35
- Checking brake fluid level 36
- Checking brake system for correct operation and freedom from leaks repairing replacing if necessary 36
- Front brake 36
- Max min 36
- Rear brake 36
- Checking brake disc wear 37
- Checking brake pads and discs for wear replacing 37
- Checking front brake pad wear 37
- Checking rear brake pad wear 37
- Replacing brake pads front brake 38
- Replacing brake pads rear brake 38
- Bleeding front brake circuit changing brake fluid 39
- Changing brake fluid and bleeding brake system 39
- Bleeding rear brake circuit changing brake fluid 41
- Max min 41
- Changing the clutch fluid 42
- Checking clutch operating fluid level 42
- Checking rear wheel bearing play by tilting wheel 43
- Checking swinging arm bearings adjusting if necessary 43
- Checking tightness of rear wheel studs 43
- Checking function of side stand contact switch 44
- Checking replacing spark plugs 44
- Greasing the side stand pivot 44
- Checking adjusting valve clearances 45
- Tightening cylinder heads 45
- Checking freedom of throttle cable checking for chaffing and kinks replacing if necessary checking throttle cable play checking and adjusting idle speed and throttle valve synchronisation 46
- Final inspection with road safety and functional check 47
- Assembling pistons 48
- Checking pistons and cylinders 48
- Contents 48
- Cooling oil circuit 48
- Cutaway drawing of engine 48
- Disassembling assembling valve gear carrier 48
- Disassembling checking repairing and reassembling cylinder head 48
- Disassembling engine 48
- Engine 48
- Locking the engine at tdc 48
- Lubricating oil circuit 48
- Remove valve gear carrier 48
- Removing and disassembling piston 48
- Removing and installing alternator mount cover with engine installed 48
- Removing and installing chain tensioner 48
- Removing and installing conrod 48
- Removing cylinder 48
- Removing cylinder head 48
- Removing cylinder head cover 48
- Removing engine 48
- Technical dat 48
- Assembling engine 49
- Assembling engine block 49
- Checking conrods 49
- Contents 49
- Disassembling crankcase 49
- Installing auxiliary shaft drive 49
- Installing auxiliary shaft timing chains 49
- Installing clutch housing 49
- Installing conrods 49
- Installing crankshaft 49
- Installing oil pump 49
- Installing piston 49
- Installing radial shaft seals on crankshaft 49
- Installing timing chain tensioning and slide rails 49
- Measuring big end bearing play 49
- Measuring crankshaft bearing play 49
- Removing alternator mount cover 49
- Removing and installing oil intake strainers 49
- Removing and installing oil thermostat 49
- Removing auxiliary shaft drive 49
- Removing conrods 49
- Removing crankshaft auxiliary shaft and timing chain tensioning and slide rails 49
- Removing oil pump 49
- Removing radial shaft seal from crankshaft with engine installed 49
- Replacing oil level sight glass 49
- Replacing radial shaft seal in alternator mount cover 49
- Adjusting valve clearances 50
- Contents 50
- Installing alternator 50
- Installing alternator mount cover 50
- Installing cylinder 50
- Installing cylinder head 50
- Installing engine 50
- Installing left cylinder head 50
- Installing magnetic gate belt pulley 50
- Installing right cylinder head 50
- Cutaway drawing of engine 59
- Lubricating oil circuit 60
- Cooling oil circuit 61
- Removing engine 62
- Disassembling engine 66
- Removing cylinder head cover 67
- Locking the engine at tdc 68
- Removing and installing chain tensioner 69
- Remove valve gear carrier 70
- Disassembling assembling valve gear carrier 71
- Removing cylinder head 73
- Rs110110 73
- Disassembling checking repairing and reassembling cylinder head 74
- Removing and disassembling piston 78
- Removing cylinder 78
- Assembling pistons 79
- Checking pistons and cylinders 79
- Removing and installing conrod 80
- Removing alternator mount cover 81
- Removing and installing alternator mount cover with engine installed 81
- Replacing radial shaft seal in alternator mount cover 81
- Removing auxiliary shaft drive 82
- Removing oil pump 83
- Removing radial shaft seal from crankshaft with engine installed 84
- Disassembling crankcase 85
- Remove screws on right side 85
- Rs110261 85
- Turn engine on to its side 85
- Remove screws on left side 86
- Remove upper section of crankcase 86
- Rs110260 86
- Turn engine on to its side 86
- Checking conrods 88
- Removing and installing oil intake strainers 88
- Removing and installing oil thermostat 88
- Removing conrods 88
- Replacing oil level sight glass 88
- Measuring crankshaft bearing play 89
- Measuring big end bearing play 91
- Assembling engine 92
- Installing conrods 92
- Installing auxiliary shaft timing chains 93
- Installing crankshaft 93
- Installing timing chain tensioning and slide rails 93
- Assembling engine block 94
- Clean and degrease sealing faces arrow and coat with 3 bond 1209 94
- Secure the timing chain with rubber band 1 to the timing chain tensioner and slide rail 94
- Installing radial shaft seals on crankshaft 97
- Installing clutch housing 98
- Installing oil pump 99
- Installing auxiliary shaft drive 100
- Installing piston 101
- Installing cylinder 102
- Installing cylinder head 103
- Adjusting valve clearances 104
- Installing right cylinder head 105
- Installing left cylinder head 106
- Installing alternator mount cover 108
- Installing magnetic gate belt pulley 108
- Installing alternator 110
- Installing engine 111
- Checking alternator 112
- Checking armature for short to ground earth 112
- Checking ignition coil resistance 112
- Checking starter motor 112
- Checking starter relay 112
- Contents 112
- Disassembling assembling alternator 112
- Disassembling assembling alternator option 50 a 112
- Disassembling assembling starter motor 112
- Engine electrics 112
- Removing and installing alternator 112
- Removing and installing coil and ignition lead 112
- Removing and installing magnetic gate 112
- Removing and installing starter motor 112
- Replacing carbon brushes 112
- Technical dat 112
- Timing the ignition 112
- Checking ignition coil resistance 116
- Removing and installing coil and ignition lead 116
- Removing and installing alternator 117
- Checking alternator 118
- Checking armature for short to ground earth 118
- Disassembling assembling alternator 118
- Checking alternator 119
- Checking armature for short to ground earth 119
- Disassembling assembling alternator option 50 a 119
- Removing and installing starter motor 120
- Checking starter motor 121
- Checking starter relay 121
- Disassembling assembling starter motor 121
- Replacing carbon brushes 121
- Removing and installing magnetic gate 122
- Timing the ignition 123
- Contents 124
- Fuel preparation and control 124
- Removing and installing air filter housing 124
- Removing and installing motronic control unit 124
- Removing and installing throttle valve potentiometer 124
- Removing and installing trottle valve stub pipe 124
- Technical dat 124
- Removing and installing air filter housing 128
- Removing and installing trottle valve stub pipe 129
- Removing and installing motronic control unit 130
- Removing and installing throttle valve potentiometer 130
- Contents 131
- Fuel tank and lines 131
- Removing and installing fuel distributor and pressure regulator 131
- Removing and installing fuel filter 131
- Removing and installing fuel filter fuel pump and fuel level sensor 131
- Removing and installing fuel pump and fuel level sensor 131
- Removing and installing fuel tank 131
- Removing and installing roll over valve 131
- Technical dat 131
- Removing and installing fuel tank 135
- Removing and installing roll over valve 136
- Removing and installing fuel filter 137
- Removing and installing fuel filter fuel pump and fuel level sensor 137
- Removing and installing fuel pump and fuel level sensor 137
- Removing and installing fuel distributor and pressure regulator 138
- Contents 139
- Exhaust system 139
- Removing and installing exhaust manifolds 139
- Removing and installing exhaust system 139
- Removing and installing silencer and front silencer 139
- Removing and installing exhaust system 141
- Removing and installing silencer and front silencer 141
- Removing and installing exhaust manifolds 142
- Clutch 143
- Contents 143
- Filling bleeding clutch line 143
- Installing clutch 143
- Removing and installing clutch 143
- Removing and installing clutch hydraulic line 143
- Removing and installing clutch slave cylinder 143
- Removing clutch 143
- Technical dat 143
- Removing and installing clutch 147
- Removing clutch 147
- Installing clutch 149
- Removing and installing clutch hydraulic line 150
- Removing and installing clutch slave cylinder 150
- Filling bleeding clutch line 151
- Checking adjusting fully assembled length of gearbox shafts and selector drum 152
- Checking endplay 152
- Contents 152
- Disassembling assembling input shaft 152
- Disassembling assembling selector shaft 152
- Disassembling gearbox 152
- Disassembling reassembling output shaft 152
- Gearbox sectional drawing 152
- Removing and installing gear shift lever 152
- Removing gearbox housing 152
- Removing gearbox shafts 152
- Removing installing gearbox 152
- Removing selector drum 152
- Replacing grooved ball bearings of intermediate shaft 152
- Replacing the shaft sealing rings in the gearbox housing and gearbox cover 152
- Shimming selector shaft 152
- Technical dat 152
- Transmission 152
- Assembling gearbox 153
- Contents 153
- Installing gearbox housing 153
- Installing input output and intermediate shafts 153
- Installing selector drum 153
- Installing selector shaft 153
- Gearbox sectional drawing 156
- Removing and installing gear shift lever 158
- Removing installing gearbox 158
- Replacing the shaft sealing rings in the gearbox housing and gearbox cover 160
- 4 722 23 4 723 161
- Disassembling gearbox 162
- Removing gearbox housing 162
- Disassembling assembling selector shaft 163
- Removing selector drum 163
- Removing gearbox shafts 164
- Replacing grooved ball bearings of intermediate shaft 164
- Disassembling assembling input shaft 165
- Disassembling reassembling output shaft 167
- 19 18 16 15 168
- Nd gear 168
- Rd gear 168
- St gear 168
- Th gear 168
- Checking endplay 169
- Checking adjusting fully assembled length of gearbox shafts and selector drum 170
- Shimming selector shaft 174
- Assembling gearbox 175
- Installing input output and intermediate shafts 175
- Installing selector drum 176
- Installing selector shaft 176
- Installing gearbox housing 177
- Assembling telescopic fork 179
- Checking friction at ball joint angular contact ball bearing 179
- Contents 179
- Disassembling assembling leading link 179
- Disassembling assembling telescopic fork 179
- Disassembling telescopic fork 179
- Front forks 179
- Measuring telescopic fork 179
- Removing and installing fork bridge 179
- Removing and installing front spring strut 179
- Removing and installing leading link 179
- Removing and installing slider tube bridge 179
- Removing and installing telescopic fork 179
- Removing and installing telescopic fork without fork bridge 179
- Technical dat 179
- Removing and installing telescopic fork 183
- Removing and installing telescopic fork without fork bridge 183
- Removing and installing fork bridge 184
- 5 672 31 5 671 186
- Checking friction at ball joint angular contact ball bearing 186
- Removing and installing slider tube bridge 186
- Assembling telescopic fork 187
- Disassembling assembling telescopic fork 187
- Disassembling telescopic fork 187
- Measuring telescopic fork 188
- 5 601 31 5 603 189
- Disassembling assembling leading link 189
- Removing and installing front spring strut 189
- Removing and installing leading link 189
- Checking and adjusting operating clearance at front brake clutch levers 190
- Contents 190
- Disassembling bowden cable divider 190
- Removing and installing bowden cable divider bowden cable for throttle actuation and starting speed increase 190
- Removing and installing brake piston in handlebar fitting 190
- Removing and installing clutch piston in handlebar fitting 190
- Removing and installing handlebar 190
- Removing and installing left handlebar fitting 190
- Removing and installing right handlebar fitting 190
- Steering 190
- Technical dat 190
- Removing and installing left handlebar fitting 194
- Removing and installing right handlebar fitting 195
- Removing and installing brake piston in handlebar fitting 196
- Removing and installing clutch piston in handlebar fitting 197
- Checking and adjusting operating clearance at front brake clutch levers 198
- Removing and installing handlebar 199
- Removing and installing bowden cable divider bowden cable for throttle actuation and starting speed increase 200
- Disassembling bowden cable divider 201
- Assembling and installing crown wheel 202
- Assembling input bevel pinion 202
- Checking and adjusting backlash 202
- Checking tooth contact pattern 202
- Contents 202
- Disassembling input bevel pinion 202
- Installing drive shaft 202
- Installing housing cover 202
- Installing input bevel pinion 202
- Installing rear wheel drive 202
- Installing sliding element 202
- Rear wheel drive 202
- Removing and disassembling crown wheel 202
- Removing and installing flexible gaiter 202
- Removing and installing rear swinging arm 202
- Removing and installing spring strut 202
- Removing and installing taper roller bearing 202
- Removing and installing taper roller bearing in rear wheel drive 202
- Removing disassembling reassembling and installing rear wheel drive 202
- Removing drive shaft 202
- Removing input bevel pinion 202
- Removing rear swinging arm 202
- Removing rear wheel drive 202
- Shimming housing cover 202
- Shimming input bevel pinion and crown wheel 202
- Technical dat 202
- Contents 203
- Installing rear swinging arm 203
- Removing and installing taper roller bearing in rear wheel drive 206
- Removing disassembling reassembling and installing rear wheel drive 206
- Removing rear wheel drive 206
- Removing input bevel pinion 207
- Disassembling input bevel pinion 208
- Installing input bevel pinion 210
- Removing and disassembling crown wheel 212
- Assembling and installing crown wheel 213
- Shimming input bevel pinion and crown wheel 214
- Checking tooth contact pattern 215
- Checking and adjusting backlash 216
- Installing housing cover 217
- Installing sliding element 217
- Shimming housing cover 217
- Installing rear wheel drive 218
- Removing and installing spring strut 219
- Removing and installing rear swinging arm 220
- Removing rear swinging arm 220
- Installing drive shaft 221
- Removing and installing flexible gaiter 221
- Removing and installing taper roller bearing 221
- Removing drive shaft 221
- Installing rear swinging arm 222
- Abs sensor gap front adjusting 223
- Adjusting rear abs sensor gap 223
- Brakes 223
- Checking and adjusting play of piston rod 223
- Checking and adjusting sensor gap 223
- Contents 223
- Disassembling and assembling front brake caliper 223
- Disassembling and assembling rear brake caliper 223
- Installing the abs relay 223
- Installing the abs unit 223
- Marking sensor ring 223
- Marking sensor wheel 223
- Removing abs relay 223
- Removing and installing abs relay and relay socket 223
- Removing and installing abs unit 223
- Removing and installing filler adapter 223
- Removing and installing footbrake lever 223
- Removing and installing front abs sensor 223
- Removing and installing front brake caliper 223
- Removing and installing front brake disc 223
- Removing and installing rear abs sensor 223
- Removing and installing rear brake caliper 223
- Removing and installing rear brake disc mounted on rear wheel hub 223
- Removing and installing rear brake master cylinder 223
- Removing the abs unit 223
- Technical dat 223
- Contents 224
- Installing the abs relay base 224
- Removing abs relay socket 224
- Removing and installing brake line with abs 224
- Removing and installing front brake line 224
- Removing and installing rear brake line 224
- Removing and installing front brake caliper 226
- Disassembling and assembling front brake caliper 227
- Removing and installing filler adapter 228
- Removing and installing rear brake caliper 229
- Disassembling and assembling rear brake caliper 230
- Removing and installing front brake disc 231
- Removing and installing rear brake disc mounted on rear wheel hub 232
- Removing and installing front abs sensor 233
- Abs sensor gap front adjusting 234
- Checking and adjusting sensor gap 234
- Marking sensor ring 234
- Removing and installing rear abs sensor 235
- Adjusting rear abs sensor gap 236
- Checking and adjusting sensor gap 236
- Marking sensor wheel 236
- Removing and installing rear brake master cylinder 237
- Checking and adjusting play of piston rod 238
- Removing and installing footbrake lever 238
- Removing and installing abs unit 239
- Removing the abs unit 239
- Installing the abs unit 240
- Removing abs relay 240
- Removing and installing abs relay and relay socket 240
- Installing the abs relay 241
- Removing abs relay socket 241
- Installing the abs relay base 242
- Removing and installing rear brake line 244
- Centering lateral runout 245
- Centering the wheel rim 245
- Checking front rear wheel rim for runout 245
- Contents 245
- Installing rear wheel 245
- Installing the front wheel 245
- Removing and installing front wheel 245
- Removing and installing wheel bearings 245
- Removing front wheel 245
- Removing installing rear wheel 245
- Removing installing spokes 245
- Removing rear wheel 245
- Static balancing of front wheel rear wheel 245
- Technical dat 245
- Wheels and tyres 245
- Installing the front wheel 249
- Removing and installing front wheel 249
- Removing front wheel 249
- Removing and installing wheel bearings 250
- Installing rear wheel 252
- Removing installing rear wheel 252
- Removing rear wheel 252
- Static balancing of front wheel rear wheel 253
- Checking front rear wheel rim for runout 254
- Centering lateral runout 255
- Centering the wheel rim 255
- Removing installing spokes 255
- Checking running gear 256
- Contents 256
- Measuring the leading link 256
- Measuring wheel track offset 256
- Overall view frame 256
- Removing and installing bottom section of mudguard 256
- Removing and installing fairing bracket 256
- Removing and installing frame tail section 256
- Removing and installing front footrest plate 256
- Removing and installing front mudguard 256
- Removing and installing left footrest plate 256
- Removing and installing luggage rack 256
- Removing and installing main centre stand 256
- Removing and installing number plate carrier 256
- Removing and installing rear footrest plate 256
- Removing and installing right footrest plate 256
- Removing and installing side stand 256
- Removing and installing top section of mudguard 256
- Removing and installing windscreen 256
- Removing installing frame 256
- Removing installing rear mudguard 256
- Technical dat 256
- Overall view frame 260
- Removing and installing main centre stand 261
- Removing and installing side stand 262
- Removing and installing bottom section of mudguard 263
- Removing and installing front mudguard 263
- Removing and installing top section of mudguard 264
- Removing and installing windscreen 265
- Removing and installing fairing bracket 266
- Removing and installing luggage rack 267
- Removing and installing number plate carrier 268
- Removing installing rear mudguard 269
- Removing and installing rear footrest plate 270
- Removing and installing front footrest plate 271
- Removing and installing right footrest plate 271
- Removing and installing left footrest plate 272
- Removing installing frame 273
- Removing and installing frame tail section 274
- Checking running gear 275
- Measuring wheel track offset 275
- Measuring the leading link 277
- Contents 278
- Equipment 278
- Removing and installing helmet lock 278
- Removing and installing ignition light switch 278
- Removing and installing ignition switch steering lock 278
- Removing and installing lock barrel 278
- Removing and installing lock barrel for fuel tank filler cap 278
- Removing and installing seat lock 278
- Removing and installing ignition light switch 280
- Removing and installing ignition switch steering lock 280
- Removing and installing lock barrel 280
- Removing and installing lock barrel for fuel tank filler cap 281
- Removing and installing helmet lock 282
- Removing and installing lock barrel 282
- Removing and installing seat lock 282
- Contents 283
- Disassembling assembling seat 283
- Disassembling assembling seat 285
- Contents 286
- General electrical equipment 286
- Disassembling assembling central electrical equipment box 290
- Removing and installing central electrical equipment box 290
- Relay positions fuse assignments central electrical equipment box 291
- Wiring harness routing frame abs 292
- Wiring harness routing central electrical equipment box output 294
- Removing and installing battery holder 302
- Contents 303
- Instruments 303
- Removing and installing instrument panel 303
- Technical dat 303
- Removing and installing instrument panel 306
- Contents 307
- Lights 307
- Removing and installing front indicators 307
- Removing and installing headlight 307
- Technical dat 307
- Removing and installing headlight 310
- Removing and installing front indicators 311
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