BMW MOTORCYCLE SERVICE REPAIR MANUAL DOWNLOAD APPLICATION: 1999 2000 2001 2002 2003 2004 BMW R1150GS (R 1150 GS) BMW R1150GS (R 1150 GS) BMW R1150GS (R 1150 GS) - 2002-2003 BMW R1150RT (R 1150 RT, R1150 RT, R 1150RT) R1150RT (R 1150 RT, R1150 RT, R 1150RT) - 1999-2004 BMW K1200LT (K 1200 LT) (1200LT) - 1999-2004 BMW K1200RS (K 1200 RS K1200 RS) - 2001-2005 BMW F650CS (F 650 CS F650-CS) - 1999-2005 BMW R1100S (R 1100 S R1100-S R 1100S).


Remove filler cap slowly and fill fuel tank slowly to prevent
spillage; do not overfill or fill above the bottom of the filler
neck insert. In addition, leave air space to allow for fuel
expansion. Expansion can cause an overfilled tank to
overflow gasoline through the filler cap onto surrounding
areas. After refueling, be sure filler cap is securely tightened.
Inadequate safety precautions may cause an explosion
or fire which could result in death or serious injury.
BMW motorcycles were designed to obtain the
best performance and efficiency using unleaded gasoline (91
pump octane or higher for the , 87 or higher for all other models). Pump octane is
the octane number usually shown on the gas pump. Some
fuel suppliers sell gasoline/alcohol blends as a fuel. The type
and amount of alcohol added to the fuel is important.
Using gasoline that has an alcohol additive, such as
methanol, may cause fuel system rubber components’
failure and/or engine damage.
BMW motorcycles are designed to give the best
performance using unleaded gasoline. Some fuel suppliers
sell gasoline/alcohol blends as a fuel. The type and amount of
alcohol added to the fuel is important.

Using gasoline/methanol blends will result in starting and
driveability deterioration and damage to critical fuel system

ETHANOL is a mixture of 10% ethanol (Grain alcohol)
and 90% unleaded gasoline. It is identified as “gasohol,”
“ethanol enhanced,” or “contains ethanol.” Gasoline/ethanol
blends can be used in your motorcycle if the ethanol
content does not exceed 10%.

(RFG): “Reformulated gasoline” is a term used to
describe gasoline blends that are specifically designed to
burn cleaner than other types of gasoline. Your motorcycle
will run normally using this type of gas.
Because of their generally higher volatility, these blends may
adversely affect the starting, driveability and fuel efficiency of
your motorcycle. If you experience these problems, Harley-
Davidson recommends you operate your motorcycle on
straight, unleaded gasoline.
Use the proper grade of oil for the lowest temperature
expected before the next oil change.
If it is necessary to add oil and BMW oil is not
available, use an oil certified for diesel engines. Acceptable
diesel engine oil designations include CF, CF-4, CG-4 and
CH-4. The preferred viscosities for the diesel engine oils, in
descending order, are 20W-50, 15W-40 and 10W-40. At the
first opportunity, see a BMW dealer to change
back to 100 percent BMW oil.
See 1.5 ENGINE OIL AND FILTER for all service information.
Check engine oil level in oil tank at least once every 500 miles
(800 km). Check level more frequently if engine uses more oil
than normal or if vehicle is operated under harsh conditions.
Oil tank capacity is 3.6 quarts (U.S.) (3.4 liters). Refer to
Table 1-3. on the next page for recommended engine oil viscosity.
Removing and Replacing Oil Filler Cap
1. See Figure 1-1. Remove filler cap from oil tank on right
side of vehicle.
a. Press straight down on filler cap and release. Cap
will pop up.
b. Pull up on filler cap while turning counterclockwise
one-quarter turn as if unscrewing filler cap.
2. Wipe attached dipstick clean.
See Figure 1-2. Note that dipstick has a wide slot (1) and a
narrow slot (2) and can only be inserted in oil tank one way.
3. Insert dipstick into tank. Press down on filler cap while
turning clockwise one-quarter turn as if screwing filler
cap into tank. When filler cap stops turning, it is fully
seated. Press down on filler cap until it snaps in place,
flush with top of oil tank cover.
Checking Oil With Cold Engine
1. Position motorcycle so that it is leaning on jiffy stand.
2. Remove filler cap. See Removing and Replacing Oil
Filler Cap above. Wipe attached dipstick clean. Reinstall
oil filler cap in tank.
3. Remove oil filler cap again and check oil level on dipstick.
See Figure 1-3. Dipstick has two marks. If oil level is at or
below lower mark (2), add only enough oil to bring the
level to a point between the two arrows on the dipstick.
Replace filler cap.
Checking Oil With Warm Engine
1. Run engine until engine oil is at normal operating temperature.
Turn engine off.
2. Position motorcycle so that it is leaning on jiffy stand.
3. Remove filler cap. See Removing and Replacing Oil
Filler Cap above. Wipe attached dipstick clean. Reinstall
oil filler cap in tank.
4. Remove filler cap again and check warm oil level on dipstick.
See Figure 1-3. Dipstick has two marks. If oil level
in tank is at or below lower mark, add one quart (0.946
liter) of Harley-Davidson oil to tank. Replace filler cap.
5. If you added oil in step 4, remove filler cap and verify correct
engine oil level in oil tank. Do not fill oil tank to the
level above upper mark on dipstick. Replace filler cap.
1. Battery top must be clean and dry. Dirt and electrolyte on
top of the battery can cause battery to self-discharge.
Clean battery top with a solution of baking soda (sodium
bicarbonate) and water (5 teaspoons baking soda per
quart or liter of water). When the solution stops bubbling,
rinse off the battery with clean water.
2. Clean cable connectors and battery terminals using a
wire brush or sandpaper. Remove any oxidation.
3. Inspect the battery screws, clamps and cables for breakage,
loose connections and corrosion. Clean clamps.
4. Check the battery posts for melting or damage caused
by overtightening.
5. Inspect the battery for discoloration, raised top or a
warped or distorted case, which might indicate that the
battery has been frozen, overheated or overcharged.
6. Inspect the battery case for cracks or leaks.
The front and rear brakes are fully hydraulic disc brake systems
that require little maintenance. The front brake master
cylinder is an integral part of the brake hand lever assembly.
The rear brake master cylinder is located at the rear of the
motorcycle’s frame, beneath the rear fork pivot point.
Check the master cylinder reservoirs for proper fluid levels at
the 1000 mile (1600 km) point and every 5000 miles
(8000 km) thereafter. With the reservoir in a level position,
BRAKE FLUID (P/N 99902-77) from a sealed container until
the fluid level is within approximately 1/4-inch (6 mm) below
the top edge of the reservoir (front brake) or reaches the
upper fluid level in the reservoir (rear brake). Do not overfill
the reservoir.

fCheck brake pads and discs for wear every 5000 miles (8000
km). Replace brake pads if friction material is worn to 0.04 in.
(1.02 mm) or less. Minimum brake disc thickness is stamped
on side of disc. Replace any brake disc that is worn beyond
this limit. Maximum brake rotor lateral runout and warpage is
0.008 in. (0.2 mm) when measured near the outside diameter.
Check brake pads and discs:
● At every scheduled service interval.
● Whenever the components are removed from the vehicle
during service procedures.
Brake Pads
Always replace brake pads in complete sets for correct
brake operation. Never replace just one brake pad. Failure
to install brake pads as a set could result in death or
serious injury.
See Figure 1-21. Replace brake pads (3) if brake pad friction
material on either the front or rear caliper is worn to 0.04 in.
(1.02 mm) or less above the backing plate (4). Always replace
both pads in a caliper as a set. See BRAKE PAD REPLACEMENT
on the next page.
When checking the brake pads and discs, inspect the brake
hoses for correct routing and any signs of damage.
Brake Disc Thickness, Lateral Runout
and Warpage
The minimum brake disc (2) thickness is stamped on the side
of the disc. Replace disc if worn past minimum thickness or
badly scored.
Maximum brake disc lateral runout and warpage is 0.008 in.
(0.2 mm) when measured near the outside diameter.
● To replace front brake disc(s), see FRONT WHEEL
under 2.4 WHEELS.
● To replace rear brake disc, see REAR WHEEL under 2.4
Front Brake Caliper
Do not remove front caliper(s) from mounting bracket
unless caliper mounting pins require service. Removing
caliper from mounting bracket unnecessarily increases
the risk of contaminates falling into mounting pin holes
and damaging caliper during vehicle operation.
1. See Figure 1-14. Position motorcycle so that front master
cylinder reservoir (1) is level.
2. See Figure 1-15. Remove two screws (5), reservoir cover
(4), diaphragm plate (3) and diaphragm (2) from master
cylinder reservoir (1).

For your own personal safety, tires, rims and air valves
must be correctly matched to wheel rims. See your Harley-
Davidson dealer. Mismatching tires, tubes, rims and
air valves may result in damage to the tire bead during
mounting or may allow the tire to slip on the rim, possibly
causing tire failure and resulting in death or serious
● In addition, using tires other than those specified
may adversely affect motorcycle handling.
● Tubeless tires fitted with the correct size inner tubes
may be used on all BMW laced (wire
spoked) wheels. Protective rubber rim strips must be
used with tubeless tires (fitted with correct size inner
tubes) when mounted on laced (wire spoked)
● Inner tubes must not be used in radial tires and
radial tires must not be used on laced (wire spoked)
● Tubeless tires are used on all Harley-Davidson cast
and disc wheels.
● Tire sizes are molded on the tire sidewall. Inner tube
sizes are printed on the tube.
Check tire pressure and tread:
● As part of the pre-ride inspection.
● At every scheduled service interval.
1. Inspect each tire for punctures, cuts, and breaks.
2. Inspect each tire for wear. Replace tires before they
reach the tread wear indicator bars.
Do not exceed the maximum inflation pressure listed on
tire sidewall. Overinflating could lead to tire failure which
could result in death or serious injury.
3. Check for proper front and rear tire pressures when tires
are cold. Compare results against Table 1-6.
See Figure 1-31. Tread wear indicator bars appear on tire
tread surfaces when 1/32 inch (0.8 mm) or less tire tread
remains. Arrows on tire sidewalls pinpoint location of wear
bar indicators. Always remove tires from service before they
reach the tread wear indicator bars, indicating 1/32 inch (0.8
mm) tread pattern depth remaining.
New tires are needed if any of the following conditions exist.
● Tread wear indicator bars become visible on the tread
● Tire cords or fabric become visible through cracked sidewalls,
snags or deep cuts.
● A bump, bulge or split in the tire is found.
● Puncture, cut or other damage to the tire that cannot be
Table 1-6. Tire Pressures
Front 30 207 30 207
Rear 36 248 40 276
All models feature a primary cover and a quick-release clutch
cable to simplify both clutch service and adjustment.
1. See Figure 1-34. Slide rubber boot off cable adjuster.
2. Holding cable adjuster with 1/2 inch wrench, loosen jam
nut using a 9/16 inch wrench. Back jam nut away from
cable adjuster. Move adjuster toward jam nut to introduce
a large amount of free play at hand lever.
3. models: remove left side rider
footrest and mounting bracket assembly. See LEFT
4. See Figure 1-35. Remove six screws (1) and remove
clutch inspection cover (2). Exercise caution to avoid
damaging or dislodging quad ring (7) in primary cover
5. Slide hex lockplate with attached spring (3) from flats of
adjusting screw assembly (8). Turn adjusting screw
counterclockwise until resistance is felt. Back off adjusting
screw 1/4 turn.
6. Slide hex lockplate with spring onto flats of adjusting
screw. If necessary, turn adjusting screw clockwise
slightly so that lockplate slides onto flats while also fitting
within recess of outer ramp.
7. Verify that quad ring is fully seated in groove of primary
cover. Install clutch inspection cover and secure with six
screws. Tighten screws in a crosswise pattern to 84-108
in-lbs (9.5-12.2 Nm).