1999–2003 BMW R 1150 GS Repair Manual (P/N 01 79 0 021 120)

• Document coverage: Covers the BMW R 1150 GS in standard condition or fitted with genuine BMW accessories. This 311-page PDF reproduces the BMW Motorrad Repair Manual identified as order number 01 79 0 021 120, printed in Germany 02/00.
• Engine repair: Covers engine removal and complete disassembly/reassembly, including cylinder heads, valves and guides, pistons and cylinders, connecting rods, crankshaft and crankcase, oil pumps, oil thermostat, timing chains, radial seals, cam timing, and valve-clearance adjustment.
• Drivetrain work: Details dry-clutch removal and installation, clutch hydraulic service, six-speed gearbox teardown and assembly, bearing and shaft-seal replacement, endplay measurement and shimming, plus rear-drive pinion and crown-wheel rebuilding, tooth-contact checks, and backlash adjustment.
• Chassis and brakes: Documents BMW Telelever fork and bridge work, leading-link and ball-joint service, front and rear suspension components, swinging arm and drive shaft, wheel bearings, spoke replacement and rim centering, brake calipers, master cylinder, ABS sensors and unit, brake lines, and system bleeding.
• Fuel and electrical diagnosis: Includes Motronic MA 2.4 components, throttle-valve potentiometer adjustment, fuel-pump pressure testing, Hall-effect ignition timing, standard and optional alternator checks, starter testing, MoDiTeC fault-memory work, relay/fuse assignments, and wiring-harness routing.
• Reference material: Provides component-specific torque tables, fluid and lubricant data, wear limits, fits and clearances, and electrical test values. Named visual references include the engine cutaway, lubricating-oil circuit, cooling-oil circuit, gearbox sectional drawing, frame overview, and ABS wiring-harness routing views.

Workshop-Level Factory Procedures

BMW organizes the manual by construction group and follows the workshop sequence of removal, disassembly, repair, assembly, and installation. The publication is written for workshop personnel and assumes practical and theoretical service training; certain tests and adjustments also require BMW special tools or the MoDiTeC tester. It is suited to trained technicians and experienced mechanics, not first-time repair work.

Group 00 combines pre-delivery procedures with the Inspection I-IV maintenance program. It identifies the scheduled work for engine, gearbox, and rear-drive oils; filters; the Poly-V belt; battery; spark plugs; brakes; clutch fluid; valve clearances; throttle cables; idle speed; and throttle-valve synchronization. Road-safety and functional checks, approved operating fluids, and assembly-specific tightening data are included in the same section.

Internal Engine and Drivetrain Detail

The engine chapter identifies the 1,130 cc four-stroke flat twin, with air cooling, oil-cooled exhaust ports, four valves per cylinder, overhead camshafts, and electronic fuel injection. Internal repair coverage reaches beyond parts replacement: valve seats can be checked and machined, valve guides replaced, pistons and cylinders measured, and crankshaft main-bearing, guide-bearing, and connecting-rod clearances evaluated. Separate diagrams trace the lubricating-oil and cooling-oil circuits, while the assembly chapters document oil-pump installation, auxiliary-shaft and timing-chain alignment, crankshaft seals, cylinder-head installation, and valve timing.

The clutch section covers the single dry-plate assembly, hydraulic line, slave cylinder, and filling/bleeding work. The transmission chapter goes through the input, output, and intermediate shafts; selector shaft and drum; gear and bearing removal; seal replacement; endplay measurement; shimming; and final housing assembly. Rear-wheel-drive procedures cover the input bevel pinion, crown wheel, taper and needle bearings, housing-cover shimming, tooth-contact pattern, backlash, universal-joint inspection, and swinging-arm installation.

Diagnostics, Special Tools, and Scope

Motronic MA 2.4 coverage addresses the control unit, throttle bodies, injectors, throttle-valve potentiometer, air-filter housing, oxygen sensor, fuel pump, pressure regulator, ignition coil, Hall-effect gate, starter, and alternator. The engine-electrics data distinguishes the standard Denso alternator from the optional Bosch unit. Tester-guided checks are identified as MoDiTeC operations, and the throttle-potentiometer basic setting points to separate Motronic diagnosis instructions rather than reproducing the tester routine in this PDF.

Referenced tooling includes BMW service stand 00 1 520 with adapters 00 1 527, clutch-housing lock 11 5 640, TDC locating pin 11 2 650, gearbox guide pins 23 1 820, and rear-drive measuring fixture 33 2 600. Torque-angle fasteners, wear limits, fluid capacities, pressure-test data, bearing fits, shaft endplay, and adjustment specifications are supplied where applicable.

The manual flags repair risks that generic summaries usually miss. Allowing the gearbox to drop during separation can bend the clutch actuating rod, while pointed tools used to remove gearbox shaft seals can damage the sealing washers behind the grooved ball bearings. The electrical section supplies harness-routing views and relay/fuse locations, but not a complete motorcycle wiring-schematic set; BMW also treats the parts microfiche as a separate source. Secure the motorcycle with the specified workshop support before engine, transmission, or chassis work, and observe the manual's fuel, battery-isolation, brake-fluid, and ABS precautions.